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Reducing criteria pollutants while reducing greenhouse gases is an active area of research for commercial on-road vehicles as well as for off-road machines. The heavy duty on-road sector has moved to reducing NOx by 82.5% compared to 2010 regulations while increasing the engine useful life from 435,000 to 650,000 miles by 2027 in the United States (US). An additional certification cycle, the Low Load Cycle (LLC), has been added focusing on part load operation having tight NOx emissions levels. In addition to NOx, the total CO2 emissions from the vehicle will also be reduced for various model years. The off-road market is following with a 90% NOx reduction target compared to Tier 4 Final for 130-560 kW engines along with greenhouse gas targets that are still being established. The off-road market will also need to certify with a Low Load Application Cycle (LLAC), a version of which was proposed for evaluation in 2021.

A prototype three-way catalyst (TWC) with NOX storage component was evaluated for ammonia (NH3) generation on a 2.0-liter BMW lean burn gasoline direct injection engine as a component in a passive ammonia selective catalytic reduction (SCR) system. The passive NH3 SCR system is a potential approach for controlling nitrogen oxides (NOX) emissions from lean burn gasoline engines. In this system, NH3 is generated over a close-coupled TWC during periodic slightly-rich engine operation and subsequently stored on an underfloor SCR catalyst. Upon switching to lean, NOX passes through the TWC and is reduced by the stored NH3 on the SCR catalyst. Adding a NOX storage component to a TWC provides two benefits in the context of a passive SCR system: (1) enabling longer lean operation by storing NOX upstream and preserving NH3 inventory on the downstream SCR catalyst; and (2) increasing the quantity and rate of NH3 production during rich operation.

Reliable means for on-board detection of particulate filter failures or malfunctions are needed to meet diagnostics (OBD) requirements. Detecting these failures, which result in tailpipe particulate matter (PM) emissions exceeding the OBD limit, over all operating conditions is challenging. Current approaches employ differential pressure sensors and downstream PM sensors, in combination with particulate filter and engine-out soot models. These conventional monitors typically operate over narrowly-defined time windows and do not provide a direct measure of the filter’s state of health. In contrast, radio frequency (RF) sensors, which transmit a wireless signal through the filter substrate provide a direct means for interrogating the condition of the filter itself.

The increasing use of diesel and gasoline particulate filters requires advanced on-board diagnostics (OBD) to prevent and detect filter failures and malfunctions. Early detection of upstream (engine-out) malfunctions is paramount to preventing irreversible damage to downstream aftertreatment system components. Such early detection can mitigate the failure of the particulate filter resulting in the escape of emissions exceeding permissible limits and extend the component life. However, despite best efforts at early detection and filter failure prevention, the OBD system must also be able to detect filter failures when they occur. In this study, radio frequency (RF) sensors were used to directly monitor the particulate filter state of health for both gasoline particulate filter (GPF) and diesel particulate filter (DPF) applications.

Lean gasoline engines offer greater fuel economy than the common stoichiometric gasoline engine, but the current three way catalyst (TWC) on stoichiometric engines is unable to control nitrogen oxide (NOX) emissions in oxidizing exhaust. For these lean gasoline engines, lean NOX emission control is required to meet existing Tier 2 and upcoming Tier 3 emission regulations set by the U.S. Environmental Protection Agency (EPA). While urea-based selective catalytic reduction (SCR) has proven effective in controlling NOX from diesel engines, the urea storage and delivery components can add significant size and cost. As such, onboard NH3 production via a passive SCR approach is of interest. In a passive SCR system, NH3 is generated over a close-coupled TWC during periodic slightly rich engine operation and subsequently stored on an underfloor SCR catalyst. Upon switching to lean operation, NOX passes through the TWC and is reduced by the stored NH3 on the SCR catalyst.

New regulations requiring increases in vehicle fuel economy are challenging automotive manufacturers to identify fuel-efficient engines for future vehicles. Lean gasoline direct injection (GDI) engines offer significant increases in fuel efficiency over the more common stoichiometric GDI engines already in the marketplace. However, particulate matter (PM) emissions from lean GDI engines, particularly during stratified combustion modes, are problematic for lean GDI technology to meet U.S. Environmental Protection Agency Tier 3 and other future emission regulations. As such, the control of lean GDI PM with wall-flow filters, referred to as gasoline particulate filter (GPF) technology, is of interest. Since lean GDI PM chemistry and morphology differ from diesel PM (where more filtration experience exists), the functionality of GPFs needs to be studied to determine the operating conditions suitable for efficient PM removal.

Radio frequency (RF)-based sensors provide a direct measure of the particulate filter loading state. In contrast to particulate matter (PM) sensors, which monitor the concentration of PM in the exhaust gas stream for on-board diagnostics purposes, RF sensors have historically been applied to monitor and control the particulate filter regeneration process. This work developed an RF-based particulate filter control system utilizing both conventional and fast response RF sensors, and evaluated the feasibility of applying fast-response RF sensors to provide a real-time measurement of engine-out PM emissions. Testing with a light-duty diesel engine equipped with fast response RF sensors investigated the potential to utilize the particulate filter itself as an engine-out soot sensor.

Ethanol is a very effective reductant for nitrogen oxides (NOX) over silver/alumina (Ag/Al2O3) catalysts in lean exhaust environments. With the widespread availability of ethanol/gasoline-blended fuel in the U.S., lean gasoline engines equipped with Ag/Al2O3 catalysts have the potential to deliver higher fuel economy than stoichiometric gasoline engines and to increase biofuel utilization while meeting exhaust emissions regulations. In this work a pre-commercial 2 wt% Ag/Al2O3 catalyst was evaluated on a 2.0-liter BMW lean burn gasoline direct injection engine for the selective catalytic reduction (SCR) of NOX with ethanol/gasoline blends. The ethanol/gasoline blends were delivered via in-pipe injection upstream of the Ag/Al2O3 catalyst with the engine operating under lean conditions. A number of engine conditions were chosen to provide a range of temperatures and space velocities for evaluation of catalyst performance.

A commercial three-way catalyst (TWC) was evaluated for ammonia (NH3) generation on a 2.0-liter BMW lean burn gasoline direct injection engine as a component in a passive ammonia selective catalytic reduction (SCR) system. The passive NH3 SCR system is a potential low cost approach for controlling nitrogen oxides (NOX) emissions from lean burn gasoline engines. In this system, NH3 is generated over a close-coupled TWC during periodic slightly rich engine operation and subsequently stored on an underfloor SCR catalyst. Upon switching to lean, NOX passes through the TWC and is reduced by the stored NH3 on the SCR catalyst. NH3 generation was evaluated at different air-fuel equivalence ratios at multiple engine speed and load conditions. Near complete conversion of NOX to NH3 was achieved at λ=0.96 for nearly all conditions studied. At the λ=0.96 condition, HC emissions were relatively minimal, but CO emissions were significant.

Low temperature combustion (LTC) has been shown to yield higher brake thermal efficiencies with lower NOx and soot emissions, relative to conventional diesel combustion (CDC). However, while demonstrating low soot carbon emissions it has been shown that LTC operation does produce particulate matter whose composition appears to be much different than CDC. The particulate matter emissions from dual-fuel reactivity controlled compression ignition (RCCI) using gasoline and diesel fuel were investigated in this study. A four cylinder General Motors 1.9L ZDTH engine was modified with a port-fuel injection system while maintaining the stock direct injection fuel system. The pistons were modified for highly premixed operation and feature an open shallow bowl design. RCCI operation was carried out using a certification grade 97 research octane gasoline and a certification grade diesel fuel.

Reactivity Controlled Compression Ignition (RCCI) has demonstrated diesel-like or better brake thermal efficiency with significant reductions in nitrogen oxide (NOX) and particulate matter (PM) emissions. Hydrocarbon (HC) and carbon monoxide (CO) emission levels, on the other hand, are higher and similar to those of port-fuel-injected (PFI) gasoline engines. The higher HC and CO emissions combined with the lower exhaust temperatures during RCCI operation present a challenge for current exhaust aftertreatment technologies. The reduction of HC and CO emissions in a lean environment is typically achieved with an oxidation catalyst. In this work, several diesel oxidation catalysts (DOC) with different precious metal loadings were evaluated for effectiveness to control HC and CO emissions from RCCI combustion in a light-duty multi-cylinder engine operating on gasoline and diesel fuels.

The combination of advanced combustion with advanced selective catalytic reduction (SCR) catalyst formulations was studied in the work presented here to determine the impact of the unique hydrocarbon (HC) emissions from premixed charge compression ignition (PCCI) combustion on SCR performance. Catalyst core samples cut from full size commercial Fe- and Cu-zeolite SCR catalysts were exposed to a slipstream of raw engine exhaust from a 1.9-liter 4-cylinder diesel engine operating in conventional and PCCI combustion modes. The zeolites which form the basis of these catalysts are different with the Cu-based catalyst made on a chabazite zeolite which has smaller pore structures relative to the Fe-based catalyst. Subsequent to exposure, bench flow reactor characterization of performance and hydrocarbon release and oxidation enabled evaluation of overall impacts from the engine exhaust.

Lean Gasoline Direct Injection (LGDI) combustion is a promising technical path for achieving significant improvements in fuel efficiency while meeting future emissions requirements. Though Stoichiometric Gasoline Direct Injection (SGDI) technology is commercially available in a few vehicles on the American market, LGDI vehicles are not, but can be found in Europe. Oak Ridge National Laboratory (ORNL) obtained a European BMW 1-series fitted with a 2.01 LGDI engine. The vehicle was instrumented and commissioned on a chassis dynamometer. The engine and after-treatment performance and emissions were characterized over US drive cycles (Federal Test Procedure (FTP), the Highway Fuel Economy Test (HFET), and US06 Supplemental Federal Test Procedure (US06)) and steady state mappings. The vehicle micro hybrid features (engine stop-start and intelligent alternator) were benchmarked as well during the course of that study.

Lean NOx Trap (LNT) catalysts can effectively reduce NOx from lean engine exhaust. Significant research for LNTs in diesel engine applications has been performed and has led to commercialization of the technology. For lean gasoline engine applications, advanced direct injection engines have led to a renewed interest in the potential for lean gasoline vehicles and, thereby, a renewed demand for lean NOx control. To understand the gasoline-based reductant chemistry during regeneration, a BMW lean gasoline vehicle has been studied on a chassis dynamometer. Exhaust samples were collected and analyzed for key reductant species such as H₂, CO, NH₃, and hydrocarbons during transient drive cycles. The relation of the reductant species to LNT performance will be discussed. Furthermore, the challenges of NOx storage in the lean gasoline application are reviewed.

Advanced combustion regimes such as homogeneous charge compression ignition (HCCI) and premixed charge compression ignition (PCCI) offer benefits of reduced nitrogen oxides (NOX) and particulate matter (PM) emissions. However, these combustion strategies often generate higher carbon monoxide (CO) and hydrocarbon (HC) emissions. In addition, aldehydes and ketone emissions can increase in these modes. In this study, the engine-out emissions of a compression-ignition engine operating in a fuel reactivity-controlled PCCI combustion mode using in-cylinder blending of gasoline and diesel fuel have been characterized. The work was performed on a 1.9-liter, 4-cylinder diesel engine outfitted with a port fuel injection system to deliver gasoline to the engine. The engine was operated at 2300 rpm and 4.2 bar brake mean effective pressure (BMEP) with the ratio of gasoline-to-diesel fuel that gave the highest engine efficiency and lowest emissions.

In-cylinder fuel blending of gasoline with diesel fuel is investigated on a multi-cylinder light-duty diesel engine as a strategy to control in-cylinder fuel reactivity for improved efficiency and lowest possible emissions. This approach was developed and demonstrated at the University of Wisconsin through modeling and single-cylinder engine experiments. The objective of this study is to better understand the potential and challenges of this method on a multi-cylinder engine. More specifically, the effect of cylinder-to-cylinder imbalances and in-cylinder charge motion as well as the potential limitations imposed by real-world turbo-machinery were investigated on a 1.9-liter four-cylinder engine. This investigation focused on one engine condition, 2300 rpm, 5.5 bar net mean effective pressure (NMEP). Gasoline was introduced with a port-fuel-injection system.

Accurate knowledge of diesel particulate filter (DPF) particulate matter (PM) loading is critical for robust and efficient operation of the combined engine-exhaust aftertreatment system. Furthermore, upcoming on-board diagnostics regulations require on-board technologies to evaluate the status of the DPF. This work describes the application of radio frequency (RF) - based sensing techniques to accurately measure DPF particulate matter levels. A 1.9L GM turbo diesel engine and a DPF with an RF-sensor were studied. Direct comparisons between the RF measurement and conventional pressure-based methods were made. Further analysis of the particulate matter loading rates was obtained with a mass-based total PM emission measurement instrument (TEOM) and DPF gravimetric measurements.

A hybrid LNT+SCR system is used to control NOx from a light-duty diesel engine with in-cylinder regeneration controls. A diesel oxidation catalyst and diesel particulate filter are upstream of the LNT and SCR catalysts. Ultraviolet (UV) adsorption spectroscopy performed directly in the exhaust path downstream of the LNT and SCR catalysts is used to characterize NH3 production and utilization in the system. Extractive exhaust samples are analyzed with FTIR and magnetic sector mass spectrometry (H2) as well. Furthermore, standard gas analyzers are used to complete the characterization of exhaust chemistry. NH3 formation increases strongly with extended regeneration (or “over regeneration”) of the LNT, but the portion of NOx reduction occurring over the SCR catalyst is limited by the amount of NH3 produced as well as the amount of NOx available downstream of the LNT. Control of lean-rich cycling parameters enables control of the ratio of NOx reduction between the LNT and SCR catalysts.

Advanced diesel combustion regimes such as High Efficiency Clean Combustion (HECC) offer the benefits of reduced engine out NOx and particulate matter (PM) emissions. Lower PM emissions during advanced combustion reduce the demand on diesel particulate filters (DPFs) and can, thereby, reduce the fuel penalty associated with DPF regeneration. In this study, a SiC DPF was loaded and regenerated on a 1.7-liter 4-cylinder diesel engine operated in conventional and advanced combustion modes at different speed and load conditions. A diesel oxidation catalyst (DOC) and a lean NOx trap (LNT) were also installed in the exhaust stream. Five steady-state speed and load conditions were weighted to estimate Federal Test Procedure (FTP) fuel efficiency. The DPF was loaded using lean-rich cycling with frequencies that resulted in similar levels of NOx emissions downstream of the LNT.

An optical-based sensor for detecting particulate matter (PM) in diesel engine exhaust has been demonstrated. The position of the sensor during the experiments was the exhaust manifold prior to the turbocharger. The sensor is constructed of fiber optics which transmit 532-nm laser light into the exhaust pipe and collect backscattered light in a 180° geometry. Due to the optical nature of the probe, PM sensing can occur at high temporal rates. Experiments conducted by changing the fuel injection properties of one cylinder of a four cylinder engine demonstrated that the sensor can resolve cycle dependent events. The feasibility of the probe for examining PM emissions in the exhaust manifold will be discussed.