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The future of combustion engines
A historical reflection on internal combustion engines up to state of the art today
(With a Swedish touch)
Martin Tunér
2
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What do we mean with state of the art?
World’s largest combustion engine?
Wärtsilä-Sulzer RTA96-C2300 ton, 109.000 hp
World’s smallest engine?
Most liquid hydrocarbon fuels hold over 300 times more energy per unit weight than a NiCad battery and 100 times more than a Li-ion battery. A micro-engine would have the potential to release the energy from the fuels and possibly replace batteries in portable devices. It would not only last much longer than a battery of the same weight (about 20 times at 10% efficiency), but also requires little time to change its fuel capsule.
Read more at: http://phys.org/news/2006-01-micro-engines.html#jCp
11.2 W
World’s most common engine?Toyota 2ZR-FE, 1.8 liter, gasoline, 136 hp
Husqvarna manufactures around 6.5 million engines yearly
Most sensual engine?
Ducati –sings in Italian!
State of art depends on the application
• Functionality
• Affordability
• Scalability
And more recently:
• Sustainability
Isaac de Rivaz 1802-1813
• Built a car• 5x2 m
• 3m / stroke
• 1 stroke / 5s (car stops inbetween)
• 12% uphill!
• Atmospheric/ballistic motor• Manually controlled combustion
• Town-gas as fuel
• Considered net of gas generators every km
• Electric ignition
Functional?Affordable?
Scalable?Sustainable?
1885 Benz Patent-Motorwagen: The patented automobile
1885-1886 (93)0.9 hp16 km/h265 kg1 gear
Belt drive
No body
Solid rubber tyres
Hand brake working on belt
Steering
Clutch, differentialtwin chain drive
single cyl, 0.954 l Otto-
engine
Start it up!
Functional?Affordable?
Scalable?Sustainable?
Most common car year 1900 – the electric car
Functional?Affordable?
Scalable?Sustainable?
So, how come gasoline became dominant?
• Combustion engine cars cost 1/3 of electriccars
• Ethanol is considered, but…
• Oil is available in large amounts and makes gasoline available and relatively cheap
• Gasoline has very high volumetric energy content and is easy to distribute - easy to carry “700 km" in the car
• “Charging” takes minutes – transfer rate is ~20MW!
• The number of cars, roads and gas stations is increasing rapidly hand in hand Functional?
Affordable?Scalable?
Sustainable?
Heavy engines
First trucks in Sweden 1902 (first sold 1903)Tidaholm 1.5 ton payload, 10 hp, 15km/h. It is shortly after returned
since there are no roads.
Functional?Affordable?
Scalable?Sustainable?
Scania and Vabis sell first trucks 1907.
Jonas Hesselman 1901Technical genius Jonas Hesselman increases diesel engine output 100% by new
piston shape - Boss expects ”all major problems should be solved as cheaply”
Jonas Hesselman Functional?Affordable?
Scalable?Sustainable?
The Hesselman engine 1927• Gasoline is expensive and so is developing a new diesel type engine of reasonable size and power suitable
for trucks…
• Hesselman adapts the gasoline type engine with a special injection-system. World´s first DISI!
• Multifuel capability: diesel, gasoline, alcohol and more
• Used by Volvo until 1947• Should be run red hot
Functional?Affordable?
Scalable?Sustainable?
Why are Volvo and Scania global players?Sweden is after all a small country
Fierce competition Scania-Vabis and Volvo: Both use Hesselman and gasoline engines but shift to even more efficient in-house diesel engines:
• Scania first diesel engine in production 1937. Volvo 1944.
• DI (V 1949, S 1952) 20% less consumption, longer life
• Turbocharging in production engines (S 1953, V 1954)
• Scania V8 low rpm philosophy (1969) strongest in Europe 350hp, Volvo counters: 385hp (1973)
• Intercooler (V 1979, S 1982)
• 4 valve (V 1987 465hp)
• Turbo compound (S 1990) give 46% total efficiency
• Today top models >700hp and >3000Nm
Functional?Affordable?
Scalable?Sustainable?
Coming back to lighter engines
Turbo in gasoline engines
Per Gillbrand
Functional?Affordable?
Scalable?Sustainable?
Increased power outputHeat recoveryRefinement – bling factor…
Cleaner engines
Emissions regulations demand better engine technology!• Catalytic converter• Unleaded fuel (hardened valve seats)• Electronic fuel injection• Lambda sensor• Four valve pent-roof (Directly from race engines)
Low fuel consumption – low emissions – high specific power
Engines became better not worse!!!
Ford Cosworth DFV (1967)
Functional?Affordable?
Scalable?Sustainable?
Flex-Fuel
Functional?Affordable?
Scalable?Sustainable?
State of the art today
The internal combustion engine was always a compromise between performance and cost that could be evolved when needed over 100 years…
Per Gillbrand use to say that you have to time the development steps
- Too early = too expensive = bankrupt
- Too late = lost market shares = bankrupt
Proved by that Volvo and Scania still exist!
Volvo Cars
Roadmap approaches to 55% BTE are outlined.DOE AMR 6/16
Daimler (2015) Navistar
Volvo
Cummins
SAE INTERNATIONAL
DCEE Concept layout
2015-01-1260 26
HP cylinder
CAC (V = 30 L)
Crossover channel
LP cylinder
Inlet valve AOutlet valve
Exhaust valve
A
Exhaust valve
B
Inlet valve B
Inlet port from
cross-over
Not to scale!
28
Shamun et al.
Methanol PPC meet EURO VI w/o EATS (steady state)
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Values can vary with operating conditions
State of art in the future?
The energy source has dominant influence on GHGSeveral fuels and powertrain combinations relevant!
Functional?Affordable?
Scalable?Sustainable?
7 TW
14 TW
7 TW
44 TW
72 TW
85.000 TW
Continued domination of fossil energy in transportation by year 2040 – less than 3% electric energy?
biodiesel
e85
34
H2
35
H2
?
Functional?
Affordable?
Scalable?
Sustainable?
LIQUIDS: DISTRIBUTION & STORAGE EASIER
36
€ 250 € 10.000 € 25.000
CANDIDATE FUELS?
Simple molecules are preferred Production is more efficient
Conversion (end-use) can be controlled more easily (h, emissions)
Abundantly available building blocks: C, H, O, N, …
Thus, most simple fuels: Hydrogen, H2 (at patm, liquid at 20K)
Methane, CH4 (at patm, liquid at 91K)
Ammonia, NH3 (at Tatm, liquid at 8.6 bar)
Methanol, CH3OH (liquid)
Dimethylether (DME), CH3OCH3 (liquid at 5.3 bar)
…
37
LIQUID
AN INTEGRATED SYSTEM
38
CH3OH
n(-CH2-)Transport
Liquid
storage
Grid Electricity
H2
H2O
CH4
CO2
Gas
storage
Heat
Waste
Heat
…And this can be brought into play quickly
using GEM blends in existing E85/gasoline
flex-fuel vehicles
“Renewable Power Methane”,
now supported by Audi as E-gas;
however, vehicle fuel tanks still
expensive because CH4 is not a liquid…
Massive storage of
renewable energy makes
investment in it viable
Remember!
Transportation accounts for
25% of global GHG
75%
-Chemicals
-Domestic use
-Heat and Power
…
Huge demand for “green” chemicals!
39
Source: Hexaresearch
Electric drive
• Refined, effective, no tailpipe
• Battery is expensive and dirty
• Charging infrastructure?
• Case for range extender engines• Combining the best of two worlds
• Electric roads
Forecast energy-mixes with powertrain development
41
0
20
40
60
80
100
120
140
160
2015 2020 2025 2030 2035 2040
CO
2 e
q g
/km
WTW CO2 Trends for various powertrains
ICE => HEV Fossil Fuels
EV World Average Electricity
ICE => HEV World Average Fuels
Data: Bloomberg, Mazda, JEC-2014, Ricardo, Corning, EIA 2017
Discussion• History tells us that functionality, scalability, affordability but also timing are key factors for success
• Sustainability is the new additional challenge
• Engine efficiencies of 60% are getting closer
• Electric drive makes combustion engines better
Future scenarios
• Long term future seems to depend on solar power and hydrogen – it will take long time to build such infrastructure
• Biofuels seems to be especially valuable in the transition period
– Case for low cost alcohol engines – low cost cars for emerging markets – upper end hybrid cars
– Case for advanced alcohol engines – trucks, marine vessels, gen-sets
Lot of unknowns
• Clean battery production?
• Resource efficiency improvements, and recycling schemes? Energy intensity of recycling rare earth materials etc.?
• How low emissions are low enough?
• How will demand drive price for biomass and electricity
• Energy security?
ConclusionWe need to combine resources and technologies that offer best
sustainability, scalability, affordability and functionality
Electric drive + engines on sustainable fuels
