Condensation; EGR cooler; Exhaust gas; Fouling; Review; Thermal performance; Beneficial effects; Compact heat exchanger; Exhaust gas condensation; Exhaust gas recirculation cooler; Harmful effects; Hydrocarbon vapors; Thermal Performance; Vapor condensation; Vapor water; Water vapour; Engineering (miscellaneous); Fluid Flow and Transfer Processes
Abstract :
[en] Fouling has limited the evolution of compact heat exchangers (represented by EGR cooler) to smaller and more efficient sizes, an important reason is the unclear mechanism of the effect of exhaust gas condensation on fouling and thermal performance. This paper reviews the effects of hydrocarbon vapor, water vapor and acid vapor condensation on EGR cooler fouling and thermal performance from 1998 to 2023. Three paths of vapors condensation can occurr: interaction with particles, homogeneous nucleation and interaction with fouling. Beneficial effect (3) and harmful effects (2) to EGR cooler thermal performance have identified: filling, removal and chemical are beneficial effects whereas adhesion and nucleation are harmful effects. Three pathways and five effects play a key role on the composition, the mass, the thickness, density, the morphology and thermal resistance of fouling layer. The involvement level of sub-paths and contribution degree of sub-effects of vapor condensation under different boundary conditions, standard database, holistic model and the effect of renewable synthetic fuels on fouling and thermal performance can be further explored. The results will help researchers to understand the logical relationship between exhaust vapor condensation and fouling and thermal performance from the new perspective of condensation.
Disciplines :
Mechanical engineering Energy
Author, co-author :
Yao, Yipeng ; Thermodynamic Laboratory, School of Engineering, University of Mons, Mons, Belgium ; Key Laboratory of Fluid and Power Machinery, Ministry of Education, Xihua University, Chengdu, China ; Vehicle Measurement, Control and Safety Key Laboratory of Sichuan Province, Xihua University, Chengdu, China
Han, Zhiqiang; Key Laboratory of Fluid and Power Machinery, Ministry of Education, Xihua University, Chengdu, China ; Vehicle Measurement, Control and Safety Key Laboratory of Sichuan Province, Xihua University, Chengdu, China ; Engineering Research Center of Ministry of Education for Intelligent Air-Ground Fusion Vehicles and Control, Xihua University, Chengdu, China
Tian, Wei; Key Laboratory of Fluid and Power Machinery, Ministry of Education, Xihua University, Chengdu, China ; Vehicle Measurement, Control and Safety Key Laboratory of Sichuan Province, Xihua University, Chengdu, China ; Engineering Research Center of Ministry of Education for Intelligent Air-Ground Fusion Vehicles and Control, Xihua University, Chengdu, China
Wu, Xueshun; Key Laboratory of Fluid and Power Machinery, Ministry of Education, Xihua University, Chengdu, China ; Vehicle Measurement, Control and Safety Key Laboratory of Sichuan Province, Xihua University, Chengdu, China ; Engineering Research Center of Ministry of Education for Intelligent Air-Ground Fusion Vehicles and Control, Xihua University, Chengdu, China
Wu, Yi; Vehicle Measurement, Control and Safety Key Laboratory of Sichuan Province, Xihua University, Chengdu, China
Yan, Yan; Vehicle Measurement, Control and Safety Key Laboratory of Sichuan Province, Xihua University, Chengdu, China
Xia, Qi; School of Intelligent Manufacturing and Electronic Engineering, Wenzhou University of Technology, Wenzhou, China
Fang, Jia; Key Laboratory of Fluid and Power Machinery, Ministry of Education, Xihua University, Chengdu, China ; Vehicle Measurement, Control and Safety Key Laboratory of Sichuan Province, Xihua University, Chengdu, China
Luo, Liping; Key Laboratory of Fluid and Power Machinery, Ministry of Education, Xihua University, Chengdu, China
De weireld, Guy ; Université de Mons - UMONS > Faculté Polytechniqu > Service de Thermodynamique, Physique mathématiques
Language :
English
Title :
Three condensation paths of exhaust and its five effects on exhaust gas recirculation (EGR) cooler fouling and thermal performance: A review
This work is jointly funded by the National Defense Science and Technology Key Laboratory Fund Project [ 2022-JCJQ-LB-062-0102 ], the National Natural Science Foundation of China [ 51776177 , 51876145 ], the Science and Technology Department of Sichuan Province [ 2021YJ0332 ]. Yipeng Yao acknowledge the China Scholarship Council (CSC) [ 202208510023 ], Wallonie-Bruxelles International (WBI) and Belgian National Fund for Scientific Research (F.R.S.-FNRS) for their financial support. The authors thank Tianyuan Yang of Xihua University for his help.This work is jointly funded by the National Defense Science and Technology Key Laboratory Fund Project [2022-JCJQ-LB-062-0102], the National Natural Science Foundation of China [51776177, 51876145], the Science and Technology Department of Sichuan Province [2021YJ0332]. Yipeng Yao acknowledge the China Scholarship Council (CSC) [202208510023], Wallonie-Bruxelles International (WBI) and Belgian National Fund for Scientific Research (F.R.S.-FNRS) for their financial support. The authors thank Tianyuan Yang of Xihua University for his help.
Kwon, J.S., et al. Compact Heat Exchangers for Supercritical CO2 Power Cycle Application, 2020, Energy Conversion and Management.
Ajeeb, W., Murshed, S.M.S., Nanofluids in compact heat exchangers for thermal applications: a State-of-the-art review. Thermal Science and Engineering Progress, 2022.
Ghassembaglou, N., Torkaman, L., Efficient design of exhaust gas cooler in cold EGR equipped diesel engine. Alex. Eng. J., 55(2), 2016.
Sahaya Surendira Babu, P., Kumar, P., External exhaust gas recirculation. Energy, Environment, and Sustainability, 2020.
Hoseini, S.S., Najafi, G., Ghobadian, B., Thermal and fluid simulation of a new diesel engine cooling exhaust gas recirculation system to reduce exhaust gas emissions. J.Adv. Res.Fluid Mech.Thermal Sci., 51(2), 2018.
Vijayendernath, A.K., Ajitkumar, R., Tyagi, R., Design of EGR cooler for improving the effectiveness to constraint NOx emission. Lecture Notes in Mechanical Engineering, 2019.
Teng, H., A semi-empirical model for predicting pressure drops of fouled EGR coolers. SAE Int. J. Commerc.Vehicl. 3:2010–01-1948 (2010), 156–163.
Zhang, F., van Nieuwstadt, M., Adaptive EGR Cooler Pressure Drop Estimation. 2008, SAE Technical Paper.
Williams, R., et al. Development of an engine test to rate the EGR deposit formation propensity of fuels in light-duty diesel engines. SAE Int.J.Adv. Curr. Pract. Mobil., 2020.
Sluder, C.S., Storey, J.M., Lance, M.J., Effectiveness Stabilization and Plugging in EGR Cooler Fouling. 2014, SAE Technical Paper.
Lance, M.J., et al. Analysis of Lacquer Deposits and Plugging Found in Field-Tested EGR Coolers, vol. 1, 2014, SAE Technical Paper.
Tomuro, M., et al. The Influence of the Operating Duty Cycles on the Composition of Exhaust Gas Recirculation Cooler Deposits of Industrial Diesel Engines. 2020, SAE Technical Paper 2020-April.
Cook, S.L., et al. Thermogravimetric analysis applied to characterisation of the evolution of EGR deposits in a working engine. Int. J. Engine Res., 2022.
Park, S.-K., Lee, J., Kim, H.-M., Experimental study on the spiral and oval spiral EGR cooler efficiencies in a diesel engine. Heat Mass Tran. 50:12 (2014), 1783–1789.
Shabgard, H., et al. Numerical simulation of cooling performance of an exhaust gas recirculation (EGR) cooler using nano-fluids. Appl. Therm. Eng. 110 (2017), 244–252.
Paz, C., et al. Development of a computational fluid dynamics model for predicting fouling process using dynamic mesh model. Heat Tran. Eng. 41:2 (2019), 199–207.
Pourrezaei, M.H., Malayeri, M.R., Hooman, K., Thermal performance and mechanisms of soot deposition in foam structured exhaust gas recirculation coolers. Int. J. Therm. Sci., 2019, 146.
Razmavar, A.R., Malayeri, M.R., Mitigation of soot deposition on modified surfaces of exhaust gas recirculation coolers. Heat Tran. Eng. 40:20 (2019), 1680–1690.
Paz, C., et al. Fouling evolution on ribbed surfaces under EGR dry soot conditions: experimental measurements and 3D model validation. Int. J. Therm. Sci., 2020, 151.
Razmavar, A., Malayeri, M.R., Abd-Elhady, M.S., Influence of secondary flow on the thermal performance of exhaust gas recirculation (EGR) coolers. Int. J. Therm. Sci., 161, 2021, 106720.
Zhang, X., et al. Effects of gas flow on particulate deposition in EGR coolers. J. Mech. Sci. Technol. 36:1 (2022), 491–497.
Khoshnood, A., et al. Effect of Soot Particle Deposition on Porous Fouling Formation and Thermal Characteristics of an Exhaust Gas Recirculation Cooler. Available at: SSRN 4336815, 2023.
Love, N.D., Szybist, J.P., Sluder, C.S., Effect of heat exchanger material and fouling on thermoelectric exhaust heat recovery. Appl. Energy 89:1 (2012), 322–328.
Paz, C., et al. Experimental evaluation of the critical local wall shear stress around cylindrical probes fouled by diesel exhaust gases. Exp. Therm. Fluid Sci. 38 (2012), 85–93.
Abd-Elhady, M.S., Malayeri, M.R., Asymptotic characteristics of particulate deposit formation in exhaust gas recirculation (EGR) coolers. Appl. Therm. Eng. 60:1–2 (2013), 96–104.
Abd-Elhady, M.S., Malayeri, M.R., Mitigation of soot deposition in exhaust gas recirculation coolers using a spiral insert. Aerosol. Sci. Technol. 48:2 (2013), 184–192.
Malayeri, M.R., et al. Deposition of nanosized soot particles in various EGR coolers under thermophoretic and isothermal conditions. Heat Tran. Eng. 34:8–9 (2013), 665–673.
Paz, C., et al. Development of a predictive CFD fouling model for diesel engine exhaust gas systems. Heat Tran. Eng. 34:8–9 (2013), 674–682.
Sluder, C.S., et al. Removal of EGR cooler deposit material by flow-induced shear. SAE Int.J.Engine 6:2 (2013), 999–1008.
Li, H., et al. Visual study of in-situ EGR cooler fouling layer evolution. ASME 2014 Internal Combustion Engine Division Fall Technical Conference, 2014.
Abd-Elhady, M.S., Malayeri, M.R., Müller-Steinhagen, H., Fouling problems in exhaust gas recirculation coolers in the automotive industry. International Conference on Heat Exchanger Fouling and Cleaning VIII - 2009, 2009.
Abarham, M., et al. Review of soot deposition and removal mechanisms in EGR coolers. SAE Int. J. Fuel.Lubric. 3:1 (2010), 690–704.
Abd-Elhady, M.S., Malayeri, M.R., Müller-Steinhagen, H., Fouling problems in exhaust gas recirculation coolers in the automotive industry. Heat Tran. Eng. 32:3–4 (2011), 248–257.
Kumar, N.P., Krishnan, S.S.J., Thasan, N.S., Effects of fouling in EGR coolers in automobiles - a review study. Int. J. Innovat.Res. Sci. Eng. Technol., 2013.
Han, T., et al. Review and a conceptual model of exhaust gas recirculation cooler fouling deposition and removal mechanism. Proceedings of International Conference on Heat Exchanger Fouling and Cleaning - 2015, 2015, Heat Exchanger Fouling and Cleaning.
Paz, C., et al. Numerical modelling of fouling process in EGR system: a review. Environmental Issues and Sustainable Development, 2021.
Abarham, M., et al. Modeling of thermophoretic soot deposition and hydrocarbon condensation in EGR coolers. SAE Int. J. Fuel.Lubric. 2:1 (2009), 921–931.
Warey, A., et al. A one-dimensional model for particulate deposition and hydrocarbon condensation in exhaust gas recirculation coolers. Aerosol. Sci. Technol. 46:2 (2012), 198–213.
Warey, A., et al. Influence of water vapor condensation on exhaust gas recirculation cooler fouling. Int. J. Heat Mass Tran. 65 (2013), 807–816.
Paz, C., et al. Experimental study of the effect of hydrocarbon condensation on the fouling deposits of exhaust gas recirculation coolers. Heat Exchanger Fouling and Cleaning – 2019, 2019.
Razmavar, A., Malayeri, M.R., Thermal performance of a rectangular exhaust gas recirculation cooler subject to hydrocarbon and water vapor condensation. Int. J. Therm. Sci. 143 (2019), 1–13.
Paz, C., et al. Evolution of EGR cooler deposits under hydrocarbon condensation: analysis of local thickness, roughness, and fouling layer density. Int. J. Therm. Sci., 2021, 161.
Han, Z., et al. Effect of hydrocarbon condensation on fouling and heat exchange efficiency in EGR cooler. Int. J. Therm. Sci., 184, 2023 107898-107898.
Bika, A.S., et al. Characterization of soot deposition and particle nucleation in exhaust gas recirculation coolers. Aerosol. Sci. Technol. 46:12 (2012), 1328–1336.
Abarham, M., et al. In-situ visualization of exhaust soot particle deposition and removal in channel flows. Chem. Eng. Sci. 87 (2013), 359–370.
Warey, A., et al. Visualization and Analysis of Condensation in Exhaust Gas Recirculation Coolers. 2013, SAE Technical Paper.
Paz, C., et al. CFD study of the fouling layer evolution due to soot deposition and hydrocarbon condensation inside an exhaust gas recirculation cooler. Heat Exchanger Fouling and Cleaning – 2019, 2019.
Li, J., et al. Effect of hydrocarbon concentration on particulate deposition and microstructure of the deposit in exhaust gas recirculation cooler. Int. J. Automot. Technol. 23:3 (2022), 775–784.
Khalek, I.A., Kittelson, D.B., Brear, F., Nanoparticle growth during dilution and cooling of diesel exhaust: experimental investigation and theoretical assessment. SAE Technical Papers, 2000.
Baumgard, K.J., Johnson, J.H., The effect of fuel and engine design on diesel exhaust particle size distributions. SAE Technical Papers, 1996.
Sluder, C.S., Storey, J.M.E., EGR Cooler Performance and Degradation: Effects of Biodiesel Blends. 2008, SAE Technical Paper.
Sluder, C.S., et al. Hydrocarbons and particulate matter in EGR cooler deposits: effects of gas flow rate, coolant temperature, and oxidation Catalyst. SAE Int.J.Engine 1:1 (2008), 1196–1204.
Lance, M.J., et al. Direct Measurement of EGR Cooler Deposit Thermal Properties for Improved Understanding of Cooler Fouling. 2009, SAE Technical Paper.
Sluder, C.S., Storey, J.M.E., Youngquist, A., ULSD and B20 hydrocarbon impacts on EGR cooler performance and degradation. SAE Technical Paper, 2009, SAE International.
Styles, D., et al. Factors impacting EGR cooler fouling: main effects and interactions benefits and challenges of cooled EGR. 16th Directions in Engine-Efficiency and Emission Research Conference (DEER), 2010, 1–25 Detroit, MI, September. 2010.
Hong, K.S., et al. Parametric study on particle size and SOF effects on EGR cooler fouling. Atmos. Environ. 45:32 (2011), 5677–5683.
Hong, K.S., Park, J.S., Lee, K.S., Experimental evaluation of SOF effects on EGR cooler fouling under various flow conditions. Int. J. Automot. Technol. 12:6 (2011), 813–820.
Lee, Y., et al. Evaluation of SOF Effects on Deposit Characteristics of the EGR Cooler Using a PM Generator. 2011, SAE Technical Paper.
Bravo, Y., et al. Effects of soot deposition on EGR coolers: dependency on heat exchanger technology and engine conditions. Proceedings of International Conference on Heat Exchanger Fouling and Cleaning - 2013, 2013.
Bravo, Y., Lujan, J., Tiseira, A., Characterization of EGR cooler response for a range of engine conditions. SAE Int.J.Engine 6:1 (2013), 587–595.
Lance, M.J., et al. Microstructural Analysis of Deposits on Heavy-Duty EGR Coolers, vol. 2, 2013, SAE Technical Paper.
Prabhakar, B., Boehman, A.L., Effect of engine operating conditions and coolant temperature on the physical and chemical properties of deposits from an automotive exhaust gas recirculation cooler. J. Eng. Gas Turbines Power, 135(2), 2013.
Storey, J.M.E., et al. Exhaust gas recirculation cooler fouling in diesel applications: fundamental studies of deposit properties and microstructure. Heat Tran. Eng. 34:8–9 (2013), 655–664.
Kuhara, K., et al. Evaluation of degradation behavior of EGR-cooler performance and deposits characterization. Trans. Soc. Automot. Eng. Jpn. Inc, 45(2), 2014.
Salvi, A., et al. Effect of volatiles on soot based deposit layers. J. Eng. Gas Turbines Power, 136(11), 2014.
Paz, C., Suárez, E., López, B., Gas and particle size characterizations of a soot generator for fouling studies in exhaust gas recirculation systems. 12th International Conference on Heat Transfer, 2016, Fluid Mechanics and Thermodynamics.
Tanaka, K., et al. Investigation of mechanism for formation of EGR deposit by in situ ATR-FTIR spectrometer and SEM. SAE Int.J.Engine 9:4 (2016), 2242–2249.
Yoo, K.H., et al. Experimental Studies of EGR Cooler Fouling on a GDI Engine. 2016, SAE Technical Paper 2016-April.
Bravo, Y., et al. Impact on Fouling of Different Exhaust Gas Conditions with Low Coolant Temperature for a Range of EGR Cooler Technologies. 2018, SAE Technical Paper 2018-April.
Lance, M.J., et al. The effect of engine operating conditions on exhaust gas recirculation cooler fouling. Int. J. Heat Mass Tran. 126 (2018), 509–520.
Park, S., Lee, K., Park, J., Parametric study on EGR cooler fouling mechanism using model gas and light-duty diesel engine exhaust gas. Energies, 11(11), 2018.
Kodama, S., et al. Effect of Exhaust Gas Composition on EGR Deposit Formation. 2019, SAE Technical Paper.
Tanaka, K., et al. Evaluation of mechanism for EGR deposit formation based on spatially- and time-resolved scanning-electron-microscope observation. SAE Int.J.Adv. Curr. Pract. Mobil. 3:1 (2020), 150–158.
Zhang, X., et al. Effects of coolant temperature on particulate deposition and cooling efficiency of EGR coolers. J. Mech. Sci. Technol. 35:7 (2021), 3231–3237.
Liebsch, S., et al. EGR Cooler Fouling Reduction: A New Method for Assessment in Early Engine Development Phase. 2022, SAE Technical Paper.
Williams, R., et al. Control of Diesel Engine Exhaust Gas Recirculation System Deposits with Fuel Additives. 2022, SAE Technical Paper.
Lance, M.J., et al. Neutron tomography of exhaust gas recirculation cooler deposits. SAE Technical Paper, 2014.
Teng, H., Barnard, M., Physicochemical Characteristics of Soot Deposits in EGR Coolers. 2010, SAE Technical Paper.
Abd-Elhady, M.S., et al. Influence of gas velocity on particulate fouling of exhaust gas recirculation coolers. Int. J. Heat Mass Tran. 54:4 (2011), 838–846.
Furuhata, T., Gunatilaka, T., Arai, M., PM deposition in an EGR cooler and removal of the deposited PM by air flow. Proceed.Autom. Vehicle Technol.Conf. 42 (2011), 1117–1123.
Abarham, M., et al. A Visualization Test Setup for Investigation of Water-Deposit Interaction in a Surrogate Rectangular Cooler Exposed to Diesel Exhaust Flow. 2012, SAE Technical Paper.
Völk, P., et al. Deposition mechanisms in exhaust heat exchangers. MTZ Worldwide 73:9 (2012), 58–64.
Furuhata, T., et al. Experimental study on PM deposition behavior in an EGR cooler. Trans. JSME (in Japanese), 80(820), 2014 TEP0365-TEP0365.
Uchiyama, K., et al. Effect of Exhaust Gas Inlet Condition and Wall Temperature on PM Deposition Behavior in an EGR Cooler. 2014, The Proceedings of Mechanical Engineering Congress, Japan, G0710206.
Warey, A., et al. Combination of pre-EGR cooler oxidation Catalyst and water vapor condensation to mitigate fouling. SAE Int.J.Engine 7:1 (2014), 21–31.
Konno, M., et al. Analysis of factors contributing to EGR deposit formation. Proceed.Autom. Vehicle Technol.Conf. 48:5 (2017), 993–999.
Matsudaira, N., et al. Visualization of the Heat Transfer Surface of EGR Cooler to Examine Soot Adhesion and Abruption Phenomena. 2017, SAE Technical Paper.
Woo, S., et al. An experimental study on removal of exhaust gas recirculation cooler fouling using washer fluid steam. Int. J. Heat Mass Tran. 108 (2017), 301–308.
Itoh, Y., et al. Effects of Cooled Wall Temperature and HC Concentration on Separation Behavior of PM Deposit Layer in an EGR Cooler. 2019, SAE Technical Paper.
Girard, J.W., et al. A study of the character and deposition rates of sulfur species in the EGR cooling system of a heavy-duty diesel engine. SAE Trans., 1999, 1777–1788.
Usui, S., Ito, K., Kato, K., The Effect of Semi-circular Micro Riblets on the Deposition of Diesel Exhaust Particulate. 2004, SAE Technical Paper.
Lance, M.J., et al. Characterization of field-aged EGR cooler deposits. SAE Int.J.Engine 3:2 (2010), 126–136.
Sturm, M., et al. AGR-Kühlung - Eine Herausforderung zur Erfüllung zukünftiger Emissionsvorschriften an Großdieselmotoren. 2012.
Bika, A.S., et al. An Investigation of Diesel EGR Cooler Fouling and Effectiveness Recovery, vol. 2, 2013, SAE Technical Paper.
Hörnig, G., et al. Fouling of EGR heat exchangers – investigation of mechanisms involved in soot particle deposition. Proceedings of International Conference on Heat Exchanger Fouling and Cleaning - 2011, 2011.
Arnal, C., et al. Characterization of different types of diesel (EGR cooler) soot samples. SAE Int.J.Engine 8:4 (2015), 1804–1814.
Zhan, R., et al. EGR system fouling control. SAE Int.J.Engine 1:1 (2009), 59–64.
Chang, J., et al. Plasma suppression of diesel soot deposition during diesel engine operations. Int. J. Plasma Environ. Sci. Technol. 3 (2009), 15–21.
Chen, Y.Y., et al. Experimental study on regenerating fouled EGR cooler by NTPI technology. Int. J. Automot. Technol. 16:2 (2015), 183–191.
Li, X., et al. Deposit removal in EGR cooler and effectiveness improvement by non-thermal plasma reactor with different gas sources. Appl. Therm. Eng. 111 (2017), 694–702.
