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High Efficiency Combustion Engines – What is the limit?

High Efficiency Combustion Engines – What is the limit?. Prof. Bengt Johansson Lund University. Outline. Introduction The future is hard to predict Options Other combustion engines? Fuel cells? Batteries? Combustion engines What is high efficiency?

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High Efficiency Combustion Engines – What is the limit?

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  1. High Efficiency Combustion Engines – What is the limit? Prof. Bengt Johansson Lund University

  2. Outline • Introduction • The future is hard to predict • Options • Other combustion engines? • Fuel cells? • Batteries? • Combustion engines • What is high efficiency? • Combustion, thermodynamic, gas exchange and mechanical efficiencies. All four must be high. • What options do we have? • Combustion to enable high efficiency • Spark Ignition • Compression Ignition • HCCI • Partially Premixed Combustion • Can we do something about engine design? • Conclusions

  3. Today 100.0% of all cars and trucks have internal combustion engines The total fleet is about 1.000.000.000 cars and trucks The electric fleet is less an 1.000.000 i.e. 0.1%

  4. “Prediction is very difficult especially if it is about the future”- Niels Bohr http://wattsupwiththat.com/2014/07/27/prediction-is-very-difficult-especially-about-the-future/

  5. Newsweek April 28, 1975

  6. ”Den som ser framåt utan att se bakåt får se upp” - Per Gillbrand

  7. Car of the future 1950-60: Gas turbine

  8. Car of the future 1950-60: Gas turbine “Timetable for Next Car Engine : The Gas Turbine and Its Future” Business Week, April 2, 1955, page 134+ THEY ESTIMATE by 1960 .................60,000 - 300,000 cars 1965 ................264,000 - 3,900,000 1970 .............11,500,000 - 42,500,000 1975 .............48,000,000 - 62,000,000 http://fuel-efficient-vehicles.org/energy-news/?page_id=943

  9. Car of the future 1970: Stirling

  10. Car of the future 1980: ….

  11. Car of the future 1990: Battery Electric GM EV-1

  12. Car of the future 2000: Fuel Cell

  13. Car of the future 2000: Fuel Cell “It is generally accepted that fuel cell vehicle production will follow a timeline as follows: Starting in 2002-4: • First production FCVs tested on public roads in US, Europe and Japan in demonstration fleets. Around 2006-2007 • Second generation fuel cell systems incorporated into FCVs and the expansion of FCV fleets in the US, Europe and Japan. Starting in 2010 • Marketing of commercially viable FCVs at affordable prices - this will be the first step toward ultimately replacing the conventional internal combustion engine models.” August 29, 2002, Bloomberg News: ”Larry Burns, GM’s vice-president for R&D: “GM’sgoal is to be the world’sfirstcompanytoproduceone million fuel cell vehicles a year,” and thatGM is lookingtosellhundredsofthousandsoffuel cell vehiclesbetween 2010 and 2020 http://www.engr.uconn.edu/~jmfent/AutoCompaniesonFuelCells.pdf

  14. Car of the future 2010: Battery Electric Carlos Ghosn CEO Renault/Nissan 2010: “Nissan Will Sell 500,000 Electric Cars a Year by 2013” He predicted that 10 percent of the world car market would be electric vehicles by 2020. “There is no doubt in the minds of anyone in the industry that this is going to be a big factor in the industry,” he said.

  15. Car of the future 2010: Battery Electric Reuters news flash Sept 14 2014: Nissan faces battery plant cuts as electric car hopes fade Ghosn dropped extra battery sites planned for both alliance carmakers, leaving Nissan with the entire production capacity of 220,000 power packs through the NEC joint venture, AESC. But that still far exceeds the 67,000 electric cars Renault-Nissan sold last year, and even the 176,000 registered to date. A pledge to reach 1.5 million by 2016 has been scrapped.

  16. Toyota: ElbilenbehöverNobelprisbatteri • Teknikensombehövsförattgöraelbilaranvändbaraärinteuppfunnenän • Körsträckanärsåkort med en elbil, ochladdtidenärsålång, summerar Kato. Med den tekniknivå vi befinnerosspåi dag behövernågonuppfinnaettbatteriså bra attdetvinnerNobelpris. • Förattkunnakonkurrera med dagensbensindrivnabilarbehövssåmycketbatterierattdetökarkostnadernaochladdtiderna. • - Antaletkundersomärnöjda med elbilenskortaräckviddärbegränsad, sägerhan. Men blirintressetförsådanabilarplötsligtstörre, dåär vi bereddaattleverera. Av: Håkan Abrahamson, Ny teknik 10 juli 2014

  17. Toyota: ElbilenbehöverNobelprisbatteri • I en intervjui Automotive News gerhantummennerförsatsningenpåelbilar, ochsägerattToyota nu lägger sin tillverkningavelbilar. • Företagettrorattalternativet till bensinoch diesel hetervätgas. Nästaårlanserar Toyota enbränslecellbil, ochävenandratillverkare ligger startgroparna med den sortensdrivning. • Vid detlageterbjuder Toyota intelängrenågonhelteldrivenbil, säger Kato. De småserieravelbilarsom nu finnspåprogrammet, minibileneQoch RAV4 EV, läggsnerislutetavdethäråret. • Av: Håkan Abrahamson, Ny teknik 10 juli 2014 


  18. Battery performance “The active material for the anode and the cathode which are assumed to be a carbon-based anode (~2.7 g/Ah) and a Co-based cathode (~7.3 g /Ah) for the Li-ion cell. The specific capacity of the couple is therefore ~100 Ah/kg which combined with the  voltage of 3.85 V for this couple leads to the 385 Wh/kg number” Source: Private communications with PrabhakarPatil, CEO, LG Chem, Battery Div. Nov. 4, 2011

  19. Li-ion battery performance is now at 52% of theoretical limit 40/250=0,160 55/245=0,225 55/315=0,175 70/370=0,189 80/240=0,333 20/810=0,025 20/135=0,148 70/570=0,123 180/790=0,228 130/459=0,283 200/385=0,519 Source: Private communications with PrabhakarPatil, CEO, LG Chem, Battery Div. Nov. 3, 2011

  20. Electric Vehicle – Storagecapacity Energy density increased 1 order of magnitude Specific energy increased a factor of 4-5 200 years Even a low efficient ICE will have a better energy density and specific energy under normal running conditions. For the same rated power an electric vehicle is much heavier than a ICE. Cost of batteries! 20 Source: Tarascon and D. Foster Keynote speech at ASME ICES 2009

  21. Electric Vehicle – Electricitysource? Q: What is the similarity of a steam engine and a battery electric vehicle? A: They both run on coal… 21 www.cameco.com

  22. Summary on alternatives They have all promised much but delivered little! There is today not a viable alternative to the Internal Combustion Engine We must focus our little resources to improve what will be the prime mover of the future, not unrealistic scenarios The ICE can be improved very much in the future

  23. Car of the future, today Smaller car with small ICE in combination with hybrid system. Fuel consumption of 0.67-1 l/100km (<25 g/km CO2) ICE 60% fuel efficient with below zero levels of local emissions like NOx, PM, HC and CO. The 40% heat loss is used for heating the car. At least 100% CO2-neutral with renewable fuel

  24. Car of the future, in the future ?

  25. Car of the future, the Crystal Ball? ? German architect André Broesselof Rawlemon

  26. Outline • Introduction • The future is hard to predict • Options • Other combustion engines? • Fuel cells? • Batteries? • Combustion engines • What is high efficiency? • Combustion, thermodynamic, gas exchange and mechanical efficiencies. All four must be high. • What options do we have? • Combustion to enable high efficiency • Spark Ignition • Compression Ignition • HCCI • Partially Premixed Combustion • Can we do something about engine design? • Conclusions

  27. Energy flow in an IC engine

  28. Combustion modes + Clean with 3-way Catalyst - Poor low & part load efficiency + High efficiency - Emissions of NOx and soot + High efficiency + Ultra low NOx • Combustion control • Power density + Injection controlled - Less emissions advantage Compression Ignition (CI) engine (Diesel) Spark Ignition (SI) engine (Gasoline, Otto) Homogeneous Charge Compression Ignition (HCCI) Spark Assisted Compression Ignition (SACI)Gasoline HCCI Partially premixed combustion (PPC)Diesel HCCI

  29. ICE research in Lund vs. time HCCI Higheff. themodynamics PPC Si gas engine 2-S GenDiesel Si gas engine GDI CCV VVT SACI CCV=Cycle to Cycle Variations in Spark Ignition Engines GDI= Gasoline Direct Injection 2-S= Two Stroke engine VVT=Variable Valve Timing HCCI=Homogeneous Charge Compression Ignition SACI=Spark Assisted Compression Ignition PPC= Partially Premixed Combustion 1990 1995 2000 2005 2010 2015

  30. Emission focus vs. time NOx Particulates CO2 CO HC SOx 1970 1980 1990 2000 2010 2020

  31. HCCI -Thermodynamicefficiency Saab SVC variable compression ratio, VCR, HCCI, Rc=10:1-30:1; General Motors L850 “World engine”, HCCI, Rc=18:1, SI, Rc=18:1, SI, Rc=9.5:1 (std) Scania D12 Heavy duty diesel engine, HCCI, Rc=18:1; Fuel: US regular Gasoline SAE2006-01-0205

  32. All four efficiencies SAE keynote Kyoto 2007

  33. Net indicated efficiency= ηCηT ηGE SI std SI high HCCI +100% VCR Scania

  34. Brake efficiency SI std SI high HCCI VCR Scania

  35. Net indicated efficiency= ηCηT ηGE 47% SI std SI high HCCI VCR Scania

  36. PPC - Diesel engine running on gasoline HCCI: ηi=47% => PPC: ηi=57%

  37. Partially Premixed Combustion, PPC CI PCCI HCCI PPC Def: region between truly homogeneous combustion, HCCI, and diffusion controlled combustion, diesel SAE 2004-01-2990

  38. Experimental setup, Scania D12 Fuel: Gasoline or Ethanol 38 38 SAE 2009-01-2668

  39. Efficiencies17.1:1 39 SAE 2009-01-2668

  40. Efficiencies14.3:1 100 95 90 85 80 Combustion Efficiency [%] 75 Thermal Efficiency Gas Exchange Efficiency 70 Mechanical Efficiency 65 60 55 50 4 6 8 10 12 14 16 18 Gross IMEP [bar] 40 SAE 2010-01-0871

  41. Emissions Better tuned EGR- combination 41

  42. Emissions – different fuels SAE 2010-01-0871

  43. TestedLoad Area Stable operational load vs. fuel type 43 43

  44. EfficiencywithDiesel or Gasoline Average improvement of 16.6% points at high load by replacing diesel fuel with gasoline! D13 Diesel was calibrated by Scaniato meet EU V legislation.

  45. PPC Combustion Summary • PPC has shown very high fuel efficiency • Indicated efficiency of 57% at 8 bar IMEP • Indicated efficiency of 55% from 5-18 bar IMEP • With 70 RON fuel we can operate all the way from idle to 26 bar IMEP • Emissions are below US10/Euro 6 without aftertreatment for NOx, PM, HC and CO! • The fuel properties are critical for PPC load range

  46. ICE research in Lund vs. time HCCI Higheff. themodynamics PPC Si gas engine 2-S GenDiesel Si gas engine GDI CCV VVT SACI CCV=Cycle to Cycle Variations in Spark Ignition Engines GDI= Gasoline Direct Injection 2-S= Two Stroke engine VVT=Variable Valve Timing HCCI=Homogeneous Charge Compression Ignition SACI=Spark Assisted Compression Ignition PPC= Partially Premixed Combustion 1990 1995 2000 2005 2010 2015

  47. Energy flow in an IC engine ✔ ✔ ✖ ✖

  48. High efficiency thermodynamics:Simulation results from GT-power • Indicated efficiency 64% • Brake efficiency 60.4% • System layout is confidential

  49. Outline • Introduction • The future is hard to predict • Options • Other combustion engines? • Fuel cells? • Batteries? • Combustion engines • What is high efficiency? • Combustion, thermodynamic, gas exchange and mechanical efficiencies. All four must be high. • What options do we have? • Combustion to enable high efficiency • Spark Ignition • Compression Ignition • HCCI • Partially Premixed Combustion • Can we do something about engine design? • Conclusions

  50. The future ICE Highest possible fuel efficiency Low enough emissions of NOx, PM, HC, CO Capable of using renewable fuels And the basic requirements of all products: Very high durability Low service requirements High power/mass ratio High power/volume ratio Low cost

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