Prediction of Condensation in the Heat Exchangers of Engine Intake Systems according to External Environmental and Operating Conditions

Low-pressure exhaust gas recirculation (LP-EGR) systems are applied to diesel engines because they reduce nitrogen oxide emission by lowering the internal temperature of the cylinder by mixing the oxides with intake air. However, low-temperature ambient conditions include a large amount of vapor in the mixed gas flowing into the intercooler; when heat is exchanged, the water vapor condenses and is adsorbed on the surface of the intercooler fin to form a liquid film. Condensation occurs as the thermal resistance between the vapor and solid surface increases with the thickness of the liquid film and causing a corrosion due to condensation of the surface. In this study, the amount of condensation was predicted through calculations based on thermodynamic studies. Factors that can cause condensation inside the intercooler (fuel, air, and LP-EGR) were selected as variables. A mathematical formula was established to predict the convergence form of condensation or the amount of condensation over time at various temperature and relative humidity conditions. The formula predicted the condensation amount in the intercooler of the diesel engine, compared it to the actual amount of condensation in the test evaluation with an error of less than 4%. Additionally, because the formula can predict the amount of condensation by changing the heat exchange area of the intercooler, the application range of the formula was expanded to predict the condensation in the intercoolers of gasoline vehicles with different heat exchange areas and fuel types. The condensation error was within 2%, indicating a high consistency. Validation of the formula predicts a reliable amount of condensation under various operating and ambient temperature conditions, which means that both the time and cost of the test evaluation require the determination of the cause before solving the actual condensation problem.