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SAE TECHNICAL
PAPER SERIES 2006-01-0430

A Critical Review of Experimental Research


on Hydrogen Fueled SI Engines
Sebastian Verhelst and Roger Sierens
Ghent University

Stefaan Verstraeten
Karel de Grote-Hogeschool

Reprinted From: Hydrogen IC Engines


(SP-2009)

2006 SAE World Congress


Detroit, Michigan
April 3-6, 2006

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2006-01-0430

A Critical Review of Experimental Research on


Hydrogen Fueled SI Engines
Sebastian Verhelst and Roger Sierens
Ghent University

Stefaan Verstraeten
Karel de Grote-Hogeschool

Copyright © 2006 SAE International

ABSTRACT The internal combustion engine has benefited from a


continuous development during more than a century and
The literature on hydrogen fueled internal combustion is still showing potential for further optimization. Fuel cell
engines is surprisingly extensive and papers have been technology on the other hand is still in its infancy. This
published continuously from the 1930’s up to the present also reflects in the price, with a prohibitive cost for fuel
day. Ghent University has been working on hydrogen cells. Naturally, the conversion of an ICE to hydrogen
engines for more than a decade. A summary of the most increases its cost but this cost is very limited (not
important findings, resulting from a literature study and the counting the cost of the hydrogen storage and safety
experimental work at Ghent University, is given in the devices, as these are needed regardless of the propulsion
present paper, to clarify some contradictory claims and unit, the only additional cost of hydrogen fueled ICEs is
ultimately to provide a comprehensive overview of the the cost of additional H2 injectors, a modified engine
design features in which a dedicated hydrogen engine control unit and possibly some changes to the ignition
differs from traditionally fueled engines. and crankcase ventilation system).

Topics that are discussed include abnormal combustion Using ICEs allows bi-fuel operation (e.g. the engine can
(backfire, pre-ignition and knock), mixture formation run on gasoline as well as on hydrogen), alleviating fuel
techniques (carbureted, port injected, direct injection) and station density and autonomy requirements. This could
load control strategies (power output versus NOx trade- facilitate the start-up of a hydrogen economy, where the
off). Attention is given to the most recent research by car experience gained with transport, fuelling and storage
manufacturers BMW and Ford, reporting hybrid control directly translates to fuel cell vehicles. Fuel cells are
strategies (PFI+DI, lean burn + stoichiometric operation currently still handicapped by cold-start problems
using EGR) to obtain power outputs equivalent to gasoline (freezing of the fuel cell stack) and the necessity of very
engines with extremely low emission levels. Recent pure hydrogen to avoid poisoning of the FC. The hydrogen
results from experiments with EGR on a hydrogen engine fueled ICE does not suffer from these problems.
at Ghent University are also given. Finally, a synthesis of
hydrogen engine design features is given, that make the The most frequently hailed advantage of fuel cells is their
most of hydrogen’s advantages and counter its high theoretical efficiency. However, not only do practical
disadvantages. Areas requiring further research are fuel cells not (yet) reach these high efficiencies, the fuel
highlighted. cell stack (of which the efficiency is mostly cited) is also
part of a fuel cell system and the overall efficiency is thus
INTRODUCTION lower. Furthermore, the efficiency decreases as the load
increases. This is not an important disadvantage for light-
The incentives for a hydrogen economy are the absence of duty applications as these are in part load most of the
harmful emissions, the sustainability (potentially CO2- time, but could become important for heavy duty. The
free) and the energy security. When considering hydrogen large difference between the theoretical efficiency of the
as a fuel for transport applications, most people make the fuel cell stack and the effective efficiency of an ICE thus
link to fuel cells (FCs). However, the present paper mostly exists on paper and is much smaller in practice.
focuses on hydrogen-fueled internal combustion engines Furthermore, hydrogen fueled ICEs also have the potential
(ICEs) for the following reasons. for an increased engine efficiency (see later), with a
demonstrated indicated efficiency of 52% for a hydrogen
fueled spark-ignition engine [1] and a power generation
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efficiency of 49% for a hydrogen fueled compression- magnitude smaller than for typical hydrocarbons, and
ignition engine [2]. the wide flammability limits. Deposits and particulates
originate from the (partial) combustion of lubricating oil
Finally, the current number of motor vehicles worldwide is and/or rust formation during an extended standstill
estimated at about 800 million. To replace these in a (older engines).
relatively short time by fuel cell vehicles is impossible. • Residual energy in the ignition circuit: due to the
lower ion concentration of a hydrogen/air flame
In summary: the hydrogen fueled ICE and FC both have compared to a hydrocarbon/air flame, it is possible
their own advantages and both merit research to show that the ignition energy is not completely deposited in
their full potential. The hydrogen fueled ICE can function the flame and remains in the ignition circuit until the
as a transition technology to fuel cells or might take up its cylinder conditions are such that a second, unwanted,
own share of the market next to fuel cells (and other ignition can occur, namely during the expansion or
technologies). the intake stroke, when the pressure is low [7,13].
• Induction in the ignition cable: with multi-cylinder
EXPERIMENTAL RESEARCH: LITERATURE engines, the (controlled) ignition in one cylinder can
REVIEW cause an induced ignition in another cylinder when
the individual ignition cables are placed close to each
Papers on hydrogen fueled internal combustion engines other [5].
have been published continuously from the 1930’s up to • Combustion in the piston top land persisting up to
the present day, although most of them are concentrated inlet valve opening time and igniting the fresh charge
around a few points in time (e.g. during and in the years [7,14-16]. This is caused by the smaller quenching
following the oil crises). A summary of the most important gap of hydrogen mixtures compared to typical
findings of these works is given in the next sections, hydrocarbons, which enables a hydrogen flame to
following Verhelst [3]. propagate into the top land.
• Pre-ignition: pre-ignition is often encountered in
ABNORMAL COMBUSTION hydrogen engines because of the low ignition energy
and wide flammability limits of hydrogen. As a
The suppression of abnormal combustion in hydrogen premature ignition causes the mixture to burn mostly
engines has proven to be quite a challenge and measures during the compression stroke, the temperature in the
taken to avoid abnormal combustion have important combustion chamber rises, which causes the hot
implications for engine design, mixture formation and load spot that led to the pre-ignition to increase in
control. For spark-ignition engines, three regimes of temperature, resulting in another, earlier, pre-ignition
abnormal combustion exist: knock (auto-ignition of the in the next cycle. This advancement of the pre-ignition
end gas region), preignition (uncontrolled ignition induced continues until it occurs during the intake stroke and
by a hot spot, premature to the spark ignition) and causes backfire [1,5,11,17]. The mechanism is
backfire (premature ignition during the intake stroke, termed a runaway pre-ignition and can also result
which could be seen as an early form of pre-ignition, from a knocking cycle, increasing the chamber
backfire is also referred to as backflash, flashback and temperature and creating a hot spot [5].
induction ignition). The effects knock and pre-ignition can
have are well known: in the best case increased noise and In the present authors’ opinion, the low ignition energy is
vibration, in the worst case major engine damage. The often too easily pointed at as the main cause of backfire.
effects of backfire are a loud ‘bang’ in the best case, an The ignition energy is defined by the minimal spark energy
engine stop as the fuel is consumed before it can enter needed to ignite the mixture [18], whereas the ignition by
the cylinders and deliver work, or a destruction of the thermal masses such as the valves and residual gases is
intake manifold in the worst case. more related to the auto-ignition temperature of the
mixture, the temperature at which the mixture will
Backfire has been a particularly tenacious obstacle to the spontaneously ignite. As the auto-ignition temperature of
development of hydrogen engines. Most, if not all, of the hydrogen is quite high (higher than for methane and
early literature mentions causes of backfire and gasoline), it seems highly unlikely that these thermal
countermeasures as it so frequently occurs in hydrogen masses would induce backfire as they normally do not
engines with external mixture formation (backfire can only reach the auto-ignition temperature if the engine is
occur when a combustible charge is present in the intake properly set up. As hydrogen compression ignition
port). The causes cited for backfire are: engines have been demonstrated to require very high
compression ratios in order to ensure self-ignition [2], it is
• Hot spots in the combustion chamber: deposits and highly improbable that e.g. residual gases could initiate
particulates [4,5], the spark plug [6,7], residual gas ignition thermally (again: assuming normal working
[7-9], exhaust valves [9-12], etc. These hot spots are conditions, with optimal spark timing etc.). Furthermore,
cited to easily cause a backfire ‘because of the low this cannot explain the occurrence of backfire at lean
ignition energy of hydrogen’, which is an order of conditions (low temperatures).
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Also, deposits and particulates are frequently cited contradictory claims in the literature. To begin with, most
although (assuming an engine in good condition) the papers fail to point out that the knock resistance is a
concentration of these are extremely low for hydrogen property of the fuel/air mixture, stating octane numbers
engines. The ‘inert dust in air’ has even been cited [8], without the corresponding equivalence ratio. Some claim
probably forgetting the function of the engine air filter. the octane number to be very low [22, 23], others claim it
to be very high [1,8,11]. One paper was even found that
Experiments have been conducted where all hot spots stated both ‘hydrogen has a high effective octane number’
were eliminated (careful cleaning of the engine, enhanced and ‘the equivalent octane number of hydrogen is rather
oil control or even non-lubricated operation, scavenging of low’ [24]! Only very few papers mention octane numbers
the residual gases, cold spark plugs, cooled exhaust as a function of the mixture richness1 [20,25].
valves, ...), as well as any uncontrolled spark-induced Experiments have been reported that show hydrogen to
ignition, and backfire still occurred [7,15]. This suggests act as an anti-knock agent when added to unleaded iso-
that the small quenching distance of hydrogen (together octane [8,26]. To detect hydrogen knock, in-cylinder
with the wide flammability limits), allowing combustion in pressure transducer traces are indispensable, as these
the piston top land (when the piston rings and crevice allow a distinction between pre-ignition and harsh
geometries are those as used for the traditional fuels), is a combustion. Conventional ‘knock’ meters will mistake
parameter that has been overlooked by many workers. hydrogen pre-ignition for knocking combustion.
Hydrogen engines have been demonstrated, running on
stoichiometric mixtures without any occurrence of There is some evidence that the causes of hydrogen
backfire, by careful selection of piston rings and crevice engine knock could be different from gasoline knock,
volumes, without any need for timed injection (see later) or being caused by excessive flame speeds rather than an
cooled exhaust valves [14]. Workers that have paid end-gas reaction [8,11]. Thus, reducing the rate of
attention to increased cooling, enhanced ‘oil control’ by pressure rise might be more effective to control knock
mounting different piston rings, increased scavenging etc., than limiting the combustion period (e.g. using a
attribute the resulting wider backfire-free operation region quiescent combustion chamber, see later).
to a reduction of hot spots but have simultaneously
(sometimes possibly without realizing it) taken measures Reviewing the experimental literature on hydrogen SI
to suppress crevice combustion. engines, pre-ignition seems to be the limiting factor
concerning compression ratios, spark timings and mixture
There is some ambiguity in the literature on the relation equivalence ratios, rather than knock. Measurements with
backfire–compression ratio. Some authors mention a a compression ratio of 11:1 and a supercharging pressure
decrease of the compression ratio to increase the of 0.85 bar (gauge) on stoichiometric mixtures have been
resistance to backfire [12,19] by lowering the combustion reported [9], as well as measurements on lean mixtures
chamber temperature; others state that an increase in using compression ratios of 14:1 and higher [1,27], all
compression ratio is advi sed, resulting in an increased without any appearance of knock. It thus seems safe to
combustion chamber area to volume ratio, thus increasing say that hydrogen has a higher effective octane number
the heat transfer and cooling residual gases [8,11,20]. An than regular gasoline, although it would be interesting to
increased compression ratio also lowers the amount of have quantitative data.
residuals. Both are valid mechanisms and indicate the
existence of an optimum compression ratio: increasing it It is noteworthy that the experimental and theoretical work
results in higher power due to increased efficiency up to a of Karim and co-workers [23,28] reports very wide
certain point, where the mixture has to be set leaner to knocking regions, where stoichiometric mixtures are
avoid pre-ignition and a power decrease is noted [9,21]. claimed to knock even at compression ratios as low as
6:1. As these results disagree with every other experiment
To conclude the discussion of the backfire phenomenon: reported in the literature, they seem highly unlikely and
all causes itemized above can indeed result in backfire are probably affected by causes unknown to the authors.
and the design of a hydrogen engine should try to avoid
them, as engine conditions different from normal operation MIXTURE FORMATION
are always a possibility. Even though backfire that is
stated to be the result of hot spots might have other A range of mixture formation methods has been tested for
causes, hot spots still have to be avoided as they can hydrogen engines, mostly in the pursuit of backfire-free
lead to pre-ignition which increases the engine’s thermal operation:
loading and can have detrimental effects even without
leading to backfire (e.g. in an internal mixture formation • external mixture formation with a gas carburetor [7,
engine, see later). 20]

The knocking behavior of hydrogen engines has been


1
misunderstood more than the backfire phenomenon. With Studies conducted by Ford and Mobil Oil in 1999 showed an
backfire, some causes have been mixed up or their effects effective octane rating of about 140 for a hydrogen/air mixture
overestimated, but concerning knock there are completely with an equivalence ratio φ of 0.4 (Reviewer comment).
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• external mixture formation with ‘parallel induction’, the tank can only be emptied down to the fuel injection
that is: some means of delaying the introduction of pressure; compressing gaseous hydrogen on board would
hydrogen, e.g. a fuel line closed by a separate valve mean an extra compressor and a substantial energy
on top of the intake valve that only opens when the demand).
intake valve has lifted enough [29]
• external mixture formation with a gas carburetor and Thus, both external and internal mixture formation have
water injection [12,22], sometimes with additional their advantages and disadvantages. DI is better for full
exhaust gas recirculation (EGR) [30] load performance (maximum power output), PFI is better
• external mixture formation with timed manifold or port at part load (maximum engine efficiency). Engine designs
fuel injection (PFI) [1,5,9,14,17,21,31], sometimes have been proposed using both mixture formation
also with some means of ‘parallel induction’ [25] techniques [40-42]. Contemporary reviews of mixture
• internal mixture formation through direct injection (DI) formation techniques for hydrogen engines can be found in
[32-35], a method that BMW in particular is exploring refs. [11,41]. Finally, it should be noted that whereas
extensively [9,36-39] hydrogen injectors for PFI are currently commercially
available, DI injectors are not and still require development
The injection of water, delayed introduction of hydrogen to obtain sufficiently high flow rates and attain the
and direct injection are all primarily intended to delay or robustness needed for the harsh combustion chamber
prevent backfire either by additional cooling or by avoiding environment [38].
a combustible mixture during the intake phase. During the
last decade, only timed port injection and direct injection LOAD CONTROL STRATEGIES
(during the compression stroke or later) have been used,
as the other methods are less flexible and controllable. Hydrogen is a very versatile fuel when it comes to load
External mixture formation by means of port fuel injection control. The high flame speeds of hydrogen mixtures and
has been demonstrated to result in higher engine its wide flammability limits permit very lean operation and
efficiencies, extended lean operation, lower cyclic substantial dilution. The engine efficiency and the
variation and lower NOx production compared to direct emission of NOx are the two main parameters used to
injection [27,40]. This is the consequence of the higher decide the load control strategy. Constant equivalence
mixture homogeneity due to longer mixing times for PFI ratio throttled operation has been used but mainly for
as well as decreased mixing for DI as the intake demonstration purposes [29,30], as it is fairly easy to run
generated turbulence contributes less to the mixing. At a lean burn throttled hydrogen engine (accepting the
high loads, delaying the injection timing for DI can result severe power output penalty). Where possible, wide open
in significantly lowered NOx emissions [36,37,39]. DI also throttle (WOT) operation is used to take advantage of the
enables a multi-phase injection strategy for decreased associated increase in engine efficiency [25,27],
NOx and NVH [37]. regulating load with mixture richness (qualitative control)
instead of volumetric efficiency (quantitative control) and
Additionally, the cost and complexity are significantly thus avoiding pumping losses. Limitations to WOT
lower for PFI than for DI [10] and retrofitting an existing operation are due to misfires, unburned hydrogen and
engine is possible. On the other hand, the power output of decreased stability at very low load (e.g. idling) and NOx
an external mixture formation hydrogen engine is limited emissions at medium to full load. Thus, throttling is used
because of the decrease in volumetric efficiency: due to at very low loads to increase combustion stability and
the low density of hydrogen and small air requirement for decrease unburned hydrogen emissions [1,9,12,20,34].
stoichiometric mixtures, the cylinder volume taken up by Moreover, this increases the efficiency at these
the hydrogen in a stoichiometric mixture amounts to conditions: the efficiency gain through decrease of
29.5%. This results in a volumetric energy content unburned hydrogen emissions offsets the efficiency loss
decrease of some 18% for hydrogen compared to by throttling. The engine efficiency using throttled or WOT
gasoline. If direct injection is used to introduce the operation is compared in refs. [1,21], the lean limit at
hydrogen after the intake valve has closed, the maximum which throttling is introduced is engine dependent and
power output can be 17% higher compared to gasoline. ranges from λ = 3 / φ = 0.33 [12] to λ = 4 / φ = 0.25 [1, 9].

An important advantage of DI over PFI is the impossibility For higher loads, flame temperatures quickly exceed the
of backfire. This too increases the maximum power output NOx generation limit (see for instance Fig. 2). This results
of DI compared to PFI as richer mixtures can be used in a NOx limit to WOT operation. One could restrict the
without fear of backfire. Pre-ignition can still occur though, mixture richness and use sufficiently lean mixtures to
unless very late injection is used. External mixture stay below a 10 or 100 ppm NOx limit, but this implies a
formation provides a greater degree of freedom concerning large decrease in maximum power output. Alternatively,
storage methods: direct injection during the compression the engine can be throttled above this limit, using
stroke needs high pressure hydrogen and thus effectively stoichiometric mixtures and thus enabling the use of a
requires liquid hydrogen storage (metal hydrides can only conventional three way catalyst for NOx reduction [9], with
provide low pressure hydrogen, compressed hydrogen an associated decrease in engine efficiency. Yet another
could be used but this limits the effective tank contents as strategy is the use of EGR to control load: using
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stoichiometric mixtures but instead of throttling, recycling power output can be obtained as for a gasoline engine, as
exhaust gas in a proportion dependent on the power demonstrated by BMW obtaining an indicated mean
demand [21,43]. This gives a better efficiency compared effective pressure (imep) of 18 bar [9], and Ford reaching
to throttling. Water injection can also be used to decrease gasoline engine torque outputs with a (absolute) boost
NOx emissions from the richer mixtures [12], and is more pressure of 1.85 bar [21].
effective than EGR [30] but is impractical.
Finally for the upcoming fourth generation, research is
If a hydrogen engine is designed for single speed/power going on into advanced direct injection of hydrogen in SI
operation, e.g. for stationary power generation or for a engines, e.g. by BMW [36-39,42]. These different engine
series hybrid vehicle, very clean and highly efficient ‘generations’ are illustrated in the following sections with a
operation is possible without any after treatment (of which brief discussion of the experimental findings at Ghent
the effectiveness could deteriorate with time). NOx University.
emissions below 10 ppm or even 1 ppm, with indicated
efficiencies of perhaps 50% are possible [27,44,45]. VALMET ENGINE
Hydrogen is the only fuel with which this is possible (with
hydrocarbons, decreasing NOx emissions with lean burn The very first work done was basically a proof of concept.
implies increased unburned hydrocarbon emissions). Simply put, a direct injection diesel engine was taken
(Valmet inline four, 4.4 litre), the diesel fuel injectors were
Hybrid vehicles using a hydrogen fueled SI engine have replaced by spark plugs, the compression ratio was
been demonstrated [46,47] and have the potential of a lowered (from 16:1 to 8.7:1) by installing different pistons
driving cycle fuel economy approaching fuel cell vehicles and a gas carburettor was mounted [49]. The influence of
[47,48]. engine parameters on the combustion of hydrogen was
studied using heat release analysis of cylinder pressure
RESEARCH AT THE LABORATORY OF measurements [50]. The study of the cylinder pressure
TRANSPORT TECHNOLOGY, UGENT prior and during the occurrence of backfire showed a
runaway pre-ignition to lead to backfire [51]. The pre-
ENGINE GENERATIONS ignition was mostly accompanied by engine knock and a
knock detection algorithm based on cylinder pressure
The laboratory of Transport Technology at Ghent data was proposed to avoid knock and backfire [52]. The
University has been working on the development and gas carburettor was eventually replaced by a sequential
optimization of hydrogen engines for 15 years. The injection system, involving the testing of gas injectors for
authors consider four generations in the development of hydrogen (at the time not commercially available and
hydrogen fueled engines. unreliable) [53].

In the first generation a gas venturi was used. With a gas These tests have proved that it is not difficult to run an
carburettor a large volume of combustible mixture is engine on hydrogen (under lean conditions), but they have
always present in the inlet manifold. To avoid backfire, the also shown that special attention is necessary for the
engine has to run lean (λ = 2) which results in a low power power output, the NOx emissions and the backfire
output. problem. The original Valmet diesel engine has a power
output of 64 kW, which can also be reached with methane
For the second generation the same technologies were (CH4, major component of natural gas) but not at all with
used as for gasoline SI engines: multipoint sequential hydrogen (due to the lean conditions necessary to avoid
(port) injection and electronic engine control. A possible backfire), see Fig. 1 [49,54]. Figure 2 shows the (raw,
strategy is then to use a late injection so that the engine-out) NOx emissions, again for natural gas and
admitted air will cool the inlet manifold and the hydrogen [49,54]. At a certain air to fuel ratio the NOx
combustion chamber before the injection of hydrogen. emissions for hydrogen are higher than for natural gas
These injectors are now commercially available (after a (and gasoline). Only at very lean mixtures (? = 2), the level
delay of introduction due to the high volume of a low becomes acceptably low.
density gas to inject in a short time). Even with a late
injection a stoichiometric mixture (λ = 1) is not always
possible and the power output is lower than a
corresponding gasoline engine, see e.g. Ford’s results [1].

On third generation engines, currently under investigation,


the mixture is kept stoichiometric (λ = 1) at high loads. To
avoid backfire, exhaust gas recirculation or throttling is
used. At this stoichiometric mixture a three way catalyst
can be used to decrease the NOx emissions. With turbo
or supercharging and intercooling the same or a higher
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Figure 3: Individual pressure curves of the


runaway pre-ignition

Figure 1: Power output Pe,n of the Valmet engine as a function


GENERAL MOTORS ENGINE
of engine speed n, compression ratio ε and air/fuel
equivalence ratio λ, fueled with methane or hydrogen
Next a General Motors type 454 engine (better known as
the Chevrolet “Big Block”) was adapted for gaseous fuels.
The 7.4l V8 engine was initially equipped with a gas
carburettor and experiments were carried out with natural
gas, mixtures of natural gas and hydrogen, and pure
hydrogen [55]. Then a multipoint sequential injection
system was installed with a programmable engine
management (second generation).

Attention was given to a qualitative control of the load


(variation of the richness of the hydrogen-air mixture),
beneficial for the engine efficiency compared to a
quantitative control using a throttle valve. Also injection
and ignition maps were optimized, a forced crankcase
ventilation system was mounted and supercharging was
applied [56,57]. The lubrication oil was analyzed revealing
a substantial decrease in its lubricating quality, caused by
the presence of hydrogen (from blowby) in the crankcase.
More specifically, the concentration of various additives
had decreased, esters appearing in the unused oil had
Figure 2: NOx emissions of the Valmet engine as a function almost completely disappeared in the used oil and the
of the air/fuel equivalence ratio λ, for varying compression viscosity index had decreased. This is understandable
ratio ε, fueled with methane or hydrogen when one knows that hydrogen is used in the industry to
harden oils to fats (breaking open the double carbon to
The backfire phenomenon is shown in Fig. 3 [51]. carbon bonds).
Successive pressure cycles are shown, indicating the
runaway pre-ignition till finally the pre-ignition occurs CFR ENGINE
before the inlet valve closure (IVC) (cycle 32) resulting in
the explosion of the mixture in the inlet manifold. A single cylinder CFR engine (fixed speed of 600 rpm,
variable compression ratio) has been initially equipped
This (extended) proof of concept on the Valmet engine with a gas carburettor (first generation), then with a
has indicated the focus of all further research on hydrogen sequential injector (second generation) and is now
fueled internal combustion engines: working with a sequential injector (and MoTeC control
unit), exhaust gas recirculation and three way catalyst
• backfire-safe operation (third generation).
• increase of the power output
• decrease of the NOx emissions Detailed studies were carried out:
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• pressure measurements in the combustion chamber


as a function of load (equivalence ratio), compression
ratio, ignition timing …
• influence of the position of the injector and injection
timing on the power output and efficiency [58,59]
• NOx reduction strategies

Exhaust gas recirculation is an effective means for NOx


reduction and an especially interesting option at
stoichiometric operation as the high NOx reduction
efficiency of a standard three way catalyst can then be
exploited. Furthermore, one could vary the engine power
output by changing the amount of recycled exhaust gas,
instead of throttling, thus avoiding engine efficiency
penalties.

A comparison was made between lean burn operation and Figure 5: NOX emissions before and after TWC,
stoichiometric operation with EGR, in terms of efficiency, stoichiometric operation with variable EGR percentage
power output, NOx emissions and backfire resistance
[60]. As an example, Figs. 4 and 5 compare the lean burn AUDI ENGINE
with the EGR load control strategy. Fig. 4 shows the NOx
emissions before and after the TWC as a function of the A single cylinder research engine of Audi origin (engine
air to fuel equivalence ratio (here, the power output is speed 1000 – 4500 rpm) was equipped with a high
controlled by the equivalence ratio, the figure shows a pressure transducer and two injectors in the inlet duct (for
power range of about 90 to 75% of maximum power one cylinder). The ignition- and injection timing are
output). Fig. 5 plots the NOx emissions before and after controlled by a MoTeC M4 Pro engine control unit. Initial
the TWC as a function of the percentage of EGR (here, results using methane and hydrogen are given by
the power output is controlled by the EGR percentage, Verstraeten et al. [61].
while maintaining a stoichiometric mixture, the figure
shows a power range of about 100 to 70% of maximum Recently, a study of backfire causes was started,
power output). examining the influence of various parameters (ignition
timing, number of injectors, injection timing, injector
These tests clearly indicate the advantage of the λ=1 + location, …) on the backfire phenomenon by looking for
EGR strategy over the lean burn strategy in terms of NOx the pre-ignition limited equivalence ratio. It was found that
reduction potential. Only at stoichiometric or at rich on this engine, backfire is always caused by a runaway
conditions, there is enough hydrogen present in the pre-ignition.
exhaust to act as an active agent to reduce the NOx.
Figure 5 learns that the conversion efficiency of the TWC Unfortunately, due to problems with excessive vibration on
decreases with the EGR percentage, which is probably the pressure transducer it was not possible to obtain
due to the exhaust temperature dropping below the light- confirmation from pressure diagrams. However, runaway
off temperature of the TWC. pre-ignition is thought to be the most likely mechanism
based on previous experience and the engine behaviour. In
the following, the air to fuel equivalence ratio below which
pre-ignition and consequently backfire occurs is termed
the pre-ignition limit.

The ignition timing proved to be a very important


parameter, due to the high flame speeds of near to
stoichiometric hydrogen-air mixtures. Setting the ignition
timing one degree off can increase the thermal loading of
the engine enough for pre-ignition to occur, evolving in a
runaway pre-ignition and backfire. At near to
stoichiometric mixtures, optimal ignition timings are
mostly after TDC.

Cooling of the combustion chamber by using a late


injection strategy was found to be offset by the time
needed to ensure a homogeneous mixing. This is
Figure 4: NOX emissions before and after TWC, as a function illustrated in Fig. 6 showing the pre-ignition limit as a
of the equivalence ratio
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function of the end of injection (in °ca BTDC). It can ignition system or changing the ignition cable’s
clearly be seen that the pre-ignition limit improves at first electrical resistance [12,13]; avoid induction ignition in
with a later injection (going from 220 to 180 °ca BTDC) as an adjacent ignition cable, for instance by using a
more time is available for cooling, but gets worse for very coil-on-plug system; provide a high voltage output
late injections as mixing deteriorates (intake valve closes ignition system as the ignition of hydrogen mixtures
at 114 °ca BTDC). asks for an increased secondary ignition voltage
[12,13,37] (probably because of the lower ion
concentration of a hydrogen flame, see above), coil-
on-plug systems also satisfy this condition.
Alternatively, the spark plug gap can be decreased to
lower the ignition voltage, this is no problem for
hydrogen engines as there will be almost no deposit
formation. Spark plug gaps as small as 0.25mm have
been used [7] (although the gap was subsequently
increased to 0.5mm because of cold start difficulties
due to water condensation at the spark plug tip).
• Injection system: provide a timed injection, either
using port injection and programming the injection
timing such that an initial air cooling period is created
in the initial phase of the intake stroke and the end of
injection is such that all hydrogen is inducted, leaving
no hydrogen in the manifold when the intake valve
closes; or using direct injection during the
Figure 6: Influence of injection timing on pre-ignition limit compression stroke. High flow rate injectors are
needed in both cases, multiple injectors per cylinder
As a consequence, using 2 injectors to enable later can alleviate this requirement. The timing described
injection timings and a longer cooling period, did not prove here might not be necessary as work has been
to be beneficial, with the pre-ignition limit being the same reported where no relation between injection timing
when using 1 or 2 injectors (in this case, around λ=1.4), and backfire or pre-ignition limited equivalence ratio
there exists an optimum injection timing which is a was found [1]. Timed injection also decreases the
compromise between mixing and cooling time. Using the amount of unburned fuel in the intake manifold at any
same timing for the two injectors proved best. Using two given time, limiting the severity of a backfire should it
injectors is necessary at high engine speeds and loads for occur.
delivering the required amount of fuel. • Hot spots: avoid hot spots in the combustion chamber
that could initiate pre-ignition or backfire, use cooled
OVERVIEW OF DESIGN FEATURES OF exhaust valves; use multi-valve engine heads to further
DEDICATED HYDROGEN SI ENGINES lower the exhaust valve temperature [10-12]; ensure
proper oil control; provide additional engine coolant
This paper has indicated the advantages of hydrogen as a passages around valves and other areas with high
fuel for spark ignited internal combustion engines and has thermal loads [14] (if possible); delay fuel introduction
shown that the hydrogen engine is growing up. An to create a period of air cooling (using timed manifold
overview was given of the development by car or direct injection); ensure adequate scavenging (e.g.
manufacturers, research centers and also of the research using variable valve timing [1,9]) to decrease residual
at the laboratory of Transport Technology, Ghent gas temperatures.
University. This can be synthesized in the following • Piston rings and crevi ce volumes: decrease the piston
overview of the design features in which a dedicated top land clearance to prevent hydrogen flames from
hydrogen engine differs from traditionally fueled engines: propagating into the top land, Swain et al. [14] use a
clearance of 0.152mm to quench the hydrogen flame.
• Spark plugs: use cold rated spark plugs to avoid Change the crevice volumes and/or piston rings with
spark plug electrode temperatures exceeding the the aim of reducing the reflow of unburned mixture
auto-ignition limit and causing backfire [6,13]. Cold from the second land to the top land [14-16]
rated spark plugs can be used since there are hardly (preventing ‘fuelling’ of a top land flame during exhaust
any spark plug deposits to burn off. Do not use spark and intake).
plugs with platinum electrodes as this can be a • Valve seats and injectors: the very low lubricity of
catalyst to hydrogen oxidation [8,10] (platinum has hydrogen has to be taken into account, suitable valve
been used in the exhaust to oxidize unburned seat materials have to be chosen [10,12] and the
hydrogen [29]). design of the injectors should take this into account.
• Ignition system: avoid uncontrolled ignition due to This is the case with any dry gaseous fuel (such as
residual ignition energy by properly grounding the natural gas) but can be more critical for hydrogen
(compressed natural gas contains small amounts of
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oil originating from the oil mist in the compressor • For further improvements in power output and
whereas hydrogen compressors normally have tighter prevention of abnormal combustion, it would be
clearances to limit the leak rate). interesting to perform a systematic study of the
• Lubrication: an engine lubrication oil compatible with ‘knocking’ behavior and crevice combustion to obtain
increased water concentration in the crankcase has a better understanding of the mechanisms leading to
to be chosen, the report on the hydrogen drive test in abnormal combustion phenomena such as backfire.
Germany by TÜV [12] cites two options, a More specifically, data is needed of the knocking
demulsifying oil and a synthetic oil which forms a behavior and the quenching distance as a function of
solution with water. DeLuchi [62] claims a longer oil the equivalence ratio.
lifetime as the oil is not diluted by hydrogen and there • Hydrogen PFI engines can be considered to be ready
is less formation of acids. An ashless oil is for large scale demonstration purposes, be it as
recommended to avoid deposit formation (hot spots) dedicated hydrogen vehicles or bi-fuel vehicles with
[6]. The effect of hydrogen on the oil composition and gasoline engines retrofitted for hydrogen. Large scale
chemical structure has been reported by two of the demonstration would permit to evaluate durability and
authors [57]. possible material and lube oil degradation.
• Crankcase ventilation: positive crankcase ventilation • Hybrid powertrains using hydrogen ICEs, and DI
is generally recommended due to unthrottled engines have a lot of potential that needs to be
operation (high manifold air pressures) and to explored further. Also, load control strategies that
decrease hydrogen concentrations (from blowby) in take full advantage of today’s gasoline engine state-
the crankcase [10,63]. of–the-art such as variable valve timing and/or lift
• Compression ratio: the choice of the optimal should be developed specifically for hydrogen
compression ratio is similar to that for any fuel, it engines.
should be chosen as high as possible to increase
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