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Exhaust gas fuel reforming
Joint project with Johnson Matthey, Ford Motor Company, University of Birmingham
Mark Peckham and Steve Dinsdale (Cambustion)John Pignon, Kirsty Cockle, Paul Millington (JM)
Phil West, Andy Scarisbrick (Ford)Athanasios Tsolakis, Daniel Fennell (UoB)
CREO
2
CO2 Reduction through Emissions Optimisation
…a TSB consortium
Improving Fuel Economy
• Exhaust heat is used to reform fuel to generate mixture of H2 and CO with higher calorific value.
Reformer
FuelH2OExhaust Heat
Increase in calorific value
H2CO
Closed Coupled Exhaust Gas Reforming - Principle
After treatment Catalysts
H2
Fuels Calorific Values
• Calorific valuesGasoline = 47 MJ/kg (C6.4H11.4 )
Diesel = 45 MJ/kg (C15.1H28,4)
H2 = 141.9 MJ/kg,
CO = 10.8 MJ/kg
CH4 =50.01MJ/kg
Conventional Reformate Composition (Equilibrium Calculations)
0
5
10
15
20
25
30
400 500 600 700 800 900 1000Temperature (oC)
Pro
du
cts
(% V
ol.)
CH4
CO
CO2
H2
H2O
O2
Birmingham UniversityUniversity of Birmingham
Reformer designWhole system schematic
TWCturboengine
fuel injector
EGR valve and cooler
engine out gas
sampling point
UEGO
UEGOCOCO2
UEGO
THCPre-TWC (post-turbo)Post-TWCPre-TWC (pre-turbo)Reformate
Reformer designComponents
Some exhaust gas plus added fuel is diverted around the TWC through the reformer and recirculated into the engine (~25% EGR)
Reformer designComponents
JM built reformer installed on a 2.0L Gasoline Direct Injection engine at Cambustion Ltd
Some exhaust gas plus added fuel is diverted around the TWC through the reformer and recirculated into the engine (~25% EGR)
Reformer instrumentation
engfuelm _
•
EGR Valve
airm•
REGR cooler
UEGOsensor
UEGOsensor
T
TT
Fast gas analysersCO / CO2 – gas composition and EGR fraction
Fast HC analysers
Adopt use of fast CO&CO2 analyzer
New reformer package
12
Reformer CO production – hot drive cycle
0
10000
20000
30000
40000
50000
60000
70000
80000
90000
100000
0 200 400 600 800 1000 1200
Time [sec] -after first NEDC
CO
[ppm
]
Reference Cycle Reference CycleREGR ActiveREGR Active
WP6 Quarter 12 report
Fuel economy improvement ~3.5%
0
100
200
300
400
500
600
700
800
900
0 200 400 600 800 1000 1200
Time [sec] -after first NEDC
Fue
l use
d [g
]
Reference Cycle Reference CycleREGR ActiveREGR Active
REFERENCE CYCLES
REGR ACTIVE
3.5% Reduction in fuel used
0
2
4
6
8
10
12
14
0 5 10 15 20 25 30 35 40
REGR flow rate (kg/hr)
FE
(%
)
FE E030613b 2000/10FE E300513a 2100/30FE E040613a 1500/60FE E310513a 2500/60FE E030613a 2000/80FE E310513b 3000/50
2000/102100/301500/602500/602000/803000/50
Fu
el E
con
om
y (%
)
REGR Flow Rate (kg/h)
100 kph cruise
70 kph cruise
Fuel Economy
DMS500 fast particulate size & number
� Aerosol sample drawn through corona discharge charger
� Charged aerosol enters classifier surrounded by clean sheath airflow
� Strong electric field causes particles to drift towards electrometer detectors
� Larger particles with more drag drift more slowly and are detected further downstream
WP6 Quarter 12 report
Engine-out particulate concentration (accumulation mode)
0.00E+00
5.00E+06
1.00E+07
1.50E+07
2.00E+07
2.50E+07
3.00E+07
3.50E+07
4.00E+07
0 200 400 600 800 1000 1200
Time [sec] -after first NEDC
Par
ticul
ate
conc
entr
atio
n [n
/sec
]
Reference Cycle Reference CycleREGR ActiveREGR Active
WP6 Quarter 12 report
Engine-out particulates – reduction~ 50%
0
2E+13
4E+13
6E+13
8E+13
1E+14
1.2E+14
1.4E+14
0 200 400 600 800 1000 1200
Time [sec] -after first NEDC
Par
ticul
es [N
]
Reference Cycle Reference CycleREGR ActiveREGR Active
WP6 Quarter 12 report
Engine-out NOX (ppm)
0 200 400 600 800 1000 1200
Time [sec] -after first NEDC
NO
X [p
pm]
Reference Cycle Reference CycleREGR ActiveREGR Active
WP6 Q8 review 12/09/12
Carbon balance to check reformer yield
• Use fast instruments to ‘add up’ carbon from CO, CO2 and HC
• Compare with fuel flow
• CO production drops, HC increases
• Tests conducted at 500°C first catalyst, 70kph fuel sweep
Carbon balance and UEGO lambda
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0.18
0.2
1200 1400 1600 1800 2000 2200 2400 2600
Time (seconds)
carb
on
flo
w (
g/s
)
C in fuel g/sC in CO g/sC in HC g/sC in CO2 g/stotal C in gasesREGR LAMBDA [(-)]
WP6 Quarter 12 report
Species yield – 35Nm, 2100rpm
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0
2
4
6
8
10
12
14
0 2 4 6 8 10 12 14 16
Sp
eci
es
(%)
REGR (kg/hr)
H2 %
CO %
CO2 %
HCefficiency
HC
eff
icie
ncy
Thin lines = 1st gen. (E150113a)Thick lines = 2nd gen. (E300513a)
70kph
Research summary
• Reformer research study focussed on 2 platforms- JM bench reactor experiments on sample reformer catalysts
- Engine testing of packaged reformer at Cambustion
• Cambustion analysers used to investigate reformer species- CO and CO2 to give reformer performance and (R)EGR ratio
- HC slip from reformer measured by FID
- Carbon balance performed to check consistency
• GC used for hydrogen measurements (at steady-state)
• DMS and conventional analyser stack used for engine-out particulate and gaseous emissions
22
Project conclusions
• Reformer packaged on engine and control scheme implemented for transient use
• CO used as indication of reformate composition to allow engine parameter setting (especially MBT)
• Reformer was demonstrated to provide improved fuel economy, but further work needed on package / warm-up
• Simultaneous major improvement in particulate and NOx
• Reformer showed no long-term degradation from coking
23