Controlling fuel injector deposits is recognised as a challenge for advanced direct-injection sparkignition (DISI) engines. This paper gives a comprehensive overview of the research on formation, measurement, effect, and mitigation of injector deposits in DISI engines. Methodologies for the injector deposit studies include visual and compositional analysis. It is shown that injector deposits will reduce injector fuel flow rates, and lead to changes in spray characteristics. Consequently, spray angle and envelope are likely to be affected, and spray penetration distance as well as droplet diameter can be increased. Injector deposits are revealed to be primarily fuel-derived and created by two distinct free radical pathways, i.e., low temperature auto-oxidation and high temperature pyrolysis. Fuel compositions (olefins, aromatics, and sulphur), as well as T90 parameter, are significant factors in injector deposit formation. The worst consequences of injector fouling are pre-ignition, and engine misfiring and malfunction. Emissions, especially particulates, dramatically increase as the fuel injector becomes fouled. It appears that fuel detergent is the most effective method in controlling injector deposit formation if its chemistry and dosage rate are optimized. Outward opening piezo-driven injector configuration with a good surface finish, a sharp nozzle inlet, and a counter bore design, is useful in preventing injector deposit formation. Reducing injector nozzle temperature by methods such as designing special injector cooling passages, and improving engine design are also proven to be 2 helpful in reducing injector fouling. Anti-deposit coatings only delay the onset of injector deposit formation.

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Diesel engine emissions of oxides of nitrogen and smoke can be reduced simultaneously through the use of high levels of exhaust gas recirculation to achieve low-temperature combustion. However, single fuel injection per cycle diesel low-temperature combustion is also characterized by high fuel consumption and high total unburned hydrocarbons and carbon monoxide emissions. This work focuses on investigating the potential of a split (50/50) main fuel-injection strategy to reduce smoke, total unburned hydrocarbons and carbon monoxide emissions at exhaust gas recirculation levels lower than those required to achieve single-injection diesel low-temperature combustion at a medium-load, medium-speed operating condition. Experiments were performed on a 0.51 l single-cylinder high-speed direct-injection diesel engine running at 1500 r/min at an operating condition corresponding to a gross indicated mean effective pressure of 500 kPa. At this load, exhaust gas recirculation levels of 62% are needed to realize near-zero nitrogen oxide and smoke emissions, but this leads to an unacceptable reduction in thermal efficiency as well as high total unburned hydrocarbons and carbon monoxide emissions. This work compares the effects of split fuel injections at an exhaust gas recirculation level of 52% by volume to those from single injections at exhaust gas recirculation levels of 52% and 62%. The results demonstrate that the combined effects of exhaust gas recirculation rate and split injections can achieve near-zero nitrogen oxide with good thermal efficiency and total unburned hydrocarbons and carbon monoxide emissions much lower than at 62% exhaust gas recirculation. Single injection at this point results in excessive smoke, which can be reduced by over 75% through the split-injection strategy. These results are particularly relevant as they demonstrate very low nitrogen oxide emissions from an engine operation with acceptable thermal efficiency and at practical exhaust gas recirculation levels.

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This paper shows that a split-fuel-injection strategy can achieve robust, near-zero smoke and nitrogen oxide emissions at reduced exhaust gas recirculation levels under low-temperature combustion conditions. The overall objective of the work was to investigate the sensitivity (in terms of the engine emissions and the fuel economy) of a 50:50 (by mass) split-injection strategy to variations in the key engine operating parameters. Experiments were performed at operating conditions corresponding to a gross indicated mean effective pressure of 500 kPa at an engine speed of 1500 r/min in a 0.51 l single-cylinder high-speed direct-injection diesel engine. The paper presents the effects of different relative fuel injection timings at a variable intake oxygen mass fraction (10.5% and 12%) at a constant intake pressure (120 kPa, absolute) on the smoke, total hydrocarbon and carbon monoxide emissions with the split-main-injection strategy. The effects of a variable fuel injection pressure (90 MPa and 110 MPa) on diesel low-temperature combustion with split injection are also reported, as are the effect of an increased intake pressure (150 kPa, absolute). The combined effects of the operating parameters and the fuel injection timing on the smoke, nitrogen oxide, total hydrocarbon and carbon monoxide emissions and the gross indicated specific fuel consumption are described. For selected operating conditions, the cycle-resolved spray and combustion processes are visualized together with the flame temperature measurement using two-colour optical pyrometry to understand the combustion phenomena occurring in the split-injection strategy. The results of the optical studies show that different low-temperature combustion operating conditions producing similarly low levels of ‘engine-out’ smoke emissions have substantially different histories of soot formation and soot oxidation. An increase in the intake oxygen mass fraction reduced the total hydrocarbon emissions and the gross indicated specific fuel consumption at a given intake pressure, while a higher intake pressure reduced them further. Although significant soot formation took place from the second injection event, the majority of the soot was subsequently oxidized because of a slightly higher flame temperature and slightly higher oxygen concentration than in single-injection high-exhaust-gas-recirculation low-temperature combustion. A higher injection pressure did not have any significant effect on the emissions and the gross indicated specific fuel consumption.