Ref-1 H2
Ref-1 H2
a r t i c l e i n f o a b s t r a c t
Article history: Worldwide auto giants and research institutes have started pilot projects with hydrogen as fuel in inter-
Available online 19 November 2021 nal combustion engines of vehicles ranging from two, three-wheelers to trucks and buses. The research
on hydrogen engine has been continuing for many years, however in the recent years it has gained the
Keywords: momentum and compels the research community to find a solution for zero emission vehicles. This work
Hydrogen Fuel presents the view of the physical, chemical and combustion properties of hydrogen as well as engine
Alternate Energy design requirements, recent trends in hydrogen engine and vehicle development strategies such as port
Engine Performance
fuel injection and direct injection technologies are evaluated in the context of engine performance and
Zero Emission
Clean Fuel
emissions.
Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the Second International
Conference on Sustainable Energy Solutions for a Better Tomorrow.
https://doi.org/10.1016/j.matpr.2021.10.378
2214-7853/Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the Second International Conference on Sustainable Energy Solutions for a Better Tomorrow.
Balu Jalindar Shinde and K. K. Materials Today: Proceedings 51 (2022) 1568–1579
Table 1
Hydrogen Properties and effect on engine performance.
Table 2
Hydrogen Engine Design Requirements.
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Balu Jalindar Shinde and K. K. Materials Today: Proceedings 51 (2022) 1568–1579
Table 3
PFI Engine Performance.
Sr. No Year Engine Volume (L) Output power (kW) BTE hydrogen % Ref.
Gasoline H2
1 2014 1.998 55 33.9 – [55]
2 2019 0.270 5.94 4.99 22.71 [64]
3 2012 3.984 – – 38 [65]
4 2019 2.3 – 21 30.1 [66]
5 2015 2.5 – 66.7 – [37]
6 2017 0.661 3.2 2.59 25.99 [30]
7 2017 0.395 – 4.8 26 [48]
Table 4
Direct Injection engine performance.
also the major concern of fossil fuels. Research on hydrogen engine The carburetor with gas-air mixer
and the vehicle has been started since 1820 by Cecil[16]. Hydrogen Continuous manifold injection (CMI)
can be used in an internal combustion engine as [17]dedicated fuel, Timed manifold injection (TMI)
bi-fuel or dual-fuel operation [12]. Many research institutions and Low-pressure direct cylinder injection (LPDI)
government agencies started research base projects; some of them High-pressure direct cylinder injection (HPDI)[41]
have demonstrated the use of hydrogen in an internal combustion
engine as an effective and safe way. Hydrogen has no carbon bond All these induction methods have its own advantages and dis-
hence no production of CO and CO2 emissions. When burning of advantages considering the engine power, emissions and safety
hydrogen in internal combustion engine, NOx is formed still it is during vehicle operation. The carburetion and continuous manifold
the cleanest fuel. The recent literature review on hydrogen usage injection are very old induction methods with limitations from
on IC engine by Dinçer et al [18] revealed that the amount of performance and safety point of view hence these methods are
hydrogen added to the fuel system increased the engine power outdated. There is continuous development in fuel and air induc-
and torque almost like petrol engines, while they are decreased tion methods in internal combustion engine. Here, only modern
on LPG and diesel engines. fuel and air induction techniques are discussed.
Hydrogen has a wide range of flammability ignition limit which
1.2. Features of hydrogen allows hydrogen to be operated at extremely lean mixture condi-
tion. The hydrogen is in gaseous state and lighter than air. It occu-
Hydrogen has a high octane rating, high calorific value and pies at 30 % of combustion volume as compared to 1–2 % gasoline
because of this, it is very attractive fuel for internal combustion fuel [42]. The standard high-pressure tank stores hydrogen at
engine. Table-1 defines the properties of hydrogen gas and its 35 MPa (350 bar) pressure, recently tanks are developed to store
effect on engine and vehicle performance. hydrogen at 70 MPa pressure [43]. Sierens and Verhelst [44] found
Y-junction has delivered the highest power and highest indicated
1.3. Hydrogen engine design thermal efficiency in 45° junction. The injection quantity [45]
increased with increasing injector pulse width. The highest power
Hydrogen engines are being developed for operating near below output and indicated efficiency are obtained for an ignition timing
knock limit which demands late ignition. This late ignition pro- of 3°CA aTDC[46]. The spark advance increases combustion dura-
duces high-temperature exhaust gases. Hydrogen stoichiometric tion which imparts more heat to surroundings at 4 percentages
combustion has high thermal loads on piston top land and ring [47]. When the gasoline engine is converted to hydrogen, ignition
grooves, the first ring is coated with a hard-anodized coating as timing is retarded from 25° to 10° BTDC[29] and the mixer was
well as ring pack which reduces the blow-by gas and reduce oil set to lean side from 1.6 to 2.5 lambda, the ignition timing was
consumption. In the context of the present discussion, a hydrogen advanced[38].The gasoline converted hydrogen port fuel engine
specific engine refers to a dedicated hydrogen operation. Following [29] delivered by hydrogen engine power 80 % of gasoline but effi-
are some of the engine design requirements listed in Table2 for ciency was found increased by 2 %. Port Fuel Injection when oper-
safe, fuel-efficient and low emission engine development. ated at the stoichiometric [12] condition and it was likely to
misfire due to highest temperature at this operating condition.
2. Advanced hydrogen engines EGR has advantages of high heat capacity due to high water vapour
content, thus more fuel can be injected with the addition of EGR
There have been continues improvements on hydrogen engine develops more power than naturally or lean-burn engines. The
for performance and emission. Following are hydrogen induction gasoline converted Polo tested with a lambda of 1.6, 2 and 2.5
methods used in internal combustion engines[41]. [38] and power dropped by 50 %.
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Balu Jalindar Shinde and K. K. Materials Today: Proceedings 51 (2022) 1568–1579
Wallner et al [49]optimized a 2.3L supercharged engine from was high, combustion target was k = 1 and with TWC which
M/s Ford Motor company with different air–fuel ratios of 2, 2.25, reduced NOx to a very low level and found meeting Super Ultra
2.5 and 3. WOT efficiency was found to be between 35 and 37%. Low Emissions Vehicles (SULEV) level off to 3.9 %. Nande et al
Fig. 1 shows the improvement in thermal efficiency when increas- [53]tested a single-cylinder, CFR VCR engine, manufactured by
ing the air to fuel ratio from 2 to 2.5 and results in an increase in the Waukesha Motor Company with the addition of EGR from 0
brake thermal efficiency in 1–2% and torque reduced by 50 % when to 35 %.
lambda set to 3. Kumar et al [50] and Faizal et al[51] tested engines Wallner et al [12]checked the performance of supercharged Port
on hydrogen fuel and found brake thermal Efficiency more than fuel injection engine by changing air/fuel ration from rich to lean
gasoline. Hydrogen has a high compression ratio and high combus- condition and found NOx emission reduced from 220 ppm to
tion pressure has resulted in high torque output.Fig. 2. 3 ppm from air/fuel ratio from 2 to 3 with improvement in thermal
1st law and second law efficiency for hydrogen engine is high efficiency from 21.6 to 23.4 %. Sopena et al [38]tested Polo gasoline
than gasoline engine by 65.64, 69.4 % and 56.4, 60.5 % respec- engine. Hydrogen combustion is faster due to high flame speed and
tively[51]. Hari et al[29]tested port fuel injection engine and found combustion is taking place close to constant volume hence hydro-
bsfc of 0.32 kg/kWh for gasoline as against around 0.11 kg/kWh for gen has better thermal efficiency at medium and low speed than of
hydrogen. This is due to high thermal efficiency and high calorific gasoline. The NOx emissions were less than that of gasoline from
value of hydrogen. For NOx reduction, EGR (Exhaust gas recircula- 1000 to 2500 ppm. When hydrogen engine set to k = 1.3, NOx
tion) is one of the methods used by [44] Verhelst et al. and Tien Ho emission was of the order of 10000 ppm, that is why hydrogen
[31]. Wallner et al [52]converted BMW mono-fuel vehicle, The engine running at leaner condition is recommended in spite of
vehicle was installed with onboard cryogenic hydrogen storage lower power. Krishnan Unni et al [48] tested the single-cylinder.
and a gaseous port fuel injection system. The NOx storage catalyst The NOx formation at rich lambda is low due to deficiency of
(NSR) device was used. At high load where the demand for power oxygen and reduced combustion efficiency. Lohse-Busch et al
[54] tested V8 6L PFI engine for pickup truck application with dif-
ferent phi on chassis dynamometer cycles and NOx emissions were
measured. The NO emissions were high at 50 % WOT than 100 %
WOT. The NO emissions are dependent on produced torque, at
low engine rpm the engine produced high torque and at high
engine speed lower torque, The maximum NO produced at
1500 rpm with spark plug gap of 0.6 mm. Yao et al [55] experi-
mented on 2L hydrogen PFI engine. The power Vs NOx with and
without EGR configuration. At low speed of 1000 rpm, the power
found decreased by 27% at the cost of reduction of 73 % and high
speed of 6000 rpm power dropped by 39 % with 84 % reduction
of NOx emission.
Indicated thermal efficiency [10]depends on ignition timing.
The advanced ignition timing improves the in-cylinder tempera-
ture and pressure hence increases the indicated thermal efficiency.
Salvi et al [57] tested constant speed engine for various EGR ratio.
A significant reduction of NOx observed with increase in EGR. With
25 % EGR the NOx specific emission found reduced to 57 % and BTE
and BMEP reduced below 5 %. The NOx emission increases[30] with
an increase in engine speed. Yamin[47] tested Ricardo E6/T Vari-
able Compression Ratio engine with various equivalence ratio
Fig. 1. Trend for an engine speed of 1500 RPM. (0.7 to 1.2) with respect to spark plug locations. The heat loss
Fig. 2. Performance of the hydrogen engine, equivalence ratio = 0.74, EGR rate = 0.3, 5500 rpm[56]
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4. Direct injection
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Balu Jalindar Shinde and K. K. Materials Today: Proceedings 51 (2022) 1568–1579
Single-cylinder gasoline as well as hydrogen DI [80]tested and with 5H (5 holes) injector and spark plug located centrally. Another
found at 30 % more brake mean effective pressure as an effect of head was with the dual spark plug located at sidewise opposite to
hydrogen has high flame speed at WOT with the k = 1 condition. each other and 3 + 3H(3 and 3 holes)at central. Both cylinders head
Nakagawa et al [67]tested 3 cylinder engines in both naturally tested for optimized injection timing best thermal efficiency. The
aspirated as well as supercharged configuration. The maximum dual ignition with 3 + 3H injector has delivered the highest NOX
thermal efficiency was 34 % with a compression ratio of 12.5 with as well as high net thermal efficiency. Bleechmore et al [74] tested
135 kPa air pressure was achieved. Zanforlin et al [70]converted supercharged single cylinder hydrogen engine for EGR and water
gasoline Aprilia 651 cc engine to direct injection hydrogen engine. injection for NOX reduction. NOx could be reduced by adopting
The innovative two-step injection system was developed and the excess air, EGR in both hot and cooled and Water injection. If
engine was optimized for stoichiometric combustion. The base equivalence ratio was decreased ITE was increased due to reduced
engine has 5 valves. The gasoline and hydrogen performance was pumping loss. Dilution with EGR was achieved not by altering fuel
compared with 4 valve configurations. The engine was optimized flow but by increasing EGR to full .open condition and Airflow was
for best ignition timing as 3° aTDC and without knocking and reduced till charge has attained the stoichiometric condition The
preignition. both hot and cooled EGR was tested with different ignition timing
Younkins et al [81]tested 592 cc direct injection hydrogen swing. EGR consisting of primarily water Vapour and nitrogen gas.
engine with optimized 3 + 3H hole injector with the dual ignition The water vapour possesses a high specific heat capacity and helps
system. This performance was compared with a 5H injector in both to reduce combustion slower than dilution with excess air. When
single and dual injection configuration. The 3 + 3H injector found water injection was used, it has reduced combustion temperature
better and continued for further evaluation of injector position. and subsequently, ignition timing was optimised to achieve maxi-
The new combustion system using the dual plug cylinder head mum power. The use of EGR at higher load could be problematic
and the 3 + 3 fuel injector at b = 0° delivered a remarkable peak hence water injection was used and high power output was
indicated thermal efficiency of 47.8% at 3000 RPM. Kawamura achieved.
et al [82]developed a Truck of 6 cylinders 7.684 L four-stroke
engine. The engine has 13 compression ratio and in naturally aspi-
rated engine configuration. The actual testing was done on a 5. Water injection
single-cylinder 1.050L engine with the same compression and
injector configurations. The engine was optimized for different Nande et al[85] tested Ford Make 0.5 L hydrogen engine with
excess air ratio; MBT, injection timing, and NOx emissions were 11.5 compression ratio for different percentage of water injection.
recorded. The single-cylinder engine has delivered 950 kpa IMEP The engine was initially optimised for highest torque and NOx
which was equivalent to meeting multi-cylinder targets. Naga- emissions were recorded. The presence of water in combustion
numa et al [83]tested Turbocharged diesel converted to Naturally has reduced peak temperatures and subsequently NOx emissions.
aspirated hydrogen engine with the bowl on the piston with 12.7 At high load when water was injected, the NOx emissions were
compression ratio. The engine was optimized for injection timing, more by 12 % than retarding ignition timing, but power loss was
ignition timing, excess air ratio and EGR percentage for various reduced by 79 %, hence water injection was used than retarding
load conditions. The critical EGR rate was defined as the rate at ignition timing.
which the hydrogen concentration in the exhaust gas was less than The engine was tested with low load at 4 bar IMEP and high
2% and also the decreased in brake thermal efficiency was less than load 8 bar IMEP. Hydrogen injected pressure was 100 bar. The
3%. The application of EGR reduced NOx emissions by as much as engine was tested with h = 0.23 to 0.9 an. Younkins et al [86] tested
91%. Initially, with an application, EGR emission has a reduced 592 cc direct injection engine for different strategies for NOx emis-
level of 1.07 g/kWh. There was a possibility of reducing the NOx sion reduction. One of the strategy was to use water in the intake
level further by adding a transient fuel compensation control. A manifold. The test was conducted with 0.6 equivalence ratio with
mean NOx emission level of 0.08 g/kWh has obtained the JE05 test and without water injection. The thermal efficiency was checked
mode by installing NOx storage reduction (NSR) and Diesel oxida- for different test configurations.
tion catalyst (DOC) catalysts. The water injection strategy was demonstrated as an effective
Nakagawa et al [67] converted 3 cylinders 658 cc gasoline, 9 way of reducing NOx emissions. An 87% reduction in NOx emis-
compression ratio engine to supercharged hydrogen direct injec- sions was achieved with only a 2% fuel consumption penalty. The
tion. The air pressure was 110,135 160 and 200 kpa used for exper-
imentation. The NOx emission for all air intake pressure was
almost similar but when excess air ratio changed to 2.4, the NOx
emissions reduced. This has indicated that NOx emissions are inde-
pendent of air pressure. Tanno et al [84] tested 2.2L mass-
production diesel engine to direct injection hydrogen. This engine
has a facility to test only one cylinder out of 4 independently. In
these experiments, the engine combustion was studied at low to
medium as well as medium to high load with different combustion
strategy. At low, to medium load, the stoichiometric combustion
strategy was adopted employing changing the start of injection
timing. As SOI was towards the TDC, it had increased degrees of
constant volume and hence indicated thermal efficiency has been
increased by 3 %. The purpose of this type of combustion was to
reduce cooling loss by air heat insulation and to control the com-
bustion rate by the injection.
Younkins et al [81] tested 592 cc single-cylinder for a single and
dual ignition system for engine performance and NOx production.
The compression ratio of 12.5 and 11.6 was used for dual and sin-
gle ignition respectively. Two cylinders were proto made, one was Fig. 7. Comparative exergy distributions.
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NOx mitigation strategy of multiple fuel injections was less advan- gen is directly injected into the combustion chamber and gasoline
tageous, only achieving a 68% reduction in NOx emissions with a at the port. The engine was tested at constant rpm of 1500. The
6% fuel consumption penalty. The minimum NOx achieved with equivalence ratio was maintained to 1.0, 1.1, 1.2, and 1.5 by inject-
water injection approximately 30 ppm, albeit with a 12% increase ing hydrogen by 0, 3.99, 5.87, 7.68, 9.41 and 11.09 % of total energy.
in fuel consumption. As this U = 0.6 condition was anticipated to The injector pulse width was modified to maintain the desired
be the peak load of the engine, it was reasonable to assume this equivalence ratio. Hydrogen was injected directly into the combus-
condition could be used in a drive cycle that complies with emis- tion chamber and gasoline into port was not reduced the volumet-
sions regulations. In contrast, the multiple fuel injection strategies ric efficiency of the engine. By the addition of hydrogen, the energy
tested were not able to reduce NOx below 125 ppm as shown in of total charge was increased and accelerated the Combustion reac-
Fig. 7. Naganuma et al [87] used a single-cylinder to study the tion. With the addition of hydrogen thermal efficiency increased
effect of EGR on NOx emission. By adding EGR the degrees of drastically. The combustion was found stable even at 1.5 equiva-
advance to get same power output. Similarly, the application of lence ratios. This addition of hydrogen in the port fuel gasoline
EGR makes it possible to advance the onset of fuel injection, engine, NOx and CO found significantly reduced. The lean-burn
thereby promoting better mixing before ignition, which should combustion resulted in improvement in economic and emission
also work to reduce NOx emissions performance of the engine.
6.2. Diesel
6. Hydrogen as additional fuel
Hydrogen fuel is also used in a diesel engine. Antunes et al [92]
6.1. Gasoline modified 825 cc research engine from diesel direct injection to
hydrogen direct injection. For developing hydrogen direct opera-
Hydrogen can be used with gasoline as an energy booster. Zhao tion, the main target was to redesign injectors for hydrogen fuel
et al [88] tested optical 561.8 cc spray-guided spark ignition direct as well as the requirement of hot air for attaining a self-ignition
injection engine with 150 bar to review the effect of hydrogen on temperature of charge. The base engine of diesel fuel has rated
particulate mass and number. Hydrogen with 2%, 5%, and 10% of power of 9000 W. To increase the inlet air temperature 120° C
the stoichiometric fraction was introduced in gasoline direct injec- heating system of 3.5 kW was used. The engine efficiency increased
tion engine. Ignition and injection sweeps were conducted to from 27.9 % on diesel to 42.8 % on hydrogen. Saravanan et al [93]
achieve the best thermal efficiency with hydrogen blending condi- studied direct injection diesel 553 cc for hydrogen and diesel
tions. The direct-injection engine has the potential to achieve dual-fuel operation. The % hydrogen and diesel was varied accord-
power more than port fuel configuration and with same as diesel ing to the engine load requirement. At NO load /idle condition
engine efficiency. For Direct Injection engine time for mixing hydrogen and diesel was used in 24.48 and 75.52 %. And at Full
fuel–air mixing is reduced hence PM (Particulate emissions) are a load operation, 6.76 % hydrogen energy and 93.24 of diesel energy
major drawback. The test was conducted with two load condition, were used. At full load, condition efficiency found increased with
high load and low load. In both cases, lambda was maintained with both cases i.e. without and with EGR. The optimized fuel flow
0.9 and 1.Ignition and injection timing sweep was performed. Due was 7.5 lpm with 30° CA injection timing.
to higher diffusion coefficient and higher flame speed with small Chintala et al[94]studied three compression ratios of 19.5, 16.5
quenching distance improves combustion hence organic PM emis- and 15.4. The base engine was 947.3 cc with a compression ratio of
sion is reduced. MBT timing was retarded due to an addition of 19.5. The main fuel was hydrogen and diesel was pilot fuel. Hydro-
hydrogen fraction. At low load with 5% of the stoichiometric blend gen was introduced just before the engine knock limit. The energy
has reduced PM and PN by up to 90 %. Further to that after addition share of hydrogen increased from 19 % to 59 % with 19.5 compres-
of 10% of hydrogen can further reduce PN and PM by 97 % and95 % sion ratio and subsequently increased to 63% for 15.4 compression
respectively. At low load with richer mixture found a remarkable ratio. The optimum compression ratio was 16.5:1 based on energy
reduction in Particulate Number (PN). share utilised and minimum NOx emissions with the highest ther-
Amrouche et al [89] tested hybrid gasoline-hydrogen rotary mal efficiency. The NOx emission found reduced with lower com-
engine 530 cc. The engine performance was checked at pression ratio. Sandalci et al[95]tested 5.1 kW single-cylinder
3000 rpm. The modified engine was suitable for the testing blend constant speed 1300 rpm engine. The system was with diesel fuel
of gasoline and hydrogen. The ignition timing was not altered as pilot fuel and hydrogen as a main fuel. The hydrogen was added
and kept same as gasoline timing. Hydrogen was introduced in in 0, 16, 36 and 46 % of total energy. With the addition of hydrogen,
intake manifold from 0 to 10 % of total energy fraction. The enrich- there was a drastic reduction in engine-out smoke.
ment of the lean-burn engine found improved at high speed. The
brake thermal efficiency was also increased by 28 % when 10 % 6.3. CNG
hydrogen energy fraction was added. With the addition of hydro-
gen energy fraction from 0% to 10%, the peak combustion pressure HCNG is nowadays considered to promising fuel for spark-
and temperature increased which has increased the NOx brake- ignition engines. Moreno et al [96]modified 505 cc, 2 cylinder gaso-
specific emissions by 137% and reductions in CO, CO2 and HC by line engine to operate on CNG and hydrogen. The engine was
64 %, 36%and 85% respectively. This was due to the addition of updated with a knock sensor, cam sensor, and Wideband lambda
hydrogen has resulted in better combustion of charge. sensor. The original EUM was blocked by any new PEMS (Pro-
Kim et al[90] tested 1998 cc 4 cylinder T-GDI with 9.5:1 com- grammable Engine Management System) was used. Liu et al [97]
pression ratio. The Max.Power 204 kW and Torque of 352 Nm at the original diesel engine was modified to run on Liquefied
6000 rpm and at1750-4500 rpm respectively with hydrogen and Methane Gas (LMG) and hydrogen. The engine compression ratio
EGR. The engine was tested at 2000 rpm with three loads of 4, 6, maintained at 13.6:1. The engine performance was measured with
and 8 bar with 0 %, 1 %, 3 % and 5 % energy fraction of total energy. different BMEP(Brake Mean Effective Pressure) condition. The BTE
CO2 and HC were drastically reduced and NOx emission found at 0% hydrogen energy was 24.7 %, 31.2 % and 32.7 % .At 1000 rpm
increased with hydrogen addition. When EGR was added the with BMEP of 2,6 and 10 bar, the maximum BTE increase was
cycle-to-cycle variation reduced. Du et al [91] converted original 12.6%, 3.6% and 1.4%. This was due to increase in power developed
gasoline direct injection engine to hydrogen engine where hydro- due to an increase in load and reduction in heat loss. The 50 % com-
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Balu Jalindar Shinde and K. K. Materials Today: Proceedings 51 (2022) 1568–1579
bustion location is advanced and the combustion duration is 7.4. Leakage detection-Engine
reduced with an increase in the percentage of hydrogen content
due to a higher flame speed of hydrogen fuel. When 10.4 % and Engine compartment–For the development of the 6.8L V10
16.2 % hydrogen energy added, the peak cylinder pressure engine, final delivery point of fuelling system is the engine com-
increased by 27.8 % and 36.9 % as compared to 0% hydrogen energy partment. The fuel rail is fitted at engine top and connected by
content. two low-pressure fuel lines. The front and bottom portion of the
bonnet is open for ventilation and an engine-driven fan is also
7. Hydrogen safety there. This compartment is separated from the passenger compart-
ment. All wiring harness are sealed by rubber grommet when it
The safety requirements of hydrogen fuel are different from passes through the bulkhead. [105].
gasoline and methane. All the possible operating condition must
be taken into consideration during the vehicle design stage itself. 7.5. Leakage detection-Vehicle
This includes driving through tunnels, parking the vehicle out of
use in an enclosed space, refueling and engine and vehicle servic- At the start of the hydrogen vehicle project, safety was prime
ing. As discussed earlier in this paper, hydrogen has a wide range most things. The Ford team had experience of developing engines
of flammability (4 to 75 %) in the air and require low ignition on fuel cell and compressed natural gas. The redundancy safety
energy (0.02 MJ) which is lower than methane and gasoline fuel is a combination of both active and passive ventilation with hydro-
The hydrogen has higher auto-ignition temperature, high specific gen detectors. This system contains four sensors which are located
heat value and high diffusivity is considered as safe fuel. Hydrogen in the engine compartment, trunk and passenger compartment.
safety fact is published by DOE[98] shows the difference between The hydrogen sensors are set to hydrogen concentration of 0.6
hydrogen and gasoline cars when fire. The gasoline car was %,1% and 1.6 % [23].
destroyed completely. This indicates hydrogen is safe fuel. Vezir-
oǧlu and Sßahin[99] made a comparison of Gasoline, Methane and 7.6. Engine test cell safety requirements
Hydrogen safety ranking. The parameters were considered such
as ignition temperature, flame emissivity, toxicity concerning com- While using hydrogen in laboratory purpose, the gas line is
bustion and fuel, specific heat and found hydrogen as safest fuel. preferably routed from rooftop to minimise the dangerous effect
due to unintentional leakage. An emergency shut off valve with
7.1. Storage electrical connections must be fitted just before the gas to the
engine. The material properties such as diffusion coefficient, per-
Hydrogen is used in various forms in internal combustion engi- meability, machinability and hardness must be taken into consid-
nes and vehicles including compressed hydrogen gas, liquid hydro- eration for hydrogen use. The hydrogen has a high diffusion
gen (LH2), organic or metal hydride and Carbon nanotubes. These coefficient and lower permeability with steel.[106]. The ASTM
storage systems have disadvantage and advantages over each A269-2001 grade stainless steel pipes shall be used for fuel tanks.
other. The commonly used system is compressed gas. Propane [107]. Test cell should be fitted with a leakage detector sensor at
storage pressure is 300 psi whereas hydrogen is from minimum top of the test cell.
5000 to a maximum of 10,000 psi. The hydrogen fuel has a negative
value of J-T coefficient which is more dangerous in case of failure
8. Challenges and scope for future development
but the temperature increased was 33.8° C from 25.8° C for 5000
and 1000 psi pressure which is found to be safe with these high
The detailed analysis has been performed for engine perfor-
pressures. [100]DOE (Department Of Energy, US) which is the
mance and emission with both PFI and Direct injections. Still, there
authority to revise hydrogen standards. The mainly SAE J2578
are various challenges such as an increase in efficiency and heat
and J1766 are used for hydrogen fuel. Technical Information
transfer to the cylinder wall. To achieve the high engine power out-
Reports (TIR) is also published by Working Group. The perfor-
put, high efficiency and lower emissions, understanding the heat
mance and system-level requirement are defined in SAE J2579
transfer inside the engine is always subject of interest. Sierens
standard. [101].
et al[108] investigated heat transfer between methane and hydro-
gen engine at same indicated power. The peak cylinder pressure
7.2. Transportation was 42 bar for hydrogen as against 28 bar due to a slow flame
speed of methane. The peak combustion pressure was drastically
The in-depth of study of issues of internal combustion engine reduced when air to fuel equivalence changed from 1 to 2. The
such as wear, corrosion, leakage and compatibility of material is peak in the heat flux was reduced by 80 % and power reduced by
required. Hydrogen can be stored at cryogenic temperature to store 23 % but not heat transfer. The indicated efficiency of hydrogen
more gas. It requires a special tank with safety arrangements. The at the highest power was less due to high heat loss of hydrogen
tank consists of mainly filling and venting connections heat engine at high load and speed.
exchanger, electrical shut-off valve and safety valves [102]. It is
estimated by Japan that highest fuel use in 2050 will be hydrogen Demuyncke et al [109] studied engine parameters and heat flux
fuel.[103] The observations are similar to Sierens.
Heat flux increased with an increase in compression ratio.
7.3. Dispensing Heat flux also increases with advancing the ignition timing.
Currently, hydrogen dispensers are specially designed and Wimmer [110] studied the comparative performance of PFI and
available for refuelling public vehicles. The filling time required Direct Injection at Ghent University. The detailed analysis of differ-
is three to five minutes which is similar to gasoline or diesel vehi- ent losses was done. Losses during injection during compression
cle refuelling. These dispensers are designed as per ASME standard stroke were negligible in case of gasoline and diesel engine but
with a fuel pressure of 3600 or 3000 psig and 17,000 Nm3/hr fuel in case of hydrogen engines, it was major portion. Losses due to
flow rate. [104] real combustion are same for PFI and DI operation. Loss due to
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Balu Jalindar Shinde and K. K. Materials Today: Proceedings 51 (2022) 1568–1579
compression during an injection can be reduced. For DI operation [11] V. Kumar, D. Gupta, N. Kumar, Hydrogen Use in Internal Combustion Engine:
A Review, Int J Adv Cult Technology 3 (2) (2015) 87–99, https://doi.org/
efficiency is directly proportional to compression ratio hence com-
10.17703/IJACT.2015.3.2.87.
pression ratio needs to be optimised and injection timing can be [12] S. Verhelst, P. Maesschalck, N. Rombaut, R. Sierens, Increasing the power
optimised for improving DI efficiency. Stratified combustion [84] output of hydrogen internal combustion engines by means of supercharging
has improved engine efficiency by 3 %(44.4 to 47.4) as against and exhaust gas recirculation, Int J Hydrogen Energy 34 (10) (2009) 4406–
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