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Compound expansion plus water injection to increase fuel efficiency of a Diesel cycle engine? 4

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TSLexi

Automotive
May 27, 2014
28
I was recently reading the research of Prof Dr-Ing Gerhard Schmitz into compound expansion ICEs, and Mr Bruce Crower into water injection. So I'd like your advice as to whether this is feasible, as I am merely a community college student planning on entering automotive or mechanical engineering.

Most ICEs waste a whole bunch of power by having the exhaust expand into the outside world. And they require massive radiators to keep the parts from getting heat-damaged. And they also require camshafts to open and close the valves, which adds a whole bunch of weight. And Otto cycle engines require spark plugs and have to use lower compression ratios to prevent detonation, which adds weight as well and decreases power.

We can solve this by starting with a basic four stroke Diesel cycle engine. We replace the camshaft with electronically-controlled solenoids to actuate the valves. Then we can dispense with the timing belt as well.

We then add a low pressure cylinder that the exhaust is directed to. This cylinder will be at TDC when the exhaust valves on the combustion cylinder are open, and when it's at BDC, it's contents will be directed into the air. Steam engine designers figured out the concept of compound expansion centuries ago, why has it taken ICE engineers this long?

Finally, the next time the combustion cylinder is at TDC, instead of injecting diesel, we inject distilled water. This will a) provide an extra power stroke, as water expands 1600x when it turns into steam, and b) cool the engine. We could also increase power-to-weight ratio, depending on the weight of water needed to replace the weight of the radiator. Once again, steam engines don't need radiators, as they produce power, they also dissipate heat. You'd just have to ensure ) that the water is very pure, and b) use steam engine lubricant.

And to ensure the engine will always be operating at peak efficiency, we couple it to a continuously-variable transmission.

So we have the benefits of a) the very efficient Diesel cycle which doesn't require spark plugs and produces more torque, b) use electronically-controlled solenoids to actuate the valves, which saves the weight of the camshaft, c) compound expansion to extract extra power from the exhaust, d) steam power, which keeps the engine cool and adds extra power, and e) a CVT, which eliminates the inefficiency involved in gear-shifting.

If we build the engine out of carbon fiber, this engine will be very light and strong, and able to survive the high temperatures involved. And a lighter engine means it can rev higher and have larger cylinders. It's better to produce torque at a higher rpm, because then you can take full advantage of the CVT's gearing to produce optimum power, and there's no replacement for displacement.

So thanks for advising me!

Lexi
 
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A third option is to use a thermoelectric generator, or peltier device.

All of these improve the thermodynamic efficiency, but at non cost effective premium.

Cheers

Greg Locock


New here? Try reading these, they might help FAQ731-376
 
Since the exhaust will be too cool to activate the turbo, couldn't we just use a supercharger for forced induction instead? Sure, we lose some percentage of power, but it should be made up.
 
Maybe we could inject hydrogen peroxide after the power stroke when the piston is at TDC to oxidize any UHCs, PMs, and CO remaining after the diesel combusts. You then have to deal with the nitric and sulfuric acid formed from the oxidation of the NOx and SOx, but you could probably neutralize them. And if you have enough nitrogen dioxide and hydrogen peroxide, you should be able to generate enough nitric acid to passivate the combustion chamber and exhaust system.
 
OK, i think we've dredeed through many cockeyed theories here. Do you actually have a work related point, or are you just randomly typing stuff in?

Cheers

Greg Locock


New here? Try reading these, they might help FAQ731-376
 
Basically, the same idea as before, but using hydrogen peroxide, a powerful oxidizer, instead of water, which I'm no realizing wouldn't quite do as much, as all it does is boil, still leaving contaminants.

We could also inject the hydrogen peroxide during the intake stroke, right before the diesel is injected, which should provide the same effect. Unlike water, H2O2 increases the oxygen content, resulting in more complete combustion. If after combustion of ULSD, you have anything other than carbon dioxide, water, and NOx, your oxygen-fuel ratio is too low.

It's like nitrous, but industrial-strength hydrogen peroxide doesn't require pressurization, and is about $4/gallon. And you only need a bit more than 1 liter to react with 1 mole of cetane, as hydrogen peroxide is a liquid, vs over a 1000 liters of O2 gas for the same reaction.
 
My main point, Greg, is trying to extract has much work from fuel as possible, and the best way to do that is to make sure the fuel combusts completely, and all the energy from the heat is used as well.
 
Hydrogen peroxide is significantly energy-intensive to produce. Think about the big picture. It's also chemically unstable when stored in a high enough concentration to be useful.

I do get the feeling that you are randomly throwing out thoughts without thinking them through. Please do that.
 
I have checked the prices of industrial-strength 70% hydrogen peroxide. It's $0.45/lb. Diesel is a bit more expensive per pound, around $0.57/lb. If the hydrogen peroxide is 70% or above, it's hypergolic with organic materials. You just need to keep it away from light, in aluminum containers.

Isn't the point of a turbocharger or supercharger to increase the amount of oxygen available to burn the fuel? The former steals hp, the second requires exhaust modification.
 
I suspect just about every man (and his dog) has seen an exhaust manifold glowing red hot and had the idea of recovering all or some of this lost energy by means of a steam engine. Many people and companies have had an attempt - for example BMW in recent times:
In the past probably the most notable example was the Still Engine:

For various reasons, it never seems to be really practical.

I was under the impression that Bruce Crower abandoned his work and patents on the very clever Six-Stroke Engine because testing showed that the power recovered was not worth the added complexity etc.
 
Actually, BigClive, Mr Crower fell ill, so he couldn't finish development. And no-one's figured out yet how to deal with the corrosion from the hot steam, and make sure the steam doesn't wash away the oil.
 
HI TsLexi,

Send my regards to Mr Crower. For the hot steam corrosion, there are several coatings used by the steam turbine engines that you can apply to the piston top surface, combustion chamber and valves. It will also help for you to inject the water upward rather than downward. Attach the water injector to the cylinder block rather than the cylinder head. Make sure that your expansion ratio is properly designed to avoid the cylinder temperature dropping too low at the end of expansion stroke that the hot steam will condense. Even when some steam condenses, if you coat the piston rings with diamond like carbon coating and skirt with anti scuffing coating, you will get away from from accelerated wear and seizure. I see big potentials in what you believe in thus I will be more than happy to resolve the challenges that you will surely face.
 
Yeah, azmio3. And if we use hydrogen peroxide to augment the oxygen from the forced induction system, we can get more complete combustion, which means higher power and lower BSFC.
 
If what you want is to generate steam to power a heat engine using hydrogen peroxide, why don't you simply flow the hydrogen peroxide over a metal catalyst bed to produce high temperature steam?
 
That's a better idea. We can divert the steam into a turbine, and use the oxygen to power a gas turbine, and connect the two shafts.
 
TSLexi,

Why not use oxygen. The chinese researchers use onboard oxygen generator for the oxygen supply. You can burn low quality fuels without HC, CO and PM problems.
 
Think about the energy that it took to make the hydrogen peroxide in the first place.

"There is no such thing as a free lunch"
 
The Crower 6-stroke is an interesting engine. But, it uses water as a consumable, NO GOOD for a mobile powerplant, unless you recover the water by condensing it, NO GOOD for a mobile powerplant. Also, the power gain from the extra 2 strokes is on the order of 10-20% for a loss of 1/3 the 4-stroke power strokes -equivalent to wasting 1/3 the mass of the engine; NO GOOD for a mobile powerplant.
For a stationary plant with a continuous supply of fresh water it may be fine. Cooling costs become power from cooling -provided you don't insist on distilled water.

Past efforts at solenoid valve actuation have not been impressive. However, the ones I have seen use a magnetic core attached to the valve stem with a coil around it -classic solenoid. Do you think the voice coil model may offer better performance???? Look at hard drive head actuators. Super magnets keep getting stronger.
 
Compound expansion recovers energy "dumped" by the single expansion process. However, it costs mechanical weight and complexity. The old compound piston steam engines were WAY larger and heavier than the 1st, single expansion stage.
The stages that follow the 1st stage are "bottom cycle" stages. The energy they recover is normally only a fraction of the energy recovered by the 1st stage and the volume of gasses they process is MUCH greater.
If the bottom cycle stages are of the same design as the 1st stage this is a big time looser for a mobile powerplant. However, the exhaust turbine is a relatively very small device for recovering bottom cycle energy behind a piston engine.
 
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