Numerical Investigation of Hydrogen Substitution Ratio Effects on Spray Characteristics, Combustion Behavior, and Emissions in a Dual-Fuel Compression Ignition Engine

Hydrogen is a promising alternative fuel for internal combustion engines due to its high specific energy, fast flame speed, and carbon-free combustion. In dual-fuel operation, it offers a practical route to reducing greenhouse gas emissions while remaining compatible with existing engine hardware. This work evaluates how the hydrogen energy substitution ratio (HSR = 50, 70, and 90%) influences spray dynamics, combustion characteristics, and emissions in a heavy-duty compression ignition engine. Simulations are validated against experiments and use a URANS RNG k–ε framework with a hybrid combustion model: the Eddy Dissipation Concept (EDC) coupled with detailed kinetics (111 species, 768 reactions) for auto-ignition and diffusion burning of diesel, and a G-equation for propagation of a hydrogen-rich premixed flame. The results reveal clear spray–combustion linkages. At HSR 50, the higher Weber number induces stronger breakup, yielding a smaller Sauter mean diameter and higher number-averaged droplet velocity; at HSR 90, the spray is more stable and less atomized, with larger droplets and a shorter vapor penetration length. Increasing the HSR reduces unburned hydrocarbons (UHCs) by more than 50% from HSR 50 to HSR 90 while modestly altering combustion phasing (a later CA50 and a shorter burn duration due to faster hydrogen flame propagation). The validated model provides a practical tool for optimizing dual-fuel settings and HSR–EGR–SOI trade-offs to balance efficiency and emissions.