a novel high efficient zero-emission process for stationary internal combustion engines utilizing h 2 and o 2

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Hydrogen Days 2016 8 April 2016 a novel high

1 Hydrogen Days April 2016 a novel high efficient zero-emission process for stationary internal combustion engines utilizing h 2 and o 2 a thermodynamic concept Johannes Haller, M.Eng.

2 Agenda 1 Background 2 Research Objectives 3 Novel Process Concept 4 Modeling results 5 Next Steps Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 1 / 18

3 Background 1 Background 2 Research Objectives 3 Novel Process Concept 4 Modeling results 5 Next Steps Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 1 / 18

4 Power Storage for the Energy Transition Predicted future electricity surplus in Germany with a rising share of renewables Background (Figure based on Sterner and Stadler, OTH Regensburg, 2014) Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 2 / 18

5 Power Storage Options Discharge Duration vs. Storage Capacity Background Long-term storage options will be needed on a large scale in the medium term At present only limited mid-term capacity (pump storage plants) and no longterm capacity is available in Germany (Figure based on Sterner and Stadler, OTH Regensburg, 2014) The only options for longterm storage of renewable energy on the necessary scale for Germany are the possible exploitation of scandinavian hydropower and the storage of hydrogen or methane (Windgasstudie of Fraunhofer IWES 2011) Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 3 / 18

6 Reconversion from Hydrogen to Electricity Comparison of Systems on Commercial Scale ( 300kWel) Background Electrical efficiency 42-60% Specific costs e/kw Average lifetime up to 10 years without overhaul (Dodds et.al.: Hydrogen and fuel cell technologies for heating A review 2015) Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 4 / 18

7 Reconversion from Hydrogen to Electricity Comparison of Systems on Commercial Scale ( 300kWel) Background Electrical efficiency 42-60% Specific costs e/kw Average lifetime up to 10 years without overhaul (Dodds et.al.: Hydrogen and fuel cell technologies for heating A review 2015) Electrical efficiency 40-45% (>50% with combined cycle) Specific costs e/kw (Biogas CHP unit) Average lifetime years (ASUE BHKW-Kenndaten 2014/2015 ) Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 4 / 18

8 Research Objectives 1 Background 2 Research Objectives 3 Novel Process Concept 4 Modeling results 5 Next Steps Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 4 / 18

9 Research Objectives Research Objectives The designed process is intended to Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 5 / 18

10 Research Objectives Research Objectives The designed process is intended to emid no pollutants (zero-emission) Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 5 / 18

11 Research Objectives Research Objectives The designed process is intended to emid no pollutants (zero-emission) show a higher efficiency than internal combustion engines fired with hydrogen and air Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 5 / 18

12 Research Objectives Research Objectives The designed process is intended to emid no pollutants (zero-emission) show a higher efficiency than internal combustion engines fired with hydrogen and air require lower investment costs than todays fuel cell systems Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 5 / 18

13 Research Objectives Research Objectives The designed process is intended to emid no pollutants (zero-emission) show a higher efficiency than internal combustion engines fired with hydrogen and air require lower investment costs than todays fuel cell systems assure a longer lifetime than todays fuel cell systems due to well-established technology Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 5 / 18

14 Research Objectives Research Objectives The designed process is intended to emid no pollutants (zero-emission) show a higher efficiency than internal combustion engines fired with hydrogen and air require lower investment costs than todays fuel cell systems assure a longer lifetime than todays fuel cell systems due to well-established technology The Process can provide a bridge technology for stationary applications until fuel cells become cost competitive. Storage is already needed to steady the production in windy regions as grid expansion is not progressing as needed (555GWh lost in 2014) Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 5 / 18

15 Novel Process Concept 1 Background 2 Research Objectives 3 Novel Process Concept 4 Modeling results 5 Next Steps Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 5 / 18

16 Concept for a Novel Combined 2-Stroke Cycle Novel Process Concept The two-stage process consists of a two-stroke in-cylinder combustion and an external steam process Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 6 / 18

17 System Scheme of the Combined Cycle Novel Process Concept Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 7 / 18

18 System Scheme and Thermodynamic Cycle Changes of State in PV and TS Diagrams Novel Process Concept Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 8 / 18

19 Complete Modeled Thermodynamic Process Cycle Novel Process Concept Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 9 / 18

20 Modeling results 1 Background 2 Research Objectives 3 Novel Process Concept 4 Modeling results 5 Next Steps Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 9 / 18

to be below exhaust gas temperatures to be able to close the cycle.

21 Is it a Cycle? Modeling results Evaporation and overheating temperatures in the heat exchanger have to be below exhaust gas temperatures to be able to close the cycle. Steam temperatures are limited by engine material limits. Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 10 / 18

22 Model Validation Computation of a Hydrogen-Air Internal Combustion Engine Modeling results Results are in good agreement with literature data and losses are accounted for with an isentropic efficiency of 85% Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 11 / 18

23 Modeling Results Computed Using Real Gas Data in the Software EES Modeling results For a maximum cylinder pressure of 100 bar and an isentropic efficiency of 85% the modeled inner efficiency of the combined process can outreach the efficiency of an ICE operated with air by more than 20% Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 12 / 18

24 Limiting Factors To Avoid Knocking and Comply with Material Limits Modeling results Limitations to the process: T max 2000 C p max 100 bar T exhaust 1300 C In comparison to an otto or diesel cycle, the compression ratio is not limited by the maximum cylinder pressure, but by the decreasing power output and the maximum possible exhaust gas temperature Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 13 / 18

25 Next Steps 1 Background 2 Research Objectives 3 Novel Process Concept 4 Modeling results 5 Next Steps Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 13 / 18

26 A: Zero-Dimensional Model Consideration of Time-Dependent Processes Next Steps In a zero-dimensional model, losses caused by friction and nonideal combustion can be directly modeled considering engine geometry Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 14 / 18

Next Steps B: 3-D CFD Simulation Discretization & Dynamic Remeshing Geometry is based on a series engine, computational mesh is dynamically deformed

27 Next Steps B: 3-D CFD Simulation Discretization & Dynamic Remeshing Geometry is based on a series engine, computational mesh is dynamically deformed and refined at locatins with high gradients Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H2 -O2 -ICE Hydrogen Days 2016 Prague 15 / 18

Next Steps B: 3-D CFD Simulation Validation Against

Calculated velocity fields are in well agreement with

size and turbulence model Johannes Haller, M.Eng.

28 Next Steps B: 3-D CFD Simulation Validation Against Velocity Measurements in an Optical Research Engine Calculated velocity fields are in well agreement with measurements, further improvement by variation of mesh size and turbulence model Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H2 -O2 -ICE Hydrogen Days 2016 Prague 16 / 18

29 C: Optimization & Prototype Optimization of Valve Timing, Injection Timing, Ignition Timing Next Steps Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 17 / 18

30 Discussion Thank you for your attention! Johannes Haller, M.Eng. High efficient Zero-Emission Stationary H 2 -O 2 -ICE Hydrogen Days 2016 Prague 18 / 18

wb Thermodynamics 2 Lecture 11 Energy Conversion Systems

wb Thermodynamics 2 Lecture 11 Energy Conversion Systems wb1224 - Thermodynamics 2 Lecture 11 Energy Conversion Systems Piero Colonna, Lecturer Prepared with the help of Teus van der Stelt 16-12-2010 Delft University of Technology 3mE, Process and Energy Dept.