Combustion and Emissions Optimization of Diesel–Methanol Dual-Fuel Engine: Emphasis on Valve Phasing and Injection Parameters

Diesel–methanol dual-fuel (DMDF) mode holds significant potential for achieving highly efficient and clean combustion in modern marine engines. However, issues such as low methanol substitution rate and high pollutant emissions persist, and the underlying mechanisms are not fully understood. This study numerically investigated the combustion and emissions of a heavy-duty marine engine operating in DMDF mode. Multi-cycle simulations, incorporating diesel and methanol dual-fuel chemical mechanisms, were carried out to explore engine performance across various key parameters, including valve phasing, injection pressure, injection phasing, and nozzle diameter. The results indicate that valve phasing can greatly affect the indicated thermal efficiency, particularly at large valve overlap angles. This is primarily attributed to the variations of methanol film mass and thereby overall combustion efficiency. The optimized valve phasing increases the indicated thermal efficiency by 2.4%. By optimizing injection parameters, the formation of methanol film is effectively reduced, facilitating the improvement in the indicated thermal efficiency. The optimal injection pressure and nozzle diameter are 20 bar and 0.3 mm, respectively, resulting in increases in indicated thermal efficiency of 1.28% and 1.07%, compared to the values before optimization. Advancing injection timing and increasing nozzle diameter markedly decrease methanol film mass because some methanol remains undisturbed by the intake flow, while large droplet sizes tend to enhance the resistance to airflow. As injection pressure rises from 20 bar to 50 bar, the spray–wall interaction region expands, droplet size diminishes, and methanol film formation increases. Consequently, the combustible methanol in the cylinder is reduced, undermining the indicated thermal efficiency. Additionally, there exists a trade-off relationship between NOx and soot emissions, and the high heat release rate results in increased NOx but decreased soot emissions for diesel–methanol dual-fuel engines.