The future of combustion enginesA historical reflection on internal combustion engines up to state of the art today

(With a Swedish touch)

Martin Tunér

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What do we mean with state of the art?

World’s largest combustion engine?

Wärtsilä-Sulzer RTA96-C

2300 ton, 109.000 hp

World’s smallest engine?

Most liquid hydrocarbon fuels hold over 300 times more energy per unit weight

than a NiCad battery and 100 times more than a Li-ion battery. A micro-engine

would have the potential to release the energy from the fuels and possibly replace

batteries in portable devices.

It would not only last much longer than a battery of the same weight (about 20

times at 10% efficiency), but also requires little time to change its fuel capsule.

Read more at: http://phys.org/news/2006-01-micro-engines.html#jCp

11.2 W

World’s most common engine?Toyota 2ZR-FE, 1.8 liter, gasoline,

136 hp

Husqvarna manufactures around 6.5 million engines yearly

Most sensual engine?

Ducati –sings in Italian!

State of art depends on the application

• Functionality

• Affordability

• Scalability

And more recently:

• Sustainability

Isaac de Rivaz 1802-1813

• Built a car

• 5x2 m

• 3m / stroke

• 1 stroke / 5s (car stops inbetween)

• 12% uphill!

• Atmospheric/ballistic motor

• Manually controlled combustion

• Town-gas as fuel

• Considered net of gas generators

every km

• Electric ignition

Functional?

Affordable?

Scalable?

Sustainable?

1885 Benz Patent-Motorwagen: The patented automobile

1885-1886 (93)

0.9 hp

16 km/h

265 kg

1 gear

Belt drive

No body

Solid

rubber

tyres

Hand brake

working on belt

Steering

Clutch, differential

twin chain drive

single cyl,

0.954 l Otto-

engine

Start it up!

Functional?

Affordable?

Scalable?

Sustainable?

Most common car year 1900 – the electric car

Functional?

Affordable?

Scalable?

Sustainable?

So, how come gasoline became dominant?• Combustion engine cars cost 1/3 of electric

cars

• Ethanol is considered, but…• Oil is available in large amounts and makes

gasoline available and relatively cheap

• Gasoline has very high volumetric energy

content and is easy to distribute - easy to

carry “700 km" in the car

• “Charging” takes minutes – transfer rate is

~20MW!

• The number of cars, roads and gas stations is

increasing rapidly hand in hand Functional?

Affordable?

Scalable?

Sustainable?

Heavy engines

First trucks in Sweden 1902 (first sold 1903)Tidaholm 1.5 ton payload, 10 hp, 15km/h. It is shortly after returned

since there are no roads.

Functional?

Affordable?

Scalable?

Sustainable?

Scania and Vabis sell first trucks 1907.

Jonas Hesselman 1901Technical genius Jonas Hesselman increases diesel engine output 100% by new

piston shape - Boss expects ”all major problems should be solved as cheaply”

Jonas Hesselman

Functional?

Affordable?

Scalable?

Sustainable?

The Hesselman engine 1927• Gasoline is expensive and so is developing a new diesel type engine of reasonable size and power suitable

for trucks…• Hesselman adapts the gasoline type engine with a special injection-system. World´s first DISI!

• Multifuel capability: diesel, gasoline, alcohol and more

• Used by Volvo until 1947

• Should be run red hot

Functional?

Affordable?

Scalable?

Sustainable?

Why are Volvo and Scania global players?Sweden is after all a small country

Fierce competition Scania-Vabis and Volvo: Both use Hesselman and gasoline engines but shift to even more efficient in-house diesel engines:

• Scania first diesel engine in production 1937. Volvo 1944.

• DI (V 1949, S 1952) 20% less consumption, longer life

• Turbocharging in production engines (S 1953, V 1954)

• Scania V8 low rpm philosophy (1969) strongest in Europe 350hp, Volvo counters: 385hp (1973)

• Intercooler (V 1979, S 1982)

• 4 valve (V 1987 465hp)

• Turbo compound (S 1990) give 46% total efficiency

• Today top models >700hp and >3000Nm

Functional?

Affordable?

Scalable?

Sustainable?

Coming back to lighter engines

Turbo in gasoline engines

Per Gillbrand

Functional?

Affordable?

Scalable?

Sustainable?

Increased power output

Heat recovery

Refinement – bling factor

…

Cleaner engines

Emissions regulations demand better engine technology!

• Catalytic converter

• Unleaded fuel (hardened valve seats)

• Electronic fuel injection

• Lambda sensor

• Four valve pent-roof (Directly from race engines)

Low fuel consumption – low emissions – high specific power

Engines became better not worse!!!

Ford Cosworth DFV (1967)

Functional?

Affordable?

Scalable?

Sustainable?

Flex-Fuel

Functional?

Affordable?

Scalable?

Sustainable?

State of the art today

The internal combustion engine was always a compromise between

performance and cost that could be evolved when needed over 100

years…

Per Gillbrand use to say that you have to time the development steps

- Too early = too expensive = bankrupt

- Too late = lost market shares = bankrupt

Proved by that Volvo and Scania still exist!

Volvo Cars

Roadmap approaches to 55% BTE are outlined.DOE AMR 6/16

Daimler (2015) Navistar

Volvo

Cummins

SAE INTERNATIONAL

DCEE Concept layout

2015-01-1260 26

HP cylinder

CAC (V = 30 L)

Crossover channelLP cylinder

Inlet valve AOutlet valve

Exhaust valve A

Exhaust valve B

Inlet valve B

Inlet port from cross-over

Not to scale!

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Shamun et al.

Methanol PPC meet EURO VI w/o EATS (steady state)

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Values can vary with operating conditions

State of art in the future?

The energy source has dominant influence on GHGSeveral fuels and powertrain combinations relevant!

Functional?

Affordable?

Scalable?

Sustainable?

7 TW

14 TW

7 TW

44 TW

72 TW

85.000 TW

Continued domination of fossil energy in transportation by year 2040 – less than 3% electric energy?

biodiesel

e85

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H2

35

H2

?

Functional?Affordable?Scalable?

Sustainable?

LIQUIDS: DISTRIBUTION & STORAGE EASIER

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€ 250 € 10.000 € 25.000

CANDIDATE FUELS? Simple molecules are preferred

Production is more efficient Conversion (end-use) can be controlled more easily (h, emissions)

Abundantly available building blocks: C, H, O, N, … Thus, most simple fuels:

Hydrogen, H2 (at patm, liquid at 20K) Methane, CH4 (at patm, liquid at 91K) Ammonia, NH3 (at Tatm, liquid at 8.6 bar) Methanol, CH3OH (liquid) Dimethylether (DME), CH3OCH3 (liquid at 5.3 bar) …

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LIQUID

AN INTEGRATED SYSTEM

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CH3OH

n(-CH2-)Transport

Liquid storage

Grid Electricity

H2

H2O

CH4

CO2

Gas storage

Heat

Waste Heat

…And this can be brought into play quicklyusing GEM blends in existing E85/gasoline

flex-fuel vehicles

“Renewable Power Methane”, now supported by Audi as E-gas; however, vehicle fuel tanks still

expensive because CH4 is not a liquid…

Massive storage of renewable energy makes

investment in it viable

Remember!Transportation accounts for

25% of global GHG

75%-Chemicals

-Domestic use-Heat and Power

…

Huge demand for “green” chemicals!

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Source: Hexaresearch

Electric drive• Refined, effective, no tailpipe

• Battery is expensive and dirty

• Charging infrastructure?

• Case for range extender engines

• Combining the best of two worlds

• Electric roads

Forecast energy-mixes with powertrain development

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0

20

40

60

80

100

120

140

160

2015 2020 2025 2030 2035 2040

CO2

eq g

/km

WTW CO2 Trends for various powertrains

ICE => HEV Fossil Fuels

EV World Average Electricity

ICE => HEV World Average Fuels

Data: Bloomberg, Mazda, JEC-2014, Ricardo, Corning, EIA 2017

Discussion• History tells us that functionality, scalability, affordability but also timing are key factors for success

• Sustainability is the new additional challenge

• Engine efficiencies of 60% are getting closer

• Electric drive makes combustion engines better

Future scenarios

• Long term future seems to depend on solar power and hydrogen – it will take long time to build such

infrastructure

• Biofuels seems to be especially valuable in the transition period

– Case for low cost alcohol engines – low cost cars for emerging markets – upper end hybrid cars

– Case for advanced alcohol engines – trucks, marine vessels, gen-sets

Lot of unknowns

• Clean battery production?

• Resource efficiency improvements, and recycling schemes? Energy intensity of recycling rare earth materials etc.?

• How low emissions are low enough?

• How will demand drive price for biomass and electricity

• Energy security?

Conclusion

We need to combine resources and technologies that offer best sustainability, scalability, affordability and functionality

Electric drive + engines on sustainable fuels