Diesel Engine Performance and Aftertreatment Systems

This course begins with a high-level engine system overview and then dives into the details of component and system design, performance, control, and failure. Understand torque (versus speed characteristics) of your engine within thermodynamic, emission, and mechanical limits to meet customer requirements. You will also learn how to identify critical variables and design parameters controlling intake, the combustion chamber, and exhaust flows through the engine and aftertreatment systems. The course culminates in a comparison of aftertreatment system architecture across all major vehicle classifications.

In Person Course Topics

Online Course Topics

Online Course Tabs

IN PERSON COURSE TOPICS

Overview of IC Engine Systems

• Power Technology Comparison
• Combustion Cycles and Regimes
• Design Configuration and Criteria
• Current and Future Markets

Pressure-Volume Analysis, Work, and Power

• Power and Efficiency
• Piston Work Calculations

Engine Torque Curves

• Applications
• Design Limits

Applying Thermodynamics in Engines

• Maximum Work of IC Engines
• Entropy and Thermodynamic Availability
• Properties of the Engine Cycles
• Heat Release and Specific Heat Ratio

Combustion Development in Diesel Engines

• Fuel Injection Spray and Mixing Processes
• Ignition Chemistry, and EGR effects
• Diffusion Flames and Temperature Considerations
• Combustion Chamber Optimization

Fuel Chemistry and Specifications

• Combustion Stoichiometry Reactions
• Fuel Energy and Performance Specifications

Diesel Fuel Systems

• Injection Nozzle Design
• Injection Fuel System Types
• Commons Rail Systems

Air Handling in Diesel Engines

• Port/Valve Flow and Motion
• Valve Event Optimization and Tuning
• Miller & Atkinson Cycles
• EGR and Exhaust Temperature Control

Turbocharging

• Compressor Maps and Optimization
• Engine Matching and Boost Control
• EGR, Two-stage, and Intercooling
• Transient Supercharging

Engine Emissions and Regulation

• Air Pollution Overview
• Emissions Regulations and Testing
• Diesel Engine Emissions

Overview of Diesel Engine Aftertreatment Systems

• System Functions and Architectures
• Catalytic converter Design Basics
• Performance and Control

Diesel Particulate Filters (DPF)

• Design
• Performance and Control
• Failures

Diesel Oxidation Catalyst (DOC)

• Design
• Performance and Control
• Failures

Selective Catalytic Reduction (SCR)

• Physics of NH3 (DEF) Catalyst System
• Design and Performance
• Ammonia Slip Catalyst (ASC) Design
• Failure Mechanisms

Lean NOx Traps (LNT)

Aftertreatment System Configurations

• Heavy and Light Duty Trucks
• Off Highway
• Passenger Cars

ONLINE COURSE TOPICS

Day 1

Overview of IC Engine Systems

• Power Technology Comparison
• Combustion Cycles and Regimes
• Design Configuration and Criteria
• Current and Future Markets

Pressure-Volume Analysis, Work and Power

• Power and Efficiency
• Piston Work Calculations

Engine Torque Curves

• Applications
• Design limits

Day 2

Applying Thermodynamics in Engines

• Maximum work of IC Engines
• Entropy and Thermodynamic Availability
• Properties of the Engine Cycles
• Heat Release and Specific Heat Ratio

Combustion and Development in Diesel Engines

• Fuel Injection Spray and Mixing Processes
• Ignition Chemistry, and EGR effects
• Diffusion Flames and Temperature Considerations
• Combustion Chamber Optimization

Diesel Fuel Systems

• Injection Nozzle Design
• Injection Fuel System Types
• Commons Rail Systems

Day 3

Fuel Chemistry and Specifications

• Combustion and Stoichiometry Reactions
• Fuel Energy and Performance Specifications

Air Handling in Diesel Engines

• Port/Valve Flow and Motion
• Valve Event Optimization and Tuning
• Miller & Atkinson cycles
• EGR and Exhaust Temperature Control

Turbocharging

• Compressor Maps and Optimization
• Engine Matching and Boost Control
• EGR, Two-stage, and Intercooling
• Transient Supercharging

Day 4

Engine Emissions and Regulation

• Air Pollution Overview
• Emissions Regulations and Testing
• Diesel Engine Emissions

Diesel Particulate Filters (DPF)

• Design
• Performance and Control
• Failures

Diesel Oxidation Catalyst (DOC)

• Design
• Performance and Control
• Failures

Day 5

Selective Catalytic Reduction (SCR)

• Physics of NH3 (DEF) Catalyst System
• Design and Performance
• Ammonia Slip Catalyst (ASC) Design
• Failure Mechanisms

Aftertreatment System Configurations

• Heavy and Light Duty Trucks
• Off Highway
• Passenger Cars

ONLINE COURSE TABS

Monday – Overview of Diesel Engine Systems

Introductions

Tab 1 - Overview of Engine Mechanical Systems

Tab 2 - Pressure-Volume Analysis, Work and Power

Tab 3 - The Torque Curve and Engine Applications

Tuesday –Diesel Engine Thermodynamics and Combustion

Tab 4 – Applying Thermodynamic in Compression,
Combustion, and Expansion

Tab 5 - Combustion and Development in Diesel Engines

Tab 6 - Diesel Fuel Systems

Wednesday – Diesel Engine Performance Development

Tab 7 - Fuel Chemistry and Specifications

Tab 8 - Air Handling in Diesel Engines

• Pulse Dynamics and System Tuning
• Miller & Atkinson cycles
• In-cylinder Flow

Tab 9 – Turbocharging

Thursday – Diesel Engine Aftertreatment Emission Systems

Tab 10 - Diesel Engine Emissions and Regulation

Tab 11 – Diesel Particulate Filters (DPF)

• Functions
• Design (Substrates, Catalyst)
• Performance (Filtration, Regeneration)
• Control (Sensors, Loading, Regeneration)
• Failures (Cracking, Ash, etc.)

Tab 12 – Diesel Oxidation Catalyst (DOC)

• Functions
• Design and Performance
• Control
• Failure Mechanisms

Friday – Diesel Engine Aftertreatment Emission Systems

Tab 13 – Selective Catalytic Reduction (SCR)

• DEF Introduction System
• SCR System Controls
• System Failure Mechanisms
• Ammonia Slip Catalyst (ASC) Design
• SCR-on-Filter (SCRF, SDPF)

Tab 14 – Aftertreatment System Configurations

• Passenger Cars
• Pick-up Trucks
• HD Trucks
• Off-Highway Equipment

Review, Question

Michael Andrie

Michael Andrie is a program director and a researcher at the Engine Research Center (ERC) at the University of Wisconsin-Madison. He has more than 35 years of experience in engine development. Andrie began his engineering career at John Deere and then spent 17 years at Cummins Engine Company, where he managed and developed engines for the automotive, industrial, and marine markets. He joined the University of Wisconsin in 2007 and is active in research, mentoring, consulting, and continuing engineering education. Andrie holds several patents and is author on numerous publications. He also serves as the program manager for the over 35 members of the “Direct-injection Engine Research Consortium” (DERC) and the Biennial ERC symposium. Andrie holds a bachelor’s and a master’s degree in Agricultural and Mechanical Engineering from the University of Minnesota.

David Foster

David Foster is the Phil and Jean Myers Emeritus Professor of Mechanical Engineering at the University of Wisconsin-Madison, and the past director of the UW Engine Research Center. He has more than 40 years of experience in diesel and spark-ignition combustion research, and continues to be a consultant throughout the internal combustion engine industry and at US National Laboratories. Through these efforts he has gained practical engine development experience to complement his expertise in the fundamental sciences. Foster holds a doctoral degree in mechanical engineering from the Massachusetts Institute of Technology.

Thomas Harris

Tom Harris, Technical Specialist, Tenneco, has a B.S. in Chemistry from Butler University, M.S. and Ph.D. degrees in Metallurgy from the Massachusetts Institute of Technology, and an M.E. in Engine Systems from the University of Wisconsin. He has over 20 years of industrial experience, including 10 years with John Deere Power Systems, where he focused on aftertreatment design and development. He joined Tenneco in 2016; currently, he is a member of Global System Engineering, where he is involved in the modeling and testing of future aftertreatment and thermal management technologies for commercial trucks and off-highway equipment. He holds over 10 patents and has over 20 peer-reviewed publications.

Andrea Strzelec

Andrea Strzelec returned to the University of Wisconsin-Madison as the Program Director for the Masters of Engineering in Engine Systems (MEES) this May after being an Assistant Professor the Department of Mechanical Engineering and principle investigator of the Combustion & Reaction Characterization Laboratory (CRCL) at Mississippi State University and Texas A&M University.

Previous to her academic career, she did postdoctoral fellowships at Oak Ridge and Pacific Northwest National Laboratories. She received her interdisciplinary Combustion Engineering, combining Chemical and Mechanical Engineering, Ph.D. from the University of Wisconsin-Madison, working through the Engine Research Center and Oak Ridge National Laboratory. Her teaching experience is in thermodynamics, heat transfer, internal combustion engines, automotive engineering and combustion science.

Dr. Strzelec is also the Vice Chair of the SAE Exhaust Aftertreatment and Emissions Committee, Associate Editor of the Journal of Emissions Control Science & Technology, a recipient of the 2016 SAE Forrest R. McFarland Service Award, 2015 SAE Ralph R. Teetor Educational Award and the recipient of the Texas A&M Mechanical Engineering 2015 Brittian Undergraduate Teaching Award