Exhaust Gas Recirculation Cooler Fouling in Diesel Applications: Fundamental Studies of Deposit Properties and Microstructure

This article reports on the results of experimental efforts aimed at improving the understanding of the mechanisms and conditions at play in the fouling of exhaust gas recirculation coolers. An experimental apparatus was constructed to utilize simplified surrogate heat exchanger tubes in lieu of full-size heat exchangers. The use of these surrogate tubes allowed removal of the tubes after exposure to engine exhaust for study of the deposit layer and its properties. The exhaust used for fouling the surrogate tubes was produced using a modern medium-duty diesel engine fueled with both ultra-low-sulfur diesel and biodiesel blends. At long exposure times, no significant difference in the fouling rate was observed between fuel types and hydrocarbons levels. Surface coatings for the tubes were also evaluated to determine their impact on deposit growth. No surface treatment or coating produced a reduction in the fouling rate or any evidence of deposit removal. In addition, microstructural analysis of the fouling layers was performed using optical and electron microscopy in order to better understand the deposition mechanism. The experimental results are consistent with thermophoretic deposition for deposit formation, and van der Waals attraction between the deposit surface and exhaust-borne particulate.