Modifications performed to convert the spark ignition gasoline-fueled internal combustion engine of a Volkswagen Polo 1. To run on hydrogen are described. Main changes included the inlet manifold, gas injectors, oil radiator and the electronic management unit. Established engine control parameters allowed the safe operation of the hydrogen-fueled engine (H 2 ICE) free of knock, backfire and pre-ignition as well with reasonably low NO x emissions.
Original Description:
Original Title
Conversion of a Commercial Spark Ignition Engine to Run on Hydrogen--Performance Comparison Using Hydrogen and Gasoline
Modifications performed to convert the spark ignition gasoline-fueled internal combustion engine of a Volkswagen Polo 1. To run on hydrogen are described. Main changes included the inlet manifold, gas injectors, oil radiator and the electronic management unit. Established engine control parameters allowed the safe operation of the hydrogen-fueled engine (H 2 ICE) free of knock, backfire and pre-ignition as well with reasonably low NO x emissions.
Modifications performed to convert the spark ignition gasoline-fueled internal combustion engine of a Volkswagen Polo 1. To run on hydrogen are described. Main changes included the inlet manifold, gas injectors, oil radiator and the electronic management unit. Established engine control parameters allowed the safe operation of the hydrogen-fueled engine (H 2 ICE) free of knock, backfire and pre-ignition as well with reasonably low NO x emissions.
Conversion of a commercial spark ignition engine to run
on hydrogen: Performance comparison using hydrogen
and gasoline C. Sopena a , P.M. Dieguez a , D. Sa inz a , J.C. Urroz a , E. Guelbenzu b , L.M. Ganda a, * a Escuela Tecnica Superior de Ingenieros Industriales y de Telecomunicacion, Universidad Pu blica de Navarra, Campus de Arrosada, E-31006 Pamplona, Spain b Acciona Biocombustibles S.A., Avenida Ciudad de la Innovacion n
5, E-31621 Sarriguren, Navarra, Spain
a r t i c l e i n f o Article history: Received 9 September 2009 Received in revised form 12 November 2009 Accepted 12 November 2009 Available online 14 December 2009 Keywords: Hydrogen-fueled internal combustion engine Spark ignition engine Hydrogen fuel Injection timing Ignition timing a b s t r a c t The modications performed to convert the spark ignition gasoline-fueled internal combustion engine of a Volkswagen Polo 1.4 to run with hydrogen are described. The car is representative of small vehicles widely used for both city and interurban trafc. Main changes included the inlet manifold, gas injectors, oil radiator and the electronic management unit. Injection and ignition advance timing maps were developed for lean mixtures with values of the air to hydrogen equivalence ratio (l) between 1.6 and 3. The established engine control parameters allowed the safe operation of the hydrogen-fueled engine (H 2 ICE) free of knock, backre and pre-ignition as well with reasonably low NO x emissions. The H 2 ICE reached best brake torque of 63 Nm at 3800 rpm and maximum brake power of 32 kW at 5000 rpm. In general, the brake thermal efciency of the H 2 ICE is greater than that of gasoline-fueled engine except for the H 2 ICE working at very lean conditions (l 2.5) and high speeds (above 4000 rpm). A signicant effect of the spark advance on the NO x emissions has been found, specially for relatively rich mixtures (l < 2). Small changes of spark advance with respect to the optimum value for maximum brake torque give rise to an increase of pollutant emissions. It has been estimated that the hydrogen-fueled Volkswagen Polo could reach a maximum speed of 140 km/h with the adapted engine. Moreover, there is enough reserve of power for the vehicle moving on typical urban routes and routes with slopes up to 10%. 2009 Professor T. Nejat Veziroglu. Published by Elsevier Ltd. All rights reserved. 1. Introduction The transport sector is a crucial element of the current ener- getic and environmental policies because of the problems associated to its almost complete dependence on petroleum and very relevant contribution to greenhouse gases (GHG) emissions. Despite the measures taken to comply with the Kyoto Protocol to the United Nations Framework Convention on Climate Change, during the period 19902004, global CO 2 emissions increased by 27%, from 20,463 to 26,079 million tons, and the energy demand from the transport sector increased by 37% [1]. In this context, it is clear that stronger legal frameworks are required, as it is the case of the Renewable Energy Directive recently put in place by the European Parliament [2]. According to this Directive each Member State shall ensure that the energy from renewable * Corresponding author. Tel.: 34 948 169 605; fax: 34 948 169 606. E-mail addresses: caso@unavarra.es (C. Sopena), pmde@unavarra.es (P.M. Die guez), eguelbenzu@acciona.es (E. Guelbenzu), lgandia@unavarra.es (L.M. Ganda). Avai l abl e at www. sci encedi r ect . com j our nal homepage: www. el sevi er . com/ l ocat e/ he i nt e r na t i ona l j o ur na l o f hy d r o g e n e ne r g y 3 5 ( 2 0 1 0 ) 1 4 2 0 1 4 2 9 0360-3199/$ see front matter 2009 Professor T. Nejat Veziroglu. Published by Elsevier Ltd. All rights reserved. doi:10.1016/j.ijhydene.2009.11.090 sources in all forms of transport in 2020 is at least 10% of the nal consumption of energy in transport in that Member State. Hydrogen is considered as a clean way of powering vehi- cles for the future since neither carbon-based pollutants nor GHG would be emitted when hydrogen produced from renewable sources is used. The European Parliament has established requirements for the type-approval of motor vehicles using hydrogen as fuel and for the type-approval, installation and safety of hydrogen components and systems in hydrogen-powered vehicles [3]. This regulation establishes safety requirements in a technology-neutral basis since it is taken into account that manufacturers might follow different approaches to the development of these vehicles (e.g. using fuel cells and electric drive motors, internal combustion engines, hybrid congurations, different hydrogen onboard storage methods, etc.). Of course, care should be taken that hydrogen is produced cost-effectively from renewable energy sources so that the overall environmental balance of intro- ducing hydrogen as a fuel is positive. Muradov and Vezirog lu [4] and Winter [5] have recently updated in their excellent reviews critical aspects of hydrogen energy. Muradov and Vezirog lu showed that neither of the three options (decar- bonization of fossil energy, nuclear energy, and renewables) currently considered could alone provide the carbon-free power required by mid-century. These authors have proposed a strategy for the transition to hydrogen economy in which hydrogen produced from water using carbon-free energy sources (nuclear, solar, wind, geothermal) would play a key role [4]. According to Winter the cost of hydrogen from renewables is by the moment prohibitive since renewable energies are not yet fully developed to unsubsidized market levels. However, renewables need hydrogen as a means of energy storage in order to guarantee their contribution to the world energy trade instead of being limited to local or regional applications [5]. There is no doubt that the share of hydrogen-powered vehicles in the total eet will increase in the near future. However, it is not yet clear whether the hydrogen-fueled internal combustion engines (H 2 ICEs) or the hydrogen- powered fuel cell electric vehicles (H 2 FCEVs) will be the pre- vailing solution since both options have advantages and drawbacks. Interesting comparisons between them can be found in the above-mentioned reviews [4,5] and more specic information on each technology in the papers by Lee et al. [6], Vandenborre and Sierens [7], Guo et al. [8], Sierens et al. [9,10], Verhelst et al. [1113], White et al. [14], Mohammadi et al. [15], Kahraman et al. [16], Szwaja and Grab-Rogalinski [17], Gomes Antunes et al. [18] and Thomas [19]. Most car manufacturers are focusing their research and development efforts on the H 2 FCEVs. But the cost of polymer electrolyte membrane fuel cells (PEMFCs) is currently prohibitively high and they require hydrogen of extremely high purity (above 99.99%) thus making the fuel also more expensive. Signicant technical advances as improved PEMFCs reliability and durability and price reduction by a factor of 2050 are necessary for PEMFCs to compete with internal combustion engines (ICEs) [4]. On the other hand, some important vehicle makers like BMW, Ford, Mazda and MAN have developed and still continue developing cars and buses powered by H 2 ICEs with very good performances [2025]. Particularly relevant are the achievements made by the BMWgroup with the mono-fuel vehicles of the Hydrogen 7 series. The spark ignition (SI) engines of 6.0 l consist of 12 cylinders in V achieving a maximum brake torque (MBT) of 390 Nm at 4300 rpm and maximum brake power (MBP) of 192 kW at 5100 rpm. Emissions levels are well below the Super Ultra Low Emissions Vehicles standard for nitrogen oxides (NO x ) and the hydrogen consumption for the highway cycle is only 2.1 kg per 100 km [25]. Main argument in favor of H 2 ICEs in the short term may be that they are based on a very well-known technology with more than one hundred twenty years of experience so implementing H 2 ICEs in vehicles may be easy and fast. It will also allow taking advantage of manufacturing infrastructure now in operation for conventional ICEs. Moreover, current costs are considerable lower than that of PEMFCs and H 2 ICEs can run on relatively cheap hydrogen of industrial quality. Perhaps H 2 ICE might be a transitional technology contributing to a more rapid introduction of hydrogen in the transport sector while H 2 FCVs and hybrid congurations continue developing [5,14]. In this work the steps followed to convert a commercial SI ICE to run on hydrogen are described. An engine from Nomenclature Acronyms BDC bottom dead center BTDC before top dead center DAS data acquisition system ECU electronic control unit GHG greenhouse gases HC hydrocarbons H 2 FCEV hydrogen-fueled fuel cell electric vehicle H 2 ICE hydrogen-fueled internal combustion engine ICE internal combustion engine LEL lower explosive limit PEMFC polymer electrolyte membrane fuel cell PFI port fuel injection MBP maximum brake power MBT maximum brake torque NO x nitrogen oxides SI spark ignition TWC three-way catalyst WOT wide open throttle Symbols bmep brake mean effective pressure, kPa bsfceq brake specic fuel consumption of gasoline equivalent, g/kWh Greek l air to fuel equivalence ratio (lambda) i nt e r na t i o na l j o ur na l o f hy d r og e n e ne r gy 3 5 ( 2 0 1 0 ) 1 4 2 0 1 4 2 9 1421 Volkswagen (Polo 1.4) was selected for this study. The features of the experimental facilities, safety measures and the comparison of the engine performances when operated on gasoline and hydrogen are presented as well. This work has been carried out in the framework of a R&D contract granted by Acciona Biocombustibles S.A. (a branch of Acciona Ener- g a), a company whose activities are focused in the renew- ables sector [26]. Previous works by our group dealt with renewable hydrogen production from water electrolysis and wind energy [2730]. 2. Engine specications and modications performed The original engine was a four-cylinder naturally aspirated SI motor mounted in the Volkswagen Polo 1.4. The motor was kindly donated by Volkswagen Navarra S.A. When run on gasoline MBT and MBP were 132 Nm at 3800 rpm and 59 kW at 5000 rpm, respectively. Main engine characteristics are summarized in Table 1. All the engine transformations and the complete test program of the resulting H 2 ICE were carried out at the Laboratory of Internal Combustion Engines of the Public University of Navarra. To this end the test cell was adapted to work with hydrogen by means of suitable hydrogen supply and safety systems. Main motivation of this work was to show the technical viability of the engine conversion in order to obtain a H 2 ICE with performances well suited for using it in a Volkswagen Polo demonstration car taking care that the engine operates safely in all conditions and with acceptable level of NO x emissions. As it is well-known, the unique combustion characteristics of hydrogen (very low ignition energies, wide ammability limits of hydrogenair mixtures and very high ame propa- gation speed) are very advantageous for SI engines at low loads when safe lean burn operation at wide open throttle (WOT) is possible [1114]. However, the same characteristics give rise to some limitations at high engine loads when the mixture becomes richer, due to the risk of pre-ignition, backre, knock and increased NO x emissions. With the so- called advanced hydrogen engines [14] it is intended to over- come these limitations by implementing direct hydrogen injection into the cylinders [15] or supercharging combined with exhaust gas recirculation [13] solutions. In our case, whereas the original motor block is preserved, the main changes have been made in the fuel feeding system using naturally aspirated gaseous port fuel injection (PFI) and in the electronic management system. Some minor changes as in the exhaust system have been made as well. These modi- cations are described in more detail in the following subsections. 2.1. Hydrogen feeding system The inlet manifold in plastic of the original engine was replaced by a cast manifold to prevent breakdown in case of backre (explosion of the air-fuel mixture in the inlet mani- fold [11]). The gasoline injectors were substituted by hydrogen injectors manufactured by Quantum Technologies; therefore, it was necessary to adapt the holes where the injectors are placed in the intake manifold. In order to prevent hydrogen leakages due to engine vibration the injectors were rmly xed to the manifold by means of a support. As shown in Fig. 1 a gas accumulator was manufactured and connected to the injectors through stainless steel tubes in order to maintain constant the pressure at the injectors inlet. Hydrogen is fed to the accumulator at low-pressure from the supply line through exible tubing to compensate for engine vibrations. The accumulator has another entry connected to a venting line to purge the complete circuit with nitrogen gas in case of emergency or prolonged shutdown. 2.2. Electronic management system The electronic control unit (ECU) of the original engine was replaced by a programmable MoteC M 400 unit. Most of the sensors and actuators of the original engine were retained; however, the original lambda sensor was removed and Table 1 Specications of the original engine. Manufacturer Volkswagen Base vehicle Polo 1.4 Type Spark ignition Fuel Gasoline 95 NO Cylinder line/head material Aluminium Number of cylinders 4 in line Bore/Stroke (mm) 76.5/75.6 Swept volume (cm 3 ) 1390 Compression ratio 10.5:1 Valve train conguration DOHC Number of valves per cylinder 4 Fuel injection system Port-injection Ignition system Single spark ignition coil Maximum brake power 59 kW at 5000 rpm Maximum brake torque 132 Nm at 3800 rpm Load control Drive by wire Fig. 1 Photograph of the hydrogen feeding system of the H 2 ICE: 1) hydrogen injectors; 2) support; 3) low-pressure hydrogen accumulator; 4) hydrogen inlet; 5) purging nitrogen inlet. i nt e r na t i ona l j o ur na l o f hy d r o g e n e ne r g y 3 5 ( 2 0 1 0 ) 1 4 2 0 1 4 2 9 1422 replaced by a wideband lambda sensor (Bosch LSU 4.9) and a newoil temperature sensor was mounted. It should be noted that the original lambda sensor was a binary one that only allowed mixture control close to stoichiometric conditions (l 1). As the H 2 ICE is fed with lean mixtures (l values between1.5 and 3), a newwideband lambda sensor is required for proper operation. Sensors and actuators were connected to the MoteC unit and were calibrated either directly with the MoteC or in some cases obtaining calibration functions externally and then introducing them in the MoteC. On the basis of the test program carried out in the test bed, injection and ignition timing maps were obtained as explained in Section 4. 2.3. Other modications A wateroil heat exchanger was installed close to the oil lter to maintain as constant as possible the oil temperature. The crankcase venting pipe was replaced by another of larger diameter to reduce the possibility that hydrogen accumulated in the carter and thus reducing the risk of ammable mixtures formation in the crankcase. The exhaust was modied by removing the three-way catalyst (TWC) because the H 2 ICE was operated with lean hydrogenair mixtures so, as will be shown, the NO x formation is low due to the relatively low combustion temperatures. It should be noted that the TWC operates efciently when stoichiometric or slightly rich mixtures are used due to the presence in the exhaust gases of reducing chemical species (e.g. unburned hydrogen). 3. Test facilities The testing bed cell of the laboratory was adapted to work with hydrogen with the greatest possible safety. A data acquisition system (DAS) was mounted that allowed on-line collecting and storage of most of the engine sensors and actuators signals as well as that of the auxiliary equipment installed (hydrogen and air mass-ow meters, in-cylinder pressure transducer, etc.). A scheme of the experimental set-up is shown in Fig. 2. 3.1. Test bed cell The test bed cell consisted of an eddy current dynamometer AVL 80 capable of absorbing up to 80 kW of power, with a BME Fig. 2 Scheme of the experimental set-up: 1 & 2) hydrogen and nitrogen high-pressure regulators; 3 & 4) solenoid gas shutoff valves; 5) low-pressure regulator; 6) safety valve; 7) manual purge valve; 8) solenoid purge valve; 9) hydrogen mass- ow meter; 10) non-return valve; 11) air mass-ow meter; 12) air lter; 13) engine hydrogen sensor; 14) test bed cell hydrogen sensor; 15) MoteC M 400 ECU; 16) working pressure regulator. i nt e r na t i o na l j o ur na l o f hy d r og e n e ne r gy 3 5 ( 2 0 1 0 ) 1 4 2 0 1 4 2 9 1423 300 control system allowing performing tests using as control parameters the torque, the accelerator position and the engine speed. The engine was mounted on the test bench which included a Bosch analyzer to determine CO, CO 2 , hydrocarbons (HC) and O 2 and a Horiba 730 analyzer to determine NO x in the exhaust gases. The gas supply system consisted of two lines, one for hydrogen of industrial quality and the other for nitrogen. Nitrogen is used to purge the hydrogen line prior to start-up when the H 2 ICE is not used for long time or in the even of an emergency; such an incident has never occurred on the modied engine during the test period. Both lines are fed by gas cylinders of 50 l at 200 bar (Air Liquide). Control of the hydrogen feeding system is governed by a programmable controller performing the functions of hydrogen supply, nitrogen purge and emergency stop. The safety equipment consisted of two hydrogen sensors TQ122 (electrochemical type), capable of detecting hydrogen concentrations well below the lower explosive level (LEL) of hydrogen/air mixtures. One is located just above the engine feeding system, and the other on the test bed cell ceiling close to the hydrogen supply line. These sensors are connected to a control unit TQ4000 with two adjustable alarm levels, which indicated the concentration of hydrogen in the room. The safety system was designed in such a way that supplying hydrogen is not possible if the sensors are not in operation. If the second alarm level is reached, the controller will auto- matically stop the hydrogen supply and the line would be purged with nitrogen. The operator can also make manually a nitrogen purge, if necessary. The test cell ventilation system is equipped with an extractor for the engine exhaust as well as a blower allowing the complete air renewal of the cell in less than two minutes. All the extracted gases are sent out of the building. Similar safety measures have been adopted in related works [21,25]. 3.2. Data acquisition system The data acquisition system (DAS) consisted of a National Instruments Ni-CompacDAQ with three modules measuring up to eight channels. It allowed collecting, showing real-time and storing in a computer with a LabView program signals from the main engine sensors and actuators, as well as additional signals like brake torque, engine speed, hydrogen and air ow-rates, knock sensor, NO x and O 2 in the exhaust, etc. The engine was also equipped with a Kistler measuring spark plug with integrated cylinder pressure sensor and a Kistler crank angle encoder. 4. Engine management parameters The engine control was done by means of a MoteC M 400 electronic control unit in which injection and ignition timing maps were introduced. MoteC receives signals from engine sensors and gives the output signals to the actuators, essen- tially, width injection pulse and ignition timing. Management included also idle control, water and air temperature correc- tions, maximum speed engine control and air to fuel equiva- lence ratio (l) control. To this end, the narrow original lambda sensor was replaced by a wide lambda sensor Bosch LSU 4.9 that was calibrated to be used with hydrogen fuel. Injection and ignition timing maps introduced in the ECU were obtained from the results of tests conducted in the engine test bed. Engine speeds varying between idling and 5000 rpm and loads between unloaded and fully loaded were considered. 1400 2200 3000 3800 4400 4800 0 20 40 60 100 0 1 2 3 4 5 6 7 8 ms rev/min % Load Fig. 3 Representative injection map showing the duration of the injection pulse (ms) as a function of the engine load (%) and speed (rpm) for l [ 2. 0 10 20 30 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 rev/min S p a r k
a d v a n c e Spark advance for lambda 1.6 and WOT spark advance for lambda 2 and WOT spark advance for lambda 2.5 and WOT Spark advance for lambda 1.6 and 50% throttled Spark advance for lambda 2 and 50% throttled Spark advance for lambda 2.5 and 50% throttled Fig. 4 Ignition advance in degrees BTDC as a function of the engine speed (rpm) for l values of 1.6, 2 and 2.5 at WOT and 50% throttled engine. i nt e r na t i ona l j o ur na l o f hy d r o g e n e ne r g y 3 5 ( 2 0 1 0 ) 1 4 2 0 1 4 2 9 1424 4.1. Injection timing Injection timing has a strong inuence on the engine perfor- mance at low loads and speeds; this parameter can be adjusted also to avoid backre [11]. The strategy followed for drawing up injection maps was working with l constant in the 1.63 range at all loads varying the torque throughthe throttle. Values of l lower than 3 have been selected in this work in order to avoid incomplete hydrogen combustion, especially at high loads and low engine speeds. On the other hand, when using air to fuel equivalence ratios richer than 1.6 there is the possibility of knock in some cases at full load and high engine speeds. The start of hydrogen injection was chosen at the same point of the cycle in all cases. That point corresponded to the moment when the exhaust valve closed in order to ensure that there is no leakage of hydrogen in the exhaust manifold while the exhaust valve has been somewhat cooled with the inlet air thus reducing the possibility of backre. By choosing this point, it was achieved for all loads and engine speeds that the injection nished before the inlet valve closed and in most cases even before the piston reached bottom dead center (BDC) during the intake stroke. A representative injection map can be seen in Fig. 3 where the duration of the injection pulse is given as a function of the engine speed and load. 4.2. Ignition timing The ignition advance maps were developed using the ignition timing allowing maximumbrake torque (MBT) with the lowest NO x emissions. A very conservative approach was adopted, namely, retarding the ignition advance to values which are far from producing knock (autoignition of the mixture ahead of the ame front originated from the spark [14]). In contrast with the case of gasoline-fueled engines [31], we have found that for the H 2 ICE the optimal spark advance for MBT depended essentially on l except for low loads and speeds. This can be clearly seen in Fig. 4 where the ignition advance in crank angle degrees before top dead center (BTDC) is given as a function of the engine speed for l values of 1.6, 2 and 2.5 at WOT and 50% throttled engine. It is also shown that there is almost no difference between throttled or unthrottled operation (low load inuence) at engine speeds above about 1800 rpm and l greater than 2. The combustion is faster with 1000 2200 3800 4800 0 20 40 60 100 0 2 4 6 8 10 12 14 16 S p a r k
a d v a n c e rev/min Load % Fig. 5 Representative ignition map showing the spark advance in degrees BTDC as a function of the engine load (%) and speed (rpm) for l [ 2. 0 200 400 600 800 1000 1200 1000 2000 3000 4000 5000 rev/min b m e p
( k P a ) bmep with gasoline bmep with lambda 1.6 bmep with lambda 2 bmep with lambda 2.5 Fig. 6 Brake mean effective pressure (kPa) at WOT versus engine speed (rpm) for l values of 1.6, 2 and 2.5. Values of bmep for the gasoline-fueled engine are also included. 0 10 20 30 40 50 60 70 0 1000 2000 3000 4000 5000 rev/min k W Brake power for gasoline fuelled engine Brake power for H2ICE for lambda 1.6 Fig. 7 Brake power (kW) at WOT versus engine speed (rpm) for the gasoline-fueled engine and the H 2 ICE with l [ 1.6. 200 225 250 275 300 325 1000 2000 3000 4000 5000 rev/min B s f c
( g / k W h ) Bsfc with gasoline Bsfceq with lambda 1.6 Bsfceq with lambda 2 Bsfceq with lambda 2.5 Fig. 8 Brake specic fuel consumtion of gasoline equivalent (g/kWh) at WOT versus engine speed (rpm) for l values of 1.6, 2 and 2.5. Values of fuel consumption for the gasoline-fueled engine are also included. i nt e r na t i o na l j o ur na l o f hy d r og e n e ne r gy 3 5 ( 2 0 1 0 ) 1 4 2 0 1 4 2 9 1425 rich mixtures (lower values of l) thus requiring less spark advance. A representative ignition map can be seen in Fig. 5, where the ignition timing is given in crank angle degrees BTDC as a function of the engine speed and load. 5. Results: engine performance The performance of the H 2 ICE has been evaluated in terms of the brake mean effective pressure, brake power, brake specic fuel consumption, and pollutants emissions. These parame- ters were compared with those provided by the original gasoline-fueled engine. It has been also estimated the performance that could achieve a Volkswagen Polo powered by the H 2 ICE. 5.1. Brake mean effective pressure, brake power and brake specic fuel consumption Brake mean effective pressure (bmep) of the H 2 ICE as a func- tion of the engine speed for l values of 1.6, 2 and 2.5 at WOT are compared in Fig. 6 with the bmep of the gasoline-fueled engine. The bmep obtained with the H 2 ICE are within the values that could be expected. This is because for l values of 1.6, 2 and 2.5, theoretical bmep to obtain the same brake thermal efciency are 50, 42 and 35%, respectively, of the gasoline-fueled engine bmep because less air enters the cylinders due to the low density of hydrogen [25]. Maximum bmep of the H 2 ICE is achieved at the same engine speed than with the gasoline engine. This indicates that the engine speed at which the H 2 ICE reaches the maximum volumetric ef- ciency is similar to the value when it is run on gasoline. Of course, lower bmep are obtained when leaner (higher l) hydrogenair mixtures are fed. As concerns the brake power, the results are shown in Fig. 7. The maximumH 2 ICE brake power is limited because the maximum engine speed has been limited as well (5000 rpm). The H 2 ICE reached a MBP of 32 kW at WOT with l 1.6. When the engine was fueled with gasoline MBP was 59 kW at 5000 rpm. Brake specic fuel consumption of gasoline equivalent (bsfceq) for l values of 1.6, 2 and 2.5 at WOT are compared in Fig. 8 with the brake specic consumption of gasoline. The results show that the H 2 ICE has better brake thermal ef- ciencies than the gasoline-fueled engine, especially at lowand medium speeds. This could be due to the fact that hydrogen combustion is faster and closer to a constant volume process, and then with a more efcient thermodynamic cycle than that of gasoline combustion. This is a remarkable result taking into account that l values used with the H 2 ICE are higher than for the gasoline-fueled engine which runs on stoichiometric (l 1) or slightly rich mixtures. In the case of the H 2 ICE, it can be seen that the lowest bsfceq corresponds to the richest mixture considered (l 1.6) which is then the most brake thermal efcient. The leanest mixture (l 2.5) is the lowest efcient except for very low engine speeds. This could be attributed to a lower efciency of very lean mixtures combustion because of the higher proportion of unburned hydrogen and slower combustion for a given engine speed [6,9,22]. 0 100 200 300 400 500 600 1000 2000 3000 4000 5000 rev/min N O x
( p p m ) NOx for lambda 1.6 NOx for lambda 2 NOx for lambda 2.5 Fig. 9 NO x emissions (ppm) at WOT versus engine speed (rpm) for l values of 1.6, 2 and 2.5. 1800 2600 3400 4200 5000 0 50 100 150 200 250 300 350 400 450 N O x
( p p m ) rev/min = 1.6 Ignition advance for MBT-5 Ignition advance for MBT Ignition advance for MBT+5 Ignition advance for MBT-5 Ignition advance for MBT Ignition advance for MBT+5 1800 2600 3400 4200 5000 94 96 98 100 102 104 %
b m e p
r e s p e c t
b m e p
f o r
M B T rev/min
= 1.6 A B Fig. 10 Effect of varying 58 the ignition advance for MBT on the NO x emissions (A) and brake mean effective pressure (bmep) change with respect to MBT bmep (B) at l [ 1.6. i nt e r na t i ona l j o ur na l o f hy d r o g e n e ne r g y 3 5 ( 2 0 1 0 ) 1 4 2 0 1 4 2 9 1426 5.2. Pollutant emissions It has been found that CO and unburned hydrocarbons (HC) emissions due to lubricating oil combustion are extremely low. The most important pollutants in the exhaust were nitrogen oxides (NO x ). Unburned hydrogen emissions were negligible for l values lower than 3. NO x emissions for l values of 1.6, 2 and 2.5 at WOT are compared in Fig. 9. It should be noted that the TWC of the original engine was removed and NO x emissions for the gasoline-fueled engine are not available. As expected, NO x emissions increase when the mixture becomes richer because the maximum combustion temperature increases as l decreases. It has been found that for air to fuel equivalence ratios higher than 1.8, low NO x emissions of the order of 5075 ppm, are produced. For l 1.6 the NO x emissions varied between about 350 and 550 ppm depending on the engine speed. Although signicant, these values are well below the 10002500 ppm range, typical of the gasoline-fueled engines [31]. Nevertheless, it should be noted that maximum NO x emissions of hydrogen-fueled engines of the order of 10000 ppm usually take place with l 1.3. This is mainly why in spite of the lower power output, lean burn operation of H 2 ICEs is recommended [6,14,22]. We have also found that NO x emissions were very sensitive to the spark advance, specially for relatively rich mixtures (l < 2). Small changes of spark advance with respect to the optimum value for MBT give rise to an increase of nitrogen oxides emissions. This is illustrated in Figs. 10, 11 and 12, where the effect of varying 5
the ignition advance for MBT on
the NO x emissions and brake mean effective pressure (bmep) are shown for l values of 1.6, 1.87 and 2, respectively. On 1800 2400 3000 3600 4200 4800 0 50 100 150 200 250 300 350 400 N O x
( p p m ) rev/min = 1.87 Ignition advance MBT-5 Ignition advance for MBT Ignition advance MBT+5 Ignition advance MBT-5 Ignition advance for MBT Ignition advance MBT+5 1800 2400 3000 3600 4200 4800 96 98 100 102 % b m e p
r e s p e c t
b m e p
f o r
M B T rev/min = 1.87 A B Fig. 11 Effect of the variation of the ignition advance for MBT (MBTL58, MBTD58) on the NO x emissions (A) and brake mean effective pressure (bmep) change with respect to MBT bmep (B) at l [ 1.87. 1800 2600 3400 4200 5000 0 10 20 30 40 50 60 70 80 N O x
( p p m ) rev/min = 2 Ignition advance MBT-5 Ignition advance for MBT Ignition advance MBT+5 1800 2600 3400 4200 5000 94 96 98 100 102 104 %
b m e p
r e s p e c t
b m e p
f o r
M B T rev/min = 2 Ignition advance MBT-5 Ignition advance for MBT Ignition advance MBT+5 B A Fig. 12 Effect of the variation of the ignition advance for MBT (MBTL58, MBTD58) on the NO x emissions (A) and brake mean effective pressure (bmep) change with respect to MBT bmep (B) at l [ 2. i nt e r na t i o na l j o ur na l o f hy d r og e n e ne r gy 3 5 ( 2 0 1 0 ) 1 4 2 0 1 4 2 9 1427 changing the spark advance 5
it can be seen in Fig. 10 A that
the NO x emissions at l 1.6 almost double whereas the bmep only increases 12% (Fig. 10B). On the other hand, a change of 5
reduces the nitrogen oxides emissions but the brake mean
effective pressure decreases markedly, specially at high engine speeds, above 3000 rpm (Fig. 10B). As the mixture becomes leaner, the inuence of the spark advance on the NO x emissions decreases. This is clearly seen in Fig. 12 A where at l 2 the nitrogen oxides emissions change with the spark advance only at engine speeds above 3400 rpm; anyway, in this case, the NO x concentrationa are low, below 70 ppm. In contrast, the negative effect of changing 5
the advance for
MBT on the brake mean effective pressure is maintained under leaner conditions, as can be seenin Figs. 11B and 12B for l 1.87 and 2, respectively. 5.3. Expected performance of the hydrogen-powered vehicle The brake power required to move the Volkswagen Polo car in horizontal and straight line trajectory with constant speed is compared in Fig. 13 with the brake power delivered by the H 2 ICE working with l 1.6 and the gearbox ratio 1.0 [20,32]. It can be seen that the hydrogen-fueled engine gives power enough for the vehicle reaches a maximumspeed of 140 km/h in the above-mentioned conditions. This speed is suitable for driving safely a vehicle of these characteristics. Moreover, there is enough reserve of power for the vehicle moving smoothly on an urban route because the speed limit in these routes is usually established at 50 km/h. On the other hand, for roads with slopes of 5 and 10% and using the original gearbox, which was not designed for the H 2 ICE, the car would be able to achieve maximum speeds of 105 km/h (third speed transmission) and 70 km/h (second speed transmission), respectively. 6. Conclusions and future work The conversion of the SI gasoline-fueled ICE of a Volkswagen Polo 1.4 car to run on hydrogen has been carried out. Main mechanical modications included the inlet manifold, low- pressure hydrogen accumulator, gas injectors and oil radiator. The cost of the new components is similar to that of the items replaced. The original electronic control unit was replaced by a programmable ECU MoteC M 400 whose cost is more than twice that of the original ECU. However, it was chosen due to its great exibility to perform the test program that allowed obtaining the injection and ignition timing maps of the modied engine. In the event of using the H 2 ICE in a commercial vehicle the ECU would be similar to that of the original engine. Injection timing maps have been developed for air to hydrogen equivalence ratios between 1.6 and 3, from unloa- ded engine to full load and engine speeds between idling and 5000 rpm. Spark ignition advance maps have been obtained choosing advance values getting MBT compatible with low NO x emissions. It has been found that if l < 2 the main factor inuencing the ignition advance is the mixture richness. The performance of the H 2 ICE has been evaluated in a suitably adapted test bed cell and compared with the performance of the gasoline-fueled engine. The results are within the expected values: the H 2 ICE is capable of providing a brake torque of 63 Nm at 3800 rpm and MBP of 32 kW at 5000 rpm. The brake thermal efciency of the H 2 ICE is greater than that of gasoline-fueled engine except for l > 1.8. The brake thermal efciency decreases as l decreases from 3 to 1.6. The H 2 ICE performance is suitable to power the Volks- wagen Polo 1.4. The vehicle would be capable of reaching a maximum speed of 140 km/h in horizontal and straight line trajectory. Moreover, there is enough reserve of power for the vehicle moving on an urban route and roads with slopes up to 10%. Further work will be focused in supercharging the H 2 ICE with a mechanical compressor to increase the brake torque and power output. It is also being considered to introduce the control of the different engine loads in a similar way as in compression-ignition engines, that is, working at WOT and changing the air to fuel equivalence ratio. The pumping losses will be decreased with this strategy and it is expected that the H 2 ICE brake thermal efciency will increase. Acknowledgements We gratefully acknowledge Acciona Biocombustibles S.A. for its nancial support under R&D contract to the Public University of Navarra OTRI 2006 13 118 (CENIT project: SPHERA) and Volkswagen Navarra S.A. for the Volkswagen Polo 1.4 engine donation. LMG and PMD also acknowledge nancial support by Ministry of Science and Innovation of the Spanish Government (MAT2006-12386-C05-04). r e f e r e n c e s [1] European Environment Agency. Climate for a transport change. TERM 2007: indicators tracking transport and environment in the European Union. Report No 1/2008. 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