Optimization of a turbocharger for high EGR applications

H. Sun, D. Hanna, Ford Motor Co. L. Hu, J. Zhang, Ming-Chia Lai, Wayne State Univ. E. Krivitzky, C. Osborne, ConceptsNREC NETL Project Manager: Ralph Nine DOE Contract: DE-FC26-07-NT43280

Emission regulation: Heavy EGR needed for LTC pushes the operation points into less efficient or even surge area Market competitiveness: Centrifugal compressor needs to have wide range for high horse power and better efficiency at low end for better fuel economy on customer driving cycles

Objectives:

2-3% fuel economy improvement on customer driving cycles and 15-20% extension of turbo operation range

As more EGR is used for NOx reduction, turbine spends more time in low U/C area. Conventional turbine blade, optimized for low/none EGR applications 10-15 years ago, performs well at high U/C but not at low U/C. Therefore future diesel application requires that turbine should have high efficiency in low U/C areas.

Turbine Efficiency vs. U/C

0.8 0.75 0.7 0.65 0.6 0.55 0.5 0.45 0.4 0.35 0.3 0.000

U U = C 2C pT0 1 ( T ) 0.285

Turbine Efficiency (%)

Small nozzle opening reduces efficiency Slow turbine speed further reduces efficiency High exp ratio reduces U/C
0.200 0.400 U/C 0.600 0.800 1.000

60% open, high speed

40% open, high speed

40% open, low speed

Conventional radial flow VGT has low efficiency at small nozzle open positions and low U/C. Heavy EGR, bigger turbo pushes part load turbine operation points into less efficiency areas

Optimized compressor diffuser and volute Advanced compressor impeller

Mixed flow turbine

Advanced casing treatment

CFD Simulation to optimize casing treatment design

No casing treatment

Lean forward

Lean backward

Lean backward w/ wider slot

0.80 0.78 0.76 0.74

Adv comp tech Conventional 2 Conventional 1

Eff (t-t)

0.72 0.70 0.68 0.66 0.64 0.50

3.4 3.3

Simulation @ 120krpm

(with volute)

0.55

0.60

0.65

0.70

0.75

0.803.2 0.85
3.1 3.0 2.9 2.8 2.7 2.6 2.5 2.4 0.50

0.90

0.95

1.00

Mass flow(normalized)

Optimization of casing treatment can extend flow range/surge margin without compromising efficiency

Pr (t-t)

Adv comp tech Conventional 2 Conventional 1

0.55

0.60

0.65

0.70 0.75 0.80 Mass flow(normalized)

0.85

0.90

0.95

1.00

Turbine efficiencies, radial flow vs. mixed flow under stead state and transient conditions
86% 84%

Turbine efficiency

82% 80% 78% 76% 74% 72% 70% 68% 0.50

Mixed flow steady Mixed flow pulsating Radial flow pulsating Radial turbine steady flow

0.52

0.54

0.56

0.58

0.60

U/C

Transient CFD simulation indicated that mixed flow turbine can effectively utilize exhaust energy, esp. at low U/C area

Mass flow of mixed flow turbine vs. radial flow turbine Radialturbine turbinepulsating pulsating radial Radialturbine turbinesteady steady radial Mixed turbine pulsating Mixed turbine steady

M_param (m*sqrt(T0)/P0)

1.34

4%

1.36

1.38

1.4

1.42 Pr(T-S)

1.44

1.46

1.48

Mixed flow turbine has better flow capacity that may help downsizing

Major design changes: Arbitrary surface compressor impeller blades to improve compressor efficiency at light load conditions; optimal casing treatment to improve efficiency at high load Mixed flow turbine for better performance at high EGR (or low U/C) conditions
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Flow bench test of compressor

Efficiency on customer driving 0.80 cycle will impact 0.78 FE, emission and 0.76 0.74 transient response
0.72 0.70 0.68 0.66 0.64 0.62 0.60 0.58 Surge margin 0.56 Efficiency Improvement with Advanced Compressor (tested at two suppliers' flow benches )

Efficiency (t-t)

enhanced

0.1

0.2

0.3

0.4

0.5 0.6 0.7 0.8 0.9 Mass Flow (normalized)

Advanced Compressor

1.0

1.1

1.2

2010MY Prod

Choke capacity extended 12%

Advanced compressor with adv. casing treatment demonstrated better efficiency and wider operation range than a 2010MY production compressor that enables BSFC and performance improvement

The advanced turbo demonstrated better FE at light load conditions

The advanced turbo gained more BSFC advantages at lower NOx or higher EGR (thus low U/C) conditions

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Performances at full load conditions were improved as well

The mixed flow turbine gained better efficiency at low EGR or high U/C conditions

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Conclusions
EGR based NOx control pushes operation points into less efficient area on compressor and turbine maps, which has to be addressed with advanced turbocharger technologies Optimal design of compressor impeller, combined with advanced casing treatment improved compressor efficiency over wide operation range Mixed flow turbine has demonstrated improved efficiency at low U/C area, which is relevant to high EGR applications and pulsating exhaust environment The engine dyno test has demonstrated BSFC improved 3-5% at light load and 3% improvement at full load with wider operation range due to design optimization on compressor impeller, advanced casing treatment and mixed flow turbine
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