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Technical Paper

How Can a Sustainable Energy Infrastructure based on Renewable Fuels Contribute to Global Carbon Neutrality?

2024-07-02
2024-01-3023
Abstract. With the COP28 decisions the world is thriving for a future net-zero-CO2 society and the and current regulation acts, the energy infrastructure is changing in direction of renewables in energy production. All industry sectors will extend their share of direct or indirect electrification. The question might arise if the build-up of the renewables in energy production is fast enough. Demand and supply might not match in the short- and mid-term. The paper will discuss the roadmaps, directions and legislative boundary parameter in the regenerative energy landscape and their regional differences. National funding on renewables will gain an increasing importance to accelerate the energy transformation. The are often competing in attracting the same know-how on a global scale. In addition the paper includes details about energy conversion, efficiency as well as potential transport scenarios from production to the end consumer.
Technical Paper

Reduction of Flow-induced Noise in Refrigeration Cycles

2024-07-02
2024-01-2972
In electrified vehicles, auxiliary units can be a dominant source of noise, one of which is the refrigerant scroll compressor. Compared to vehicles with combustion engines, e-vehicles require larger refrigerant compressors, as in addition to the interior, also the battery and the electric motors have to be cooled. Currently, scroll compressors are widely used in the automotive industry, which generate one pressure pulse per revolution due to their discontinuous compression principle. This results in speed-dependent pressure fluctuations as well as higher-harmonic pulsations that arise from reflections. These fluctuations spread through the refrigeration cycle and cause the vibration excitation of refrigerant lines and heat exchangers. The sound transmission path in the air conditioning heat exchanger integrated in the dashboard is particularly critical. Various silencer configurations can be used to dampen these pulsations.
Technical Paper

Challenges of measuring low levels of CO2 and NOx on H2-ICE

2024-07-02
2024-01-2998
Society is moving towards climate neutrality where hydrogen fuelled combustion engines (H2 ICE) could be considered a main technology. These engines run on hydrogen (H2) so carbon-based emission are only present at a very low level from the lube oil. The most important pollutants NO and NO2 are caused by the exhaust aftertreatment system as well as CO2 coming from the ambient air. For standard measurement technologies these low levels of CO2 are hard to detect due to the high water content. Normal levels of CO2 are between 400-500 ppm which is very close or even below the detection limit of commonly used non-dispersive-infrared-detectors (NDIR). As well the high water content is very challenging for NOx measuring devices, like chemiluminescence detectors (CLD), where it results in higher noise and therefore a worse detection limit. Even for Fourier-transformed-infrared-spectroscopy-analysers (FT-IR) it is challenging to deal with water content over 15% without increased noise.
Technical Paper

Low NOx Emissions Performance after 800,000 Miles Aging Using CDA and an Electric Heater

2024-07-02
2024-01-3011
Engine and aftertreatment solutions have been identified to meet the upcoming ultra-low NOX regulations on heavy duty vehicles in the United States and Europe. These standards will require changes to current conventional aftertreatment systems for dealing with low exhaust temperature scenarios while increasing the useful life of the engine and aftertreatment system. Previous studies have shown feasibility of meeting the US EPA and California Air Resource Board (CARB) requirements. This work includes a 15L diesel engine equipped with cylinder deactivation (CDA) and an aftertreatment system that was fully DAAAC aged to 800,000 miles. The aftertreatment system includes an e-heater (electric heater), light-off Selective Catalytic Reduction (LO-SCR) followed by a primary aftertreatment system containing a DPF and SCR.
Technical Paper

Supercharger Boosting on H2 ICE for Heavy Duty applications

2024-07-02
2024-01-3006
Commercial vehicle powertrain is called to respect a challenging roadmap for CO2 emissions reduction, quite complex to achieve just improving technologies currently on the market. In this perspective alternative solutions are gaining interest, and the use of green H2 as fuel for ICE is considered a high potential solution with fast and easy adoption. NOx emission is still a problem for H2 ICE and can be managed operating the engine with lean air fuel ratio all over the engine map. This combustion strategy will challenge the boosting system as lean H2 combustion will require quite higher air flow compared to diesel for the same power density in steady state. Similar problem will show up in transient response particularly when acceleration starts from low load and the exhaust gases enthalpy is very poor and insufficient to spin the turbine. The analysis presented in this paper will show and quantify the positive impact that a supercharger has on both the above mentions problems.
Technical Paper

Traceability E-Fuels 2035

2024-07-02
2024-01-3022
EU legislation provides for only local CO2 emission-free vehicles to be allowed in individual passenger transport by 2035. In addition, the directive provides for fuels from renewable sources, i.e. defossilised fuels. This development leads to three possible energy sources or forms of energy for use in individual transport. The first possibility is charging with electricity generated from renewable sources, the second possibility is hydrogen generated from renewable sources or blue production path. The third possibility is the use of renewable fuels, also called e-fuels. These fuels are produced from atmospheric CO2 and renewable hydrogen. Possible processes for this are, for example, methanol or Fischer-Tropsch synthesis. The production of these fuels is very energy-intensive and large amounts of renewable electricity are needed.
Technical Paper

The influence of design operating conditions on engine coolant pump absorption in real driving scenarios.

2024-06-12
2024-37-0015
Reducing CO2 emissions in on-the-road transport is important to limit global warming and follow a green transition towards net zero Carbon by 2050. In a long-term scenario, electrification will be the future of transportation. However, in the mid-term, the priority should be given more strongly to other technological alternatives (e.g., decarbonization of the electrical energy and battery recharging time). In the short- to mid-term, the technological and environmental reinforcement of ICEs could participate in the effort of decarbonization, also matching the need to reduce harmful pollutant emissions, mainly during traveling in urban areas. Engine thermal management represents a viable solution considering its potential benefits and limited implementation costs compared to other technologies. A variable flow coolant pump actuated independently from the crankshaft represents the critical component of a thermal management system.
Technical Paper

Potential of Serial Hybrid Powertrain Concepts towards decarbonizing the Off-Highway Machinery

2024-06-12
2024-37-0018
Today’s engines used in Agriculture, Mining and Construction are designed for robustness and cost. Here, the Diesel powertrain is the established mainstream solution, offering long operation times without refueling at any desired power rating. In view of the steps towards Carbon Neutrality by 2050 this segment of the Transportation Sector needs to reduce its CO2 emissions. Currently, the EU and US emissions legislations (EU Stage V / EPA Tier4) do not include a CO2 reduction scheme but is expected to change with the next update towards EU Stage VI / EPA Tier5 coming into effect 2030 and after. Larger power and operation range still require the use of renewable, liquid fuels or hydrogen. The cost-up of such fuels could be counterbalanced by more efficient engines in combination with a hybridized powertrain.
Technical Paper

The Potential of Hydrogen High Pressure Direct Injection Toward Future Emissions Compliance: Optimizing Engine-Out NOx and Thermal Efficiency

2024-06-12
2024-37-0005
By building on mature internal combustion engine (ICE) hardware combined with dedicated hydrogen (H2) technology, the H2-ICE has excellent potential to accelerate CO2 reduction. H2-ICE concepts can therefore contribute to realizing the climate targets in an acceptable timeframe. In the landscape of H2-ICE combustion concepts, High Pressure Direct Injection (HPDI™) is an attractive option considering its high thermal efficiency, wide load range and its applicability to on-road as well as off-road heavy-duty equipment. Still, H2-HPDI is characterized by diffusion combustion, giving rise to significant NOx emissions. In this paper, the potential of H2-HPDI toward compliance with future emissions legislation is explored on a 1.8L single-cylinder research engine. With tests on multiple load-speed points, Exhaust Gas Recirculation (EGR) was shown to be an effective measure for reducing engine-out NOx, although at the cost of a few efficiency points.
Technical Paper

Effect of Dithering on post-catalyst exhaust gas composition and on short time regeneration of deactivated PdO/Al2O3 catalysts under real engine conditions

2024-06-12
2024-37-0002
Fossil fuels such as natural gas used in engines still play the most important role worldwide despite such measures as the German energy transition which however is also exacerbating climate change as a result of carbon dioxide emissions. One way of reducing carbon dioxide emissions is the choice of energy sources and with it a more favourable chemical composition. Natural gas, for instance, which consist mainly of methane, has the highest hydrogen to carbon ratio of all hydrocarbons, which means that carbon dioxide emissions can be reduced by up to 35% when replacing diesel with natural gas. Although natural gas engines show an overall low CO2 and pollutant emissions level, methane slip due to incomplete combustion occurs, causing methane emissions with a more than 20 higher global warming potential than CO2.
Technical Paper

Assessing Heavy Duty Vehicle CO2 Emissions for Qualification as a Zero Emissions Vehicle

2024-06-12
2024-37-0007
The global transportation industry, and road freight in particular, faces formidable challenges in reducing Greenhouse Gas (GHG) emissions; both Europe and the US have already enabled legislation with CO2 / GHG reduction targets. In Europe, targets are set on a fleet level basis: a CO2 baseline has already been established using Heavy Duty Vehicle (HDV) data collected and analyzed by the European Environment Agency (EEA) in 2019/2020. This baseline data has been published as the reference for the required CO2 reductions. More recently, the EU has proposed a Zero Emissions Vehicle definition of 3g CO2/t-km. The Zero Emissions Vehicle (ZEV) designation is expected to be key to a number of market instruments that improve the economics and practicality of hydrogen trucks. This paper assesses the permissible amount of carbon-based fuel in hydrogen fueled vehicles – the Pilot Energy Ratio (PER) – for each regulated subgroup of HDVs in the baseline data set.
Technical Paper

Comparison of Performance and Efficiency of different Refrigerants at high load Conditions and their Impact on CO2eq Emissions

2024-06-12
2024-37-0029
For battery-electric vehicles (BEVs), the climate control and the driving range are crucial criteria in the ongoing electrification of automobiles in Europe towards the targeted carbon neutrality of the automotive industry. The thermal management system makes an important contribution to the energy efficiency and the cabin comfort of the vehicle. In addition to the system architecture, the refrigerant is crucial to achieve high cooling and heating performance while maintaining high efficiency and thus low energy consumption. Due to the high efficiency requirements for the vehicle, future system architectures will largely be heat pump systems. The alternative refrigerant R-474A based on the molecule R-1132(E) achieved top performance for both parameters in various system and vehicle tests.
Technical Paper

A Numerical Study of the Laminar Flame Speed of Hydrogen/Ammonia Mixtures under Engine-like Conditions

2024-06-12
2024-37-0020
In the effort to achieve the goal of a climate-neutral transportation system, the use of hydrogen and other synthetic fuels plays a key role. As battery electric vehicles become more widespread, e-fuels could be used to defossilize the hard-to-electrify transportation sectors and to store energy produced from renewable and non-continuous energy sources. Among e-fuels, hydrogen and ammonia are very attractive because they are carbon-neutral and their oxidation does not lead to any CO2 emissions. Furthermore, hydrogen/ammonia mixtures overcome the issues that arise as each of the two fuels is separately used. In the automotive sector, the use of either hydrogen, ammonia or their blends require a characterization of such mixtures under engine-like conditions, that is, at high pressures and temperatures. The aim of this work is to evaluate the Laminar Flame Speed (LFS) of hydrogen/ammonia mixtures by varying the thermodynamic conditions and the molar composition of the reactants.
Technical Paper

Assessment of Equivalent Properties for Flat Multilayered Panels

2024-06-12
2024-01-2943
The use of lightweight complex heterogeneous structures increased during the last years principally in the transportation sector (i.e., aviation and trains). This sector's technology enhancement pursues reducing long-term CO2 emissions and increasing efficiency. Lightweight structures may have poor vibro-acoustic behavior and in designs with complex shapes and material heterogeneities, its vibro-acoustic modeling brings new challenges in terms of accuracy and computational cost. Techniques such as model order reduction, homogenization, mesh and meshless methods (with and without periodicity conditions) and energy methods are typically employed to tackle this problem. Within homogenization techniques, an equivalent properties strategy can be utilized to equivalently represent complex structures into more simple ones (for example, a single layer panel).
Technical Paper

Development of a Hybrid-Electric Medium-HD Demonstrator Vehicle with a Pent-Roof SI Natural Gas Engine

2024-06-12
2024-37-0026
In response to global climate change, there is a widespread push to reduce carbon emissions in the transportation sector. For the difficult to decarbonize heavy-duty (HD) vehicle sector, lower carbon intensity fuels can offer a low-cost, near-term solution for CO2 reduction. The use of natural gas can provide such an alternative for HD vehicles while the increasing availability of renewable natural gas affords the opportunity for much deeper reductions in net-CO2 emissions. With this in consideration, the US National Renewable Energy Laboratory launched the Natural Gas Vehicle Research and Development Project to stimulate advancements in technology and availability of natural gas vehicles. As part of this program, Southwest Research Institute developed a hybrid-electric medium-HD vehicle (class 6) to demonstrate a substantial CO2 reduction over the baseline diesel vehicle and ultra-low NOx emissions.
Technical Paper

Optimization of a Sliding Rotary Vane Pump for Heavy Duty Internal Combustion Engine cooling

2024-06-12
2024-37-0030
The benefits introduced by the replacement of conventional centrifugal pumps with volumetric machines for Internal Combustion Engines (ICEs) cooling were experimentally and theoretically proven in literature. In particular, Sliding Rotary Vane Pumps (SVRPs) ensure to achieve an interesting reduction of ICEs fuel consumption and CO2 emissions. Despite volumetric pumps are a reference technology for ICE lubrication oil circuits, the application in ICE cooling systems still not represent a ready-to-market solution. Particularly challenging is the case of Heavy-Duty ICE due to the wide operating range the pump covers in terms of flow rate delivered. Generally, SVRPs are designed to operate at high speeds to reduce machine dimensions and, consequently, the weight. Nevertheless, speed increase could lead to a severe penalization of pump performance since the growth of the friction losses.
Technical Paper

The evolution of conventional vehicles' efficiency for meeting carbon neutrality ambition.

2024-06-12
2024-37-0034
In 2023, the European Union set more ambitious targets for reducing greenhouse gas emissions from passenger cars: the new fleet-wide average targets became 93.6 g/km for 2025, 49.5 g/km in 2030, going to 0 in 2035. One year away from the 2025 target, this study evaluates what contribution to CO2 reduction was achieved from new conventional vehicles and how to interpret forecasts for future efficiency gains. The European Commission’s vehicle efficiency cost-curves suggest that optimal technology adoption can guarantee up to 50% CO2 reduction by 2025 for conventional vehicles. Official registration data between 2013 and 2022, however, reveal only an average 14% increase in fuel efficiency in standard combustion vehicles, although reaching almost 23% for standard hybrids. The smallest gap between certified emissions and best-case scenarios is of 14 g/km, suggesting that some manufacturers’ declared values are approaching the optimum.
Technical Paper

Transmission of sound under the influence of various environmental conditions

2024-06-12
2024-01-2933
Electrified vehicles are particularly quiet, especially at low speeds due to the absence of combustion noises. This is why there are laws worldwide for artificial driving sounds to warn pedestrians. These sounds are generated using a so-called Acoustic Vehicle Alerting System (AVAS) which must maintain certain minimum sound pressure levels in specific frequency ranges at low speeds. The creation of the sound currently involves an iterative and sometimes time-consuming process that combines composing the sound on a computer with measuring the levels with a car on an outside noise test track. This continues until both the legal requirements and the subjective demands of vehicle manufacturers are met. To optimize this process and reduce the measurement effort on the outside noise test track, the goal is to replace the measurement with a simulation for a significant portion of the development.
Technical Paper

Study of Crew Seat Impact Attenuation System for Indian Manned Space Mission

2024-06-01
2024-26-0469
The descent phase of GAGANYAAN (Indian Manned Space Mission) culminates with a crew module impacting at a predetermined site in Indian waters. During water impact, huge amount of loads are experienced by the astronauts. This demands an impact attenuation system which can attenuate the impact loads and reduce the acceleration experienced by astronauts to safe levels. Current state of the art impact attenuation systems use honeycomb core, which is passive, expendable, can only be used once (at touchdown impact) during the entire mission and does not account off-nominal impact loads. Active and reusable attenuation systems for crew module is still an unexplored territory. Three configurations of impact attenuators were selected for this study for the current GAGANYAAN crew module configuration, namely, hydraulic damper, hydro-pneumatic damper and airbag systems.
Technical Paper

Knockdown Factor Estimation of Stiffened Cylinders under Combined Loads - A Numerical Study

2024-06-01
2024-26-0417
Airframe section of rockets, missiles and launch vehicles are typically cylindrical in shape. The cylindrical shell is subjected to high axial load and an external pressure during its operation. The design of cylinders subjected to such loads is generally found to be critical in buckling. To minimize the weight of cylinders, it is typically stiffened with rings and stringers on the inner diameter to increase the buckling load factor. Conventionally the buckling load estimated by analytical or numerical means is multiplied by an empirical factor generally called Knockdown factor (kdf) to get the critical buckling load. This factor is considered to account for the variation between theory and experiment and is specified by handbooks or codes. In aerospace industry, NASA SP 8007 is commonly followed and it specifies the kdf as a lower bound fit curve for experimental data .
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