A novel exhaust heat recovery system to reduce fuel consumption

Internal combustion engines release about 1/3 of the energy bound in the fuel as exhaust waste gas energy and another 1/3 energy is wasted through heat transfer into the ambient. On the other hand losses through friction are the third largest root cause for energy loss in internal combustion engines. During city driving frictional losses can be of the same size as the effective work, and during cold start these losses are even bigger. Therefore it is obvious to utilise wasted exhaust energy to warm up the engine oil directly. Frictional losses of any engine can be reduced during part load. Sensitivity analyses have been conducted for different concepts that utilise exhaust energy to reduce engine viscosity and friction. For a new system with an exhaust gas/oil heat exchanger the following benefits have been demonstrated:

• Fuel consumption reductions of over 7% measured as an average over 5 NEDC tests
compared to the standard system configuration.
• Significant reductions in exhaust emissions, mainly CO and NOx have been achieved
• Significantly higher oil temperatures during cold start indicate large potential to
reduce engine wear through reduced water condensation in the crankcase
• Fuel consumption reductions of further 3.3% to 4.6% compared to the 7% measured
over the NEDC test can be expected under real world customer usage conditions at
lower ambient temperatures.

Oil temperature measurements and analysis resulted in the idea of a novel system with further potential to reduce fuel consumption. This Oil Viscosity Energy Recovery System (OVER 7™) consists of 3 key features that add significant synergies if combined in a certain way: an oil warm up circuit/bypass, including oil pressure control and Exhaust Gas/Oil Heat Exchanger. The system separates the thermal inertias of the oil in the engine galleries and the oil pan, reduces hydraulic pumping losses, increases the heat transfer from the cylinder head to the oil, and utilises the exhaust heat to reduce oil friction.

The project demonstrated that sensitivity analysis is an important tool for the evaluation of different concepts. Especially for new concepts that include transient heat transfer such a qualitative approach in combination with accurate experiments and measurements can be faster and more efficient in leading to the desired improvements compared to time consuming detailed simulations.

Integrated High-Efficiency Pt/Carbon Nanotube Arrays for PEM Fuel Cells

A facile strategy to deposit Pt nanoparticles with various metal-loading densities on vertically aligned carbon nanotube (ACNT) arrays as electrocatalysts for proton exchange membrane (PEM) fuel cells is described. The deposition is achieved by electrostatic adsorption of the Pt precursor on the positively charged polyelectrolyte functionalized ACNT arrays and subsequent reduction by L-ascorbic acid. The application of the aligned electrocatalysts in fuel cells is realized by transferring from a quartz substrate to nafion membrane using a hot-press procedure to fabricate the membrane electrode assembly (MEA). It is shown that the MEA with vertically aligned structured electrocatalysts provides better Pt utilization than that with Pt on conventional carbon nanotubes or carbon black, resulting in higher fuel cell performance.

Carbon nanotube architectures as catalyst supports for proton exchange membrane fuel cells

Catalyst support materials exhibit great influence on the performance and durability of proton exchange membrane (PEM) fuel cells. This minireview article summarises recent developments into carbon nanotube-based support materials for PEM fuel cells, including the membrane electrode assembly (MEA). The advantages of using CNTs to promote catalyst performance and stability, a perspective on research directions and strategies to improve fuel cell performance and durability are discussed. It is hoped that this minireview will act as a conduit for future developments in catalyst supports and MEA design for PEM fuel cells.

Fuel consumption- and emission analysis of exhaust heat recovery systems

The study examined waste heat recovery systems for combustion engines. Emission tests with a real vehicle showed that fuel consumption and CO2 emissions can be reduced by over 7% for the official certification drive cycle through direct heat transfer from the exhaust gas to the engine oil.

Economic growth with coal, oil and renewable energy consumption in China: prospects for fuel substitution

We examine the relationship between Chinese aggregate production and consumption of three main energy commodities: coal, oil and renewable energy. Both autoregressive distributed lag (ARDL) and vector error correction modeling (VECM) show that Chinese growth is led by all three energy sources. Economic growth also causes coal, oil and renewables consumption, but with negative own-price effects for coal and oil and a strong possibility of fuel substitution through positive cross-price effects. The results further show coal consumption causing pollution, while renewable energy consumption reduces emissions. No significant causation on emissions is found for oil. Hence, making coal both absolutely and relatively expensive compared to oil and renewable energy encourages shifting from coal to oil and renewable energy, thereby improving economic and environmental sustainability.