Design and Implementation of a D-EGR® Mixer for Improved Dilution and Reformate Distribution

The Dedicated EGR (D-EGR^®) engine has shown improved efficiency and emissions while minimizing the challenges of traditional cooled EGR. The concept combines the benefits of cooled EGR with additional improvements resulting from in-cylinder fuel reformation. The fuel reformation takes place in the dedicated cylinder, which is also responsible for producing the diluents for the engine (EGR). The D-EGR system does present its own set of challenges. Because only one out of four cylinders is providing all of the dilution and reformate for the engine, there are three “missing” EGR pulses and problems with EGR distribution to all 4 cylinders exist. In testing, distribution problems were realized which led to poor engine operation. To address these spatial and temporal mixing challenges, a distribution mixer was developed and tested which improved cylinder-to-cylinder and cycle-to-cycle variation of EGR rate through improved EGR distribution. This paper will discuss the process by which the mixer was designed and compare alternative solutions to the final mixer design. Engine data with and without the mixer in place will be shown to demonstrate the level of EGR distribution improvement.