The Impact of the Common Rail Fuel Injection System on Performance and Emissions of Modern and Future Compression Ignition Engines

Alessandro Ferrari () and Alberto Vassallo
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Alessandro Ferrari: Department of Energy, Politecnico di Torino, Corso Duca degli Abruzzi, 10129 Torino, Italy
Alberto Vassallo: Dumarey Torino S.p.A., Corso Castelfidardo 36, 10129 Torino, Italy

Energies, 2025, vol. 18, issue 19, 1-206

Abstract: An overview of the Common Rail (CR) diesel engine challenges and of the promising state-of-the-art solutions for addressing them is provided. The different CR injector driving technologies have been compared, based on hydraulic, spray and engine performance for conventional diesel combustion. Various injection patterns, high injection pressures and nozzle design features are analyzed with reference to their advantages and disadvantages in addressing engine issues. The benefits of the statistically optimized engine calibrations have also been examined. With regard to the combustion strategy, the role of a CR engine in the implementation of low-temperature combustion (LTC) is reviewed, and the effect of the ECU calibration parameters of the injection on LTC steady-state and transition modes, as well as on an LTC domain, is illustrated. Moreover, the exploitation of LTC in the last generation of CR engines is discussed. The CR apparatus offers flexibility to optimize the engine calibration even for biofuels and e-fuels, which has gained interest in the last decade. The impact of the injection strategy on spray, ignition and combustion is discussed with reference to fuel consumption and emissions for both biodiesel and green diesel. Finally, the electrification of CR diesel engines is reviewed: the effects of electrically heated catalysts, electric supercharging, start and stop functionality and electrical auxiliaries on NO x , CO 2 , consumption and torque are analyzed. The feasibility of mild hybrid, strong hybrid and plug-in CR diesel powertrains is discussed. For the future, based on life cycle and manufacturing cost analyses, a roadmap for the automotive sector is outlined, highlighting the perspectives of the CR diesel engine for different applications.

Keywords: Common Rail; diesel engine; low-temperature combustion; biodiesel; e-diesel; electrification; on-road sustainable mobility (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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