SEPTEMBER, 15-16 2015 ENGINE BOOSTING AND UNIVERSITI

UNIV

ERSI

TI T

EKNO

LOGI

MAL

AYSI

A, J

OHOR

BAH

RU, M

ALAY

SIA

THE LATEST DEVELOPMENTS IN

ENGINE BOOSTING AND

WASTE HEAT RECOVERY

SEPTEMBER, 15-16

2015

1st International Symposium

Engine Boosting and

Energy Recovery 2015

International Symposium: Engine Boosting and Energy Recovery 2015 (EBER ‘15)

The 1st International Symposium on

Engine Boosting & Energy

Recovery 2015

“THE LATEST DEVELOPMENTS IN ENGINE

DOWN-SIZING AND WASTE HEAT RECOVERY’

15th—16th September 2015

Universiti Teknologi Malaysia

Johor

MALAYSIA

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© UTM Centre For Low Carbon Transport in cooperation with Imperial Col-

lege

London (LOCARTIC),

Faculty of Mechanical Engineering (FKM),

Universiti Teknologi Malaysia (UTM) 2015

All right reserved. No part of this publication may be produced, copied,

stored in any retrieval system or transmitted in any form or any means —

electronic, mechanical, photocopying, recording or otherwise; without

prior permission in writing from the UTM Centre For Low Carbon

Transport in cooperation with Imperial College London (LOCARTIC), Facul-

ty of Mechanical Engineering (FKM), Universiti Teknologi Malaysia (UTM),

81310 Skudai, Johor Darul Takzim, Malaysia.

The 1st International Symposium on Engine Boosting & Energy Recovery

( EBER 2015), The Latest Developments in Engine Down-sizing and

Energy Recovery, Universiti Teknologi Malaysia, 15th—16th September

2015, Organized by Universiti Teknologi Malaysia (UTM)

Published and printed by:

UTM Centre For Low Carbon Transport in cooperation with Imperial Col-

lege

London (LOCARTIC),

Faculty of Mechanical Engineering (FKM),

Universiti Teknologi Malaysia (UTM),

81310 Johor Bahru,

Johor Darul Takzim,

Malaysia.

TEL: +607-5536240 / 5535834

Fax: +607-5536240

Website: www.utm.my/locartic

Email: [email protected]


Foreword by the Deputy Vice-Chancellor of

Universiti Teknologi Malaysia I

Foreword by the Chairman of EBER 2015 III

Organizing Committee V

Schedule VI

List of Technical Papers

Keynote speakers 01

Biography of Keynote Speakers

Keynote speakers X

Abstract of Keynote Speakers

Technical papers X

Abstract of technical papers

CONTENTS

foreword

I International Symposium: Engine Boosting and Energy Recovery 2015 (EBER ‘15)

Deputy Vice Chancellor of Research & Innovation Universiti Teknologi Malaysia

Universiti Teknologi Malaysia (UTM) is delighted to be the

host of 1st International Symposium on Engine Boosting and Energy Recovery 2015 (EBER 2015). On behalf of UTM and the organizing committee, I would like to extend our warmest welcome to all del-egates to this exciting event that bring together academicians, re-searchers and industries to showcase their research developments, while providing a collegial atmosphere for scientific exchange. To all international participants, “Selamat Datang” or Welcome to Ma-laysia, and in specific to UTM.

This symposium is intended to provide a platform for aca-

demics, industry and business communities to gain substantial ben-efits and invaluable insights on pertinent issues related to the field of engine boosting, energy recovery and its applications.

This commendable effort, not only enhance the generation

of new ideas that could contribute to the advancement of engine boosting and energy recovery technology, in many ways will also assist to bridge between the local and leading researchers among the international automotive community. It is my sincere wish that this symposium will propagate new ideas and solutions for effec-tive technology applications that will take into consideration ener-gy conservation and environmental preservation.

FOREWORD

I am confident that EBER 2015 and visit to UTM, Malaysia will be a rewarding experience to all delegates professionally, socially and culturally. I would like to congratulate the organizing commit-tee and I wish the delegates will benefit from the networking and research discussions. PROF. DR. AHMAD FAUZI BIN ISMAIL Deputy Vice-Chancellor (Research & Innovation) Universiti Teknologi Malaysia (UTM) 81310 Johor Bahru Johor, Malaysia.

II International Symposium: Engine Boosting and Energy Recovery 2015 (EBER ‘15)

III International Symposium: Engine Boosting and Energy Recovery 2015 (EBER ‘15)

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Chairman of EBER 2015

We would like to extend our warmest welcome to all the par-ticipants from around the world. Welcome to UTM and Malaysia! Today marks an important milestone in our brief history! We are gathered here for the 1st International Symposium on Engine Boosting and Energy Recovery, EBER 2015! We hope this will be the first of many more similar events for all of us to get together and share our common passion for engine boosting and energy recov-ery. EBER 2015 was first mooted in the early 2014, when UTM and Imperial College signed an agreement to setup the UTM Centre for Low Carbon Transport, LOCARTIC. This was an inspiration from the world most successful event on engine boosting and energy recov-ery, IMechE Conference on Turbochargers and Turbocharging, held every 2 years in London. The IMechE event has such a strong legacy that anyone working with turbochargers must have gone through the conference or its papers. We at LOCARTIC wanted to start something similar in Asia, not as a rival but to complement the event in London. Hence here we, in our first attempt, to bring together experts from academia and industry to exchange ideas in the exciting areas that we all love, engine boosting and energy recovery.

FOREWORD

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We have keynote speakers from Imperial College London, Daimler Germany, Proton Malaysia and LKE Group Thailand. They will share their insights and experiences from university-industry led research programs, heavy duty transport industry, Malaysian automotive industry and Asian Power industry. We are very grateful and would like to express our gratitude to all the keynote speakers for gracing our inaugural event, THANK YOU. We hope all the participants will benefit from these 2 days of intellectual discussions and most importantly networking among our peers. We, the organizing committee, are looking forward to make sure your visit one that is fruitful and memorable. THANK YOU. DR. SRITHAR RAJOO Chaiman of EBER 2015 UTM Centre for Low Carbon Transport in cooperation with Imperial College London (LOCARTIC) Faculty og Mechanical Engineering, Universiti Teknologi Malaysia (UTM)

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Chairs Dr. Srithar Rajoo

Prof . Ricardo Martinez-Botas

Dr. Alessandro Romagnoli

Event Coordinator Nur Izwanne Mahyon

Treasurer Muhammad Hanafi Md Shah

Publicity & Promotion Dr Chiong Meng Soon

Registration & Publication Nur Izrin Binti Mahyon

Logistic Kishokanna Paramasivam

Technical Aaron Edward Teo Sheng Jye

Feng Xian Tan

COMMITTEE

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SCHEDULE

15th SEPTEMBER 2015 TUESDAY

0830 – 0930 Registration

0930 – 1030 Opening Speech

1030 – 1100 Coffee Break

1100 – 1200 Keynote 1 –Prof. Ricardo

1200 – 1300 Paper Session

1200 – 1230 Paper 1

1230 – 1300 Paper 2

1300 – 1430 Lunch

1430 – 1530 Keynote 2 – Mr. Azmi


1530 – 1600 Paper 3

1600 – 1630 Paper 4

1630 – 1700 Evening Tea

1900 – 2200 Networking Dinner

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SCHEDULE

16th SEPTEMBER 2015 WEDNESDAY

0900 – 1000 Keynote 3 - Dr. -Ing Elias


1000 – 1030 Paper 5

1030 – 1100 Coffee Break


1100 – 1130 Paper 6

1130 – 1200 Paper 7

1200 – 1230 Paper 8

1230 – 1430 Lunch

1430 – 1530 Keynote 2 - Mr. Andrew


1530 – 1600 Paper 9

1600 – 1630 Ending Speech

1630 – 1700 Evening Tea


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LIST OF TECHNICAL PAPERS

Keynote 1 Future Boosting Technologies for Highly Downsized Low Carbon

Vehicles Ricardo F. Martinez-Botas

Mechanical Engineering Department Imperial College London

Keynote 2

Technology Review of the Use of Water Injection in Internal Combustion Engines Waste Heat Reduction and Recovery

Azmi Osman Proton, Malaysia

Keynote 3

Tailor-made boosting system for Daimler´s Heavy Duty Engine Platform

Dr. Elias Chebli, Torsten Palenschat DAIMLER AG, Germany

Keynote 4 Market analysis on the retrofit application of waste heat to power

technology for heavy industry in Asia Andrew Lindsay

LKE Co., Ltd

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Paper 1 An Investigation on Influence of Altitude on Engine

Performance of Turbocharged Internal Combustion Engine (ICE) Yuncheng Gu, Mingyang Yang, Kangyao Deng, Lei Shi

Paper 2

Simulation of Droplet Timescales for High Altitude Wankel Engine using Pressure Swirl Atomiser Fuelled with Iso-octane and

Dodecane Gem Kiat Teha, John Shrimptona, Jo-Han Ngb

Paper 3

One-dimensional Simulation of an Externally Waste-gated Turbocharger Turbine under Pulsating Inlet Conditions

Wan Saiful-Islam Wan Salim, Peter J. Newton, Yang Mingyang & Ricardo F. Martinez-Botas

Paper 4

A Meanline Modelling Approach for a Double Entry Turbine P Newton, R F Martinez-Botas

Paper 5 Matching the Pre-turbine Steam Injection Combined with the Miller

cycle for the turbocharged engine Sipeng Zhua, Kangyao Denga



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Paper 6 Drawbacks on the application of nozzle vanes in turbocharger

turbine under pulsating flow conditions M.H. Padzillah, S. Rajoo, R.F. Martinez-Botas

Paper 7

Single Passage and Full Turbine CFD Analysis for Non- Radial Fibre Element of Low Pressure Turbine

Bin Ahmad, A. F., Bin Ahmad, M. A., Bin Mamat, A. M. I. Paper 8

Study of parameter optimization of a turbo-compound diesel engine

Rongchao Zhaoa, Weilin Zhugea, Yangjun Zhanga,*, Yong Yinb, Yanting Zhaob, Zhen Chenb

Paper 9 Influence of Pulsating Frequency and Loading on the Performance

on an Asymmetric Double Entry Turbine B. A. Gurunathan., R.F. Martinez-Botas, Y. Minyang, S. Rajoo

KEYNOTE

SPEAKERS Biography of Keynote

Speakers

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PROF. RICARDO MARTINEZ-BOTAS Imperial College London

Ricardo Martinez-Botas is a Professor of Turbomachinery at the Department of Mechanical Engineering, Imperial College Lon-don. Ricardo has an MEng (Hons) Degree in Aeronautical Engineer-ing from Imperial College London. He obtained a DPhil in the Rolls Royce University Technology Center at the University of Oxford University in 1993 with a thesis entitled Annular Cascade Aerody-namics and Heat Transfer. He has developed the area of unsteady flow aerodynamics of small turbines, with particular application to the turbocharger in-dustry. The contributions to this area centre on the application of unsteady fluid mechanics, instrumentation development and com-putational methods. The work has attracted support not only from Government agencies but also from industry. His group has be-come a recognised centre of turbocharger turbine aerodynamics, and more particularly in the application experimental methods and one dimensional calculation procedures.

BIOGRAPHY


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In 2010 and 2009 he was awarded the best paper award by the Tur-bomachinery Committee of ASME and in 2011 has been given the Dugald Clerk Prize by the Institution of Mechanical Engineers (UK) for contributions to internal combustion engines. He is a Visiting Professor in the University Teknologi of Malaysia. He has published extensively in journals and peer reviewed conferences. He is Associ-ate Editor of the Journal of Turbomachinery (ASME) and the Journal of Mechanical Engineering Science (IMechE). He is currently the Theme Leader for Hybrid and Electric Vehicles of the Energy Futures Lab at Imperial College. He is the head of the Thermofluids Division.


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DR. –ING ELIAS CHEBLI

Truck Powertrain Engineering

Mercedes-Benz (DAIMLER AG), Germany

Elias Chebli received a degree in aerospace engineering from Stuttgart University with a major in aero-thermodynamics & aero-nautical propulsion systems. He obtained later on a Ph.D. in tur-bomachinery aerodynamics on a project at Daimler mentored by Stuttgart University (Institute of Thermal Turbomachinery and Ma-chinery Laboratory) & co-mentored by Imperial College London. Earlier in his career, Mr. Chebli (Elias) served on different pro-jects related to the analysis and development of product perfor-mance at different institutions such as German Aerospace Agency, Stuttgart University, and Liebherr Aerospace in Toulouse. Mr. Chebli joined Daimler 10 years ago and served in different positions on Turbocharging R&D projects. In his current role, he is based in Stuttgart, Germany and is working in the engine and tur-bocharging development center of the heavy duty business unit. In this role, he is leading the aero performance and the advanced de-velopment of the boosting system.

BIOGRAPHY


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MR. ANDREW LINDSAY CEO

LKE Group, Thailand Andrew started his career in the Mergers & Acquisitions /Strategy Advisory department for KPMG and Grant Thornton in London. He managed and conducted commercial due diligence pro-jects and provided strategy advisory services to a variety of clients from private equity houses to FTSE 100 banks and corporations. He has worked on over 45 transactions, with deal sizes between £22m-£11.5bn. In 2008, Andrew started LKE to pursue his interest in the field of energy efficiency technology for heavy industry. The aim is to enable businesses in this sector to reduce their operating costs, whilst also cutting their environmental impact. LKE’s primary func-tion is identifying, developing and implementing new retrofit ener-gy efficiency technologies for power generating and thermally in-tensive assets. Currently LKE has active projects implementing waste heat recovery technologies, like Organic Rankine Cycle systems, in the mining, steel, power generation, plastics, palm oil sectors as well as co-generation systems in these the textile and food manufacturing sectors.

BIOGRAPHY


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MR. AZMI BIN OSMAN R&D/ Powertrain, Proton Malaysia

Azmi Osman is a registered Professional Engineer and Corpo-rate member or the Institution of Engineers Malaysia. He is current-ly, the Head of Advanced Powertrain at Proton Malaysia. Prior to the current position, he was the Head of Powertrain at Lotus Cars in UK. His latest portfolio covers the R&D and advanced engineering of thermal management, friction reduction, combustion and light-weight engine architecture. He has published many peer reviewed papers and has many international patents. In his free time, he en-joys inventing, reading, writing, mountain biking and skiing.

BIOGRAPHY

KEYNOTE

SPEAKERS Abstract of Keynote

Speakers


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ABSTRACT

Future Boosting Technologies for Highly Downsized Low Carbon Vehicles

Ricardo F. Martinez-Botas Mechanical Engineering Department

Imperial College London

Abstract

Driven by a demand for better fuel economy and increasingly strin-

gent emissions regulations over a wide range of customers and ap-

plications, engine manufacturers have turned towards engine

downsizing as the most potent enabler to meet with these require-

ments. With boosting systems featuring a variety of technologies

ranging from single to multistage turbines and compressors to elec-

trified turbocompound systems, alternative compressor and tur-

bine technologies, the difficulty in the selection of the appropriate

system becomes obvious; overall boost performance, thermal effi-

ciency and packaging criteria are of paramount importance. These

boosting trends include variable geometry, a shift from single to

two (or more) stages, extensive actuation for bypassing exhaust

flows, exhaust flow regulation and pulsating exhaust energy recov-

ery, severe electrification and an extensive effort downstream from

the turbine to capture waste heat after the principal turbocharger/

supercharger (the last effort is spearheaded by the resurrection of

turbocompounding, both in mechanical and electrified forms).


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Tailor-made boosting system for Daimler´s Heavy Duty Engine Platform

Dr. Elias Chebli, Torsten Palenschat DAIMLER AG, Germany

Abstract

Within the Daimler AG, Daimler Trucks forms one of the business units besides Mercedes-Benz Cars, Mercedes-Benz Vans, Daimler Busses, and Daimler Financial Services. As the biggest globally ac-tive manufacturer of trucks above 6 tons the Daimler Trucks divi-sion develops and manufactures commercial vehicles. The Global Powertrain Development network within Daimler Trucks covers medium as well as heavy duty engines for global markets all over the world. Due to the increasing requirements on performance and emission regulations, as well as reduction of operating costs, Daim-ler recently presented its latest heavy duty engine featuring Ex-haust Gas Recirculation, Selectic Catalytic Reduction, an advanced Combustion system, and, as a unique combination of an advanced EGR-Valve and a tailor-made in-house engineered asymmetric twin scroll Exhaust Gas Turbocharger. The talk covers development trends as well as future engine development requirements and tar-gets in particular regarding the in-house engineering and manufac-turing of the turbocharging system.

ABSTRACT


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Market analysis on the retrofit application of waste heat to power technology for heavy industry in Asia

Andrew Lindsay LKE Co., Ltd

Abstract

The global waste heat recovery market has seen aggressive growth in recent years, with a market size of roughly $53billion expected by 2018(1). Forecast growth is expected at a CAGR of 7.3 % over the peri-od 2014-2019(2). Renewable energy's average levelized cost per kWh can be two to three times that of energy efficiency's costs (3), as such waste heat recovery projects have and will be a key driver in meeting industry emissions and energy reduction goals, especially in price sensitive regions like Asia. This sentiment is reflected by the IEA, which predicts energy efficiency (inc. non-waste heat to power technology like LED lighting) will account for 49% of GreenHouse Gases (GHG) savings in 2030, compared to 17% from renewable in-vestments. Though Asia does not currently have the largest market share, it will be the prominent player in the foreseeable future de-spite the relatively high investment cost of waste heat recovery equipment. The Asian market is expected to have the fastest growth rate out of all the other regions with a CAGR of 9.7% to 2018(1), spurred by increasing energy prices, government policy and compounded by a large and growing manufacture base-especially from China and India. Historic growth in South East Asia, primarily driven by Thailand, Philippines and Indonesia's (off grid) high kWh price, has seen a boost of waste heat to power projects. Despite the current decline in energy prices, the trend is only likely to in-crease as future energy prices increase, equipment cost lowers, Asian government policies to restrict emission/thermal pollution and reduce energy consumption are implemented and the manu-facturing sector increases its output.

ABSTRACT

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The Asian industry sector is likely to be the back bone of this mar-ket as it accounts for the largest share of the energy consumption, ahead of transport, with 30% of total energy consumption in 2011, which is expected to grow to 32% by 2035(IEA SEA Outlook). Of the 125Mtoe consumed by the Asian industry during 2011, it is assumed up to 50% of industrial energy input was wasted as heat that could have been converted into electricity (U.S. Department of Energy report). LKE expects the waste heat to power potential for the in-dustrial sector to be much higher than the transport and residential sectors for Asia, where utilizing waste heat for power is less practi-cal and economical. Andrew will give his perspective, and share his experience, on the waste heat to power market in Asia. In recent years LKE has witnessed a rise of Thai companies actively pursuing improvements in their energy efficiency through waste heat to power projects. Cement plants, power assets, boilers and furnaces have been active areas for LKE'S waste heat projects. The focus of the talk will span from the market in general, the untapped poten-tial and importance of low heat sources, key waste heat to power technologies for local industries and the implementation of Organic Rankine Cycle (ORC) systems. Cost benefits analysis and investment criteria for clients in the region will be discussed, along with what Andrew believes will be key 'next steps' R&D milestones that will facilitate Asian industry's ability to fully utilize its wasted heat to power potential.



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Technology Review of the Use of Water Injection in Internal Combustion Engines Waste Heat Reduction and

Recovery Azmi Osman

Proton, Malaysia Abstract

The stricter fuel consumption limits to be imposed worldwide from

the year 2020 onward require the automotive industry to research

for solutions beyond the conventional powertrain. In responding to

this, many automakers have decided to hybridize the powertrain

even if it adds a lot cost and weight to the final products. As an al-

ternative, typical internal combustion engines waste around 2/3 of

the combustion heat to the environment through exhaust tailpipe

and coolant radiator. With this much of waste heat, significant in-

crease in fuel efficiency can be expected if the waste heat from the

combustion can either be reduced or recovered. Nevertheless, re-

search and development progress made in this area in the past 20

years is still lagging if compared to electrification, hybridization and

fuel cell thus better awareness on the big potential for thermal effi-

ciency improvement is needed to attract more researches in this

area. Although there are many heat recovery technologies current-

ly being developed around the world, this paper focuses on the

technology review involving various water injection concepts for

waste heat reduction and recovery. In addition, the paper touches

on the thermodynamics principles that are crucial in increasing the

system’s effectiveness and efficiency. The paper also proposes cer-

tain strategic directions to be considered for further scientific evo-

lutions to take place in the future.

ABSTRACT

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TECHNICAL

PAPERS

Abstract of technical

papers


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An Investigation on Influence of Altitude on Engine Performance of Turbocharged Internal Combustion

Engine (ICE) Yuncheng Gu, Mingyang Yang*, Kangyao Deng, Lei Shi

Shanghai Jiao Tong University, Shanghai, 200240, China

Abstract

the performance of an internal combustion engine (ICE) degrades

evidently as the operational altitude increases due to low density of

intake air and hence lack of fresh intake for combustion. Turbo-

charging is the main technology for the power recovery at altitude.

The increasing boost pressure via turbocharging compensates the

reduction of density of the fresh intake as the altitude increases, by

which the power of the engine can be recovered to some extent.

This paper studies the influence of the altitude on the available en-

ergy in the exhaust manifold in a turbocharged diesel engine by nu-

merical method. An experimentally validated model of a 6-cylinder

diesel engine is employed for the investigation. The degradation of

engine performance, in terms of fuel economy, and output power/

torque, with the operational altitude is studied, followed by the dis-

cussion on the migration of matching points between the turbo-

charger and the engine. Next, detailed analysis is performed on the

available energy in the exhaust manifold at different altitudes, and

the reasons for the migration are discussed from aspect of the

available energy. The investigation of the mechanism from the as-

pect of the available energy in the exhaust manifold will be valua-

ble for the methodology of power recovery in the ICE at altitude.

PAPER 1

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PAPER 2

Simulation of Droplet Timescales for High Altitude Wankel Engine using Pressure Swirl Atomiser Fuelled

with Iso-octane and Dodecane Gem Kiat Teha, John Shrimptona, Jo-Han Ngb

a Faculty of Engineering and the Environment University of Southampton, University Rd, Southampton SO17 1BJ, United Kingdom

b Faculty of Engineering and the Environment, University of Southampton Malaysia Campus, 79200 Nusajaya, Malaysia.

Abstract The operation of a Wankel engine is directly related to the ways fuel droplets behave within the combustion chamber. It is im-portant to ensure injected fuel evaporates before colliding with the piston, as droplet collision will lead to high formation of gaseous pollutants and particulate emissions. In this simulation study of a Wankel engine with pressure swirl (PS) atomiser, the global engine timescale (time between fuel injection and ignition) is directly com-pared against droplet timescales of two fuels, namely iso-octane and dodecane, to determine the governing timescale. The dimen-sionless droplet timescales of interest includes the momentum, heat-up and evaporation timescales. The widely-used and computa-tionally efficient rapid-mixing model is used to simulate the behav-iour of a single droplet in the combustion chamber. For this study, the model is well validated against experimental data of suspended droplets. Results reveal that the evaporation timescale is the main restricting parameter when designing a Wankel engine that uses a pressure swirl nozzle. Although the evaporation timescales for both fuels exceeded that of the global engine timescale, iso-octane outperformed dodecane as the evaporation timescale for dodec-ane was found to be approximately five times longer than that of dodecane.



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As the simulated Wankel engine is designed for unmanned aircraft vehicles (UAVs), the study also covers the comparison between droplet timescales at sea level and the droplet timescales at high-altitude of 3000m above sea level. Results show that vaporization of fuel occurs earlier elevation. Therefore, evaporation timescale for preheating of fuel prior to injection into combustion chamber is simulated to ascertain if it can be shortened. It is found that the evaporation timescale can be reduced by an average of 31% when the fuel is preheated from 290K to 370K. However, the evaporation timescale is still considerably long compared to the global engine timescale. Therefore, the use of electrostatic atomiser design which can produce finer droplets which greatly reduces all of the droplet timescales is also discussed. This is due to the electrostatic atomiser having a low pressure drop of just 7.3bar as compared to PS atomis-er with a pressure drop of 80bar. In all, the potential of Wankel en-gine for UAV application is immense once the issue of evaporation timescale is resolved through the combination use of techniques such as preheating and atomisers that can produce finer droplets.

Keywords: Droplet timescales, fuel atomisation, evaporation, iso-octane, dodecane

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PAPER 3

One-dimensional Simulation of an Externally Waste-gated Turbocharger Turbine under Pulsating Inlet

Conditions Wan Saiful-Islam Wan Salim1, Peter J. Newton2, Yang Mingyang3 &

Ricardo F. Martinez-Botas4, 2 1Universiti Tun Hussein Onn Malaysia

2UTM Centre for Low Carbon Transport in cooperation with Imperial College London 3Shanghai Jiao Tong University

4Imperial College London

Abstract This paper describes the effort to model the unsteady performance of an externally waste-gated turbocharger turbine under unsteady pulsating inlet conditions. The main aim of this investigation is to propose an accurate and yet simple and robust method to model the system in a virtual environment. A commercial one-dimensional, gas dynamics, wave action software (GT-Power) was used where the turbine, waste-gate and the piping system was represented in one-dimensional form. Simulations were carried out for several cas-es accounting for the variation of turbine loads, inlet pulse frequen-cies and waste-gate openings. When compared to experimental data obtained from turbocharger turbine testing, the simulation results show encouraging agreement with the turbine speed, mass flow and torque being well predicted. The model %RMSE for the cases considered are found to be between 6.3% to 19.7% for mass prediction and 16.1% to 34.7% for torque owing largely to the phase lag between predicted and actual experimental data.



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The essential elements needed to model an externally waste-gated turbocharger turbine were identified to be the 1-D piping layout, turbine performance maps, waste-gate flow characteristics, inlet pressure and temperature profiles and a loading element. The out-come of the simulations allows further improvements and imple-mentations of the model in a complete engine environment. Keywords: unsteady performance, external waste-gate, turbo-charger turbine, 1-D engine simulation

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PAPER 4

A Meanline Modelling Approach for a Double Entry

Turbine

P Newton1,2*, R F Martinez-Botas1,2 1 Department of Mechanical Engineering

Imperial College London 2UTM Centre for Low Carbon Transport

*Corresponding author

Abstract

This paper presents a meanline model for a double entry mixed

flow turbocharger turbine. The meanline model is based on that for

a single entry machine and adjusted to include double entry flow

effects. Previous experimental and computational data is reviewed

to understand the flow within the double entry turbine. An empiri-

cal relationship is imposed to model the mixing of the two flows

from each half of the volute, which was found to be a dominant

feature during unequal admission in the double entry turbine. By

inclusion of this effect it is found that the meanline model is able to

follow the trend of the experimental data, suggesting that the rela-

tionship imposed draws upon the correct physical properties of the

flow, which affect the real turbine performance.



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Matching the Pre-turbine Steam Injection Combined with the Miller cycle for the turbocharged engine

Sipeng Zhua, Kangyao Denga aKey Laboratory for Power Machinery and Engineering of Ministry of Education,

Shanghai Jiao Tong University, Shanghai City 200240, China.

Abstract Due to the air consuming characteristics of the engine and the air supplying characteristics of the turbocharger, a compromise must be made when matching a turbocharged engine. To relieve this problem and improve the fuel economy at the same time, a new waste heat recovery system based on the pre-turbine steam injec-tion combined with the Miller cycle is adopted to rematch the tur-bocharged engine. With the superheated steam generated by ex-haust heat and injected into the pipe before the turbine, the pre-turbine steam injection can be used to control the boost pressure of the fresh air. By advancing or delaying the intake valve close tim-ing, the Miller cycle can change the volumetric efficiency of the en-gine. Thus, the engine performance can be improved by optimizing parameters of this new waste heat recovery system under different operating conditions. In this paper, thermodynamic processes of the pre-turbine steam injection and the Miller cycle are studied first. Then matching strategies of the waste heat recovery system are illustrated thoroughly with the matching map. With a calibrated GT-Power model of a diesel engine, comparative studies with the tradi-tional turbocharged engine are conducted to show merits of this new waste heat recovery system.

PAPER 5

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The results show that effects of the injected steam mass flow rate on the air supplying characteristics are larger than those of the in-jected temperature, and the Miller cycle have big influences on the air consuming characteristics. Different matching strategies of this new waste heat recovery system should be adopted according to the engine operating conditions, and the fuel economy under full load conditions can be improved by 2~3.2% with the injected steam mass flow ratio of 0.1. Key words: pre-turbine steam injection, Miller cycle, waste heat re-covery, matching strategy, turbocharged engine.



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Drawbacks on the application of nozzle vanes in turbo-charger turbine under pulsating flow conditions

M.H. Padzillah*,1, S. Rajoo1, R.F. Martinez-Botas2 1UTM Centre for Low Carbon Transport in Cooperation with Imperial College London

Universiti Teknologi Malaysia 81310 Johor, Malaysia

2Imperial College London Exhibition Road, SW7 2AZ London, United Kingdom

Abstract It is commonly agreed that a turbocharger turbine behaves differ-ently between steady and pulsating flow operations. This is due in no small part to the flow field distribution within the turbine stage. The use of nozzle vanes has significantly increased the three-dimensional complexity of the flow field, although some argue that the use of such stator could lead to improved overall turbine per-formance. This research investigates the drawbacks on the circum-ferential flow angle distributions due to existence of nozzle vanes particularly during pulsating flow conditions. In achieving this ob-jective, a validated full stage unsteady CFD model was built to gain insight of the flow field behaviour. The results indicate that applica-tion of nozzle vanes has favourable effect on flow angle distribu-tion at the rotor inlet during steady state operations for both de-sign and off-design conditions. This is achieved in such a way that the existence of nozzle vanes has reduced the fluctuation of flow angle as compared to the flow upstream the vanes. On the other hand, during pulsating flow turbine operation, the fluctuation am-plitude has spiked almost 400% the level of its counterpart under steady state operation at the rotor inlet. This behaviour could po-tentially have adverse effect on flow field distribution within the turbine passage and as such, reducing unsteady turbine efficiency. Keywords: Pulsating flow, nozzle vanes, turbocharger turbine

PAPER 6

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PAPER 7

Single Passage and Full Turbine CFD Analysis for Non-Radial Fibre Element of Low Pressure Turbine

Bin Ahmad, A. F.1,a, Bin Ahmad, M. A. 1, Bin Mamat, A. M. I.1 1Faculty of Mechanical Engineering, UniversitiTeknologi MARA, 40450 Shah Alam,

Selangor, Malaysia

Abstract The Low Pressure Turbine (LPT) is a mixed-flow low pressure tur-bine meant for extracting the energy from the exhaust of internal combustion engine. It converts the expanded exhaust energy into mechanical energy to drive an electric generator. The current avail-able design of the LPT is only able to recover the exhaust energy efficiently with a Pressure Ratio (PR) range of 1.04 to 1.30. Howev-er, the performance efficiency deteriorates significantly when the PR exceeds 1.25. In the previous studies, flow field analysis has shown that the entropy is largely generated at the exit due to greater vorticity. This vorticity can be minimized by optimizing the exit flow direction. This can be done by adjusting the exit camber-line which reduces the deflection angle of the flow. This will affect exit flow of the fluid; subsequently reduces the exit loss as stipulat-ed in the 1-Dimensional analysis of the turbine. This study consists of two analyses which use Ansys CFX. The first is the Single Passage Analysis (SPA), whereby one blade is analyzed for its aerodynamic performance to simulate the performance of an actual turbine. The second analysis is the Full Turbine Analysis (FTA). This analysis was carried out with the volute, turbine rotor and a diffuser. The pur-pose of carrying out the two analyses is to compare the perfor-mance of the new turbine design in Single Passage Analysis and Full Turbine Analysis with the baseline design. The rotor speed analyzed in this study was at 40,000 rpm, 50,000 rpm and 60,000 rpm.



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The PR simulated ranged from 1.07 to 1.70. In the SPA, results have shown that the overall efficiency of the turbine has largely im-proved at pressure ratios above 1.20 and above. Its swallowing ca-pacity is not largely affected at this point and its velocity ratio has shifted slightly from its design point, 0.70 to 0.65. However in the FTA, the performance showed very little improvement. The overall efficiency improvement was shown to be 0.44% at PR of 1.37 at 50,000rpm. As for the velocity ratio, there was little change from the baseline design, which occurred at 0.70. Keywords: Mixed-Flow Turbines, radial, non-radial, energy recovery, turbocompounding, low pressure turbine

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PAPER 8

Study of parameter optimization of a turbo-compound diesel engine

Rongchao Zhaoa, Weilin Zhugea, Yangjun Zhanga,*, Yong Yinb, Yanting Zhaob, Zhen Chenb

a State Key Laboratory of Automotive Safety and Energy, Tsinghua University, Bei-jing, China

b Dongfeng Commercial Vehicle Technical Center, Dongfeng Motor Co.,Ltd, Wuhan, China

Abstract Turbo-compounding is an important technique to recover waste

heat from engine exhaust and reduce CO2 emission. This paper pre-sents a parametric study of turbo-compound diesel engine. A ther-modynamic model was developed to investigate the influence of system parameters on the engine fuel consumption. The effects of engine component efficiency, back pressure, exhaust temperature, engine speed and pressure ratio on the recovery energy, pumping loss and engine fuel reductions were studied. Results show that exhaust temperature has greatest influence on the fuel reduction. 50 K higher temperature can reduce the fuel consumptions by ap-proximately 1%. Engine operation speed has little impact on the fuel savings obtained by turbo-compounding. The interaction mecha-nism between the power turbine recovery power and engine pumping loss is presented in the paper. There is an optimum value of power turbine expansion ratio due to the nonlinear characteris-tic of turbine power. The maximum increased power and the opti-mal expansion ratio are decided by the slopes of the curves of re-covery power and pumping loss. At the end, the improvement po-tentials of a high performance turbo-compound engine are pro-posed in the paper.

Keywords: Waste heat recovery, Turbo-compounding, Two-stage turbine, Thermodynamics model, parameter optimization



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Influence of Pulsating Frequency and Loading on the Per-formance on an Asymmetric Double Entry Turbine

B. A. Gurunathan.*,1, R.F. Martinez-Botas1, Y. Minyang2, S. Rajoo3, 1Department of Mechanical Engineering, Imperial College London, United Kingdom

2School of Mechanical Engineering, Shanghai Jiao Tong University, China 3UTM Centre for Low Carbon Transport in Cooperation with Imperial College

London,Universiti Teknologi Malaysia, 81310 Johor, Malaysia

Abstract The unsteady nature of gas emanating from different cylinders of an Internal Combustion Engine (ICE) requires ‘pulse division’ to pre-vent flow mixing before the turbine rotor. This is particularly true in an ICE with more than 4 cylinders, which has significant overlap be-tween exhaust pulses. If these pulses are not separated, unsteady mixing occurs prior to turbine rotor; thus resulting in decrease of pulse energy extraction and drop in engine efficiency. This normally happens when engine manifolds are connected to a single turbines inlet, commonly known as single entry turbines. Multiple entry tur-bines (twin or double entry) can alleviate this effect of mixing by ducting the engine cylinder flows to two or more separate turbine inlets. Unfortunately, when Exhaust Gas Recirculation (EGR) takes place an imbalance of mass flow caused by EGR extraction from one side of the exhaust manifold takes place. To overcome these problem, an asymmetric double-entry turbine is proposed here, to maximize pulse energy extraction even under high EGR condition.

PAPER 9

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This paper presents the outcome of an investigation to evalu-ate the effect of pulsating flow on the performance of a novel asymmetric double-entry turbine with variable geometry nozzle. What makes this asymmetric design different from a conventional double-entry turbine is the unequal rotor circumferential division, as opposed to equal rotor circumferential division in the latter. The first tongue and second tongue are located at azimuth angle of 0° and 160° respectively. The small scroll (inner entry) feeds the small-er circumferential area while the large scroll (outer entry) feeds the remaining circumferential area around the rotor.

All unsteady testing was carried out in the Imperial College London cold flow test rig. Two chopper plates driven by motor are used to simulate in-phase pulsating exhaust gas flow at 3 different engine speeds. Variable geometry nozzles were only fitted in the circumferential area around the rotor in the small scroll section; nozzles were not contemplated in the remaining larger circumfer-ential area. Vane angle position was based on the optimum efficien-cy obtained in steady flow test. For each pulsating frequency, the turbine was subjected to 3 different loading using the eddy-current dynamometer. Average rotor speed in this investigation is 30k RPM.

The unsteady instantaneous efficiency and mass flow parame-ter were compared to their respective steady state counterparts, to assess influence of pulsating flow on the performance of asymmet-ric double entry turbine. Apart from level of unsteadiness, effect of different degree of turbine loading for each pulsating frequency is also discussed. Steady state results used in this investigation was obtained from an experimental work under full admission condition tested on equal stagnation pressure.



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NOTES

UTM Centre for Low Carbon Transport in cooperation with Imperial College London

(LoCARtic)

P21 AUTOLAB,

UNIVERSITI TEKNOLOGI MALAYSIA, 81310 JOHOR BAHRU,

MALAYSIA.

Website: www.utm.my/locartic

Email: [email protected]

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SEPTEMBER, 15-16 2015 ENGINE BOOSTING AND UNIVERSITI