Condensation-Fouling Interaction in Low-Temperature EGR-Coolers

Abstract

EGR cooling is a worthwhile technology capable of reducing NOx-emissions and increasing the efficiency of CI engines. Challenges arise when low-temperature cooling is applied with high fuel sulfur contents. The resulting sulfuric acid condenses in conjunction with the water of the exhaust gas and gives rise to corrosion of coolers and engine components. Additionally, fouling of the EGR cooler is exacerbated by the condensation of acidic components compromising EGR performance. In order to gain a better understanding of the underlying processes a combined experimental and model-based approach is presented. Tests of two different EGR-cooler concepts under various conditions showed a strong influence of the fuel sulfur content on fouling and condensation. The one-dimensional cooler model developed alongside these experiments consists of an activity coefficient model (NRTL) of the binary system water - sulfuric acid and a condensation model that allows for simulating the coupled condensation of both vapor components. Comparison of experimental fouling and simulated condensation results show good agreement in interpreting critical fouling phenomena that occur at temperatures in between the acid-water dew point and the dew point of pure water.