The main objective of the present research activity was to investigate the effect of very fast composition transitions of the engine exhaust typical in real-world driving operating conditions, as fuel cutoff phases or engine misfire, on the aftertreatment devices, which are generally very sensitive to these changes. This phenomenon is particularly evident when dealing with engines powered by natural gas, which requires the use of a three-way catalyst (TWC). Indeed, some deviations from the stoichiometric lambda value can interfere with the catalytic converter efficiency. In this work, a numerical “quasi-steady” model was developed to simulate the chemical and transport phenomena of a specific TWC for a compressed natural gas (CNG) heavy-duty engine. A dedicated experimental campaign was performed in order to evaluate the catalyst response to a defined λ variation pattern of the engine exhaust stream, thus providing the data necessary for the numerical model validation. Tests were carried out to reproduce oxygen storage phenomena that make catalyst behavior different from the classic steady-state operating conditions. A surface reaction kinetic mechanism concerning CH4, CO, H2, oxidation and NO reduction has been appropriately calibrated at different λ values with a step-by-step procedure, both in steady-state conditions of the engine work plan and during transient conditions, through cyclical and consecutive transitions of variable frequency between rich and lean phases. The activity also includes a proper calibration of the reactions involving cerium inside the catalyst in order to reproduce oxygen storage and release dynamics. Sensitivity analysis and continuous control of the reaction rate allowed evaluating the impact of each of them on the exhaust composition in several operating conditions. The proposed model predicts tailpipe conversion/formation of the main chemical species, starting from experimental engine-out data, and provides a useful tool to evaluate the catalyst’s performance.

The scope of the work presented in this paper was to apply the latest open source CFD achievements to design a state of the art, directinjection (DI), heavy-duty, natural gas-fueled engine. Within this context, an initial steady-state analysis of the in-cylinder flow was performed by simulating three different intake ducts geometries, each one with seven different valve lift values, chosen according to an estabilished methodology proposed by AVL. The discharge coefficient (C d) and the Tumble Ratio (TR) were calculated in each case, and an optimal intake ports geometry configuration was assessed in terms of a compromise between the desired intensity of tumble in the chamber and the satisfaction of an adequate value of C d. Subsequently, full-cycle, cold-flow simulations were performed for three different engine operating points, in order to evaluate the in-cylinder development of TR and turbulent kinetic energy (TKE) under transient conditions. The latest achievements in open source mesh generation and motions were applied, along with time-varying and case-fitted inizialization values for the fields of intake pressure and temperature. Finally, direct-injection of natural gas in the cylinder was incorporated in full-cycle simulations, to evaluate the effects of injection on charge motions and charge homogeneity at the estimated spark timing. Three specific engine operating points were simulated and different combinations of turbochargers and valve lift laws were tested. Results consistency was verified by means of validations with data from 1D simulations and literature.

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This paper describes some strategies to deal with the arduous challenge of reducing emissions from the transport sector. Two different approaches in particle emissions reduction from natural gas (NG) heavy duty (HD) engines were evaluated. The focus was on reducing the ultra-fine sub 23 nm particles, a key aspect in the vehicles’ impact on human health and environment. To this end, an experimental research activity was carried out on a NG HD engine that was EURO VI regulation compliant. Lubricant oils characterized by different base compositions and ash contents were compared to provide a preferred path to develop formulations. The performed activity on world harmonized transient cycles (WHTCs) have demonstrated a high reduction potential (≈70%) that is reachable by acting on the lube formulation. A CNG particle filter (CPF), derived from the diesel and gasoline engines technology, was fully characterized in terms of its filtration efficiency. Three different types of tests were carried out: steady state, WHTCs, and several idle-to-load step maneuvers. The CPF was highly efficient in reducing solid particles over 10 nm diameter in all the different tests. During WHTCs, the mean abatement efficiency was about 85%. Both technologies provide interesting insights to make NG HD engines compliant with the upcoming Euro VII regulation.

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