The effect of engine operating conditions on exhaust gas recirculation cooler fouling

Exhaust gas recirculation (EGR) cooler fouling occurs when particulate matter (PM) and hydrocarbons (HC) in diesel exhaust form a deposit on the walls of the EGR cooler through thermophoresis and condensation. To better understand the mechanisms controlling deposit formation and removal and how operating conditions can affect cooler performance, 20 identical tube-in-shell EGR coolers with sinusoidal fins were fouled using a 5-factor, 3-level experimental design. The deposit thickness was measured using two methods: (1) epoxy-mounting and polishing cooler cross-sections and comparing deposit thicknesses on the primary (outer tube) to the secondary (fins) heat transfer surfaces, and (2) milling tube sections such that the surface of a fin could be observed and measuring the deposit thickness across the fin using a 3D profilometer. Near the cooler inlet, high inlet gas temperatures reduced deposit thickness by promoting mud-cracking and spallation. Near the middle of the cooler, the flow rate had the largest impact on the deposit thickness through the effect on residence time of the PM. The HC concentration along with flow rate had the largest effects near the cooler outlet where the lower temperatures allows for more HC condensation. These insights into how engine operating conditions influence the development of fouling layers in EGR coolers learned through this study will aid in the development of more fouling resistant coolers in the future.