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Author Topic: Making engines more efficient
Agent 204
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posted 26 March 2005 08:41 AM      Profile for Agent 204   Author's Homepage     Send New Private Message      Edit/Delete Post  Reply With Quote 
In my class on waste management, we went on a field trip to a landfill, and among the things we were shown was a bank of enormous engines, running on landfill gas, which were being used to generate electricity that is sold to Hydro One (enough to power around 3200 homes, actually). One of the things we were told was that in the near future, they are going to be adding devices to the engines that collect heat from the exhaust and use this to boil pentane and spin a turbine. This will be a closed system, so the pentane will not be consumed, and it is expected to almost double the amount of electricity produced by the system.

My question is, how scalable is this? Will a car engine produce enough heat to get a useful amount of juice out of it, or is this something limited to larger engines like these ones? If the former, this would be a terrific addition to hybrid cars, further reducing their fuel consumption.

Thoughts?


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Reverend Blair
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posted 26 March 2005 09:26 AM      Profile for Reverend Blair   Author's Homepage     Send New Private Message      Edit/Delete Post  Reply With Quote 
I'm not sure hot the hybrid engines run. The heat builds up over time, so their constant on-off cycle might effect this.

A car engine does produce a lot of heat though, so it should be workable to at least some extent.

Something I've always wondered about engine efficieny in cars is why they don't take racing tricks and use them more. Some things, like headers and free-flowing exhaust, produce more power while reducing fuel usage.


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Agent 204
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posted 26 March 2005 10:37 AM      Profile for Agent 204   Author's Homepage     Send New Private Message      Edit/Delete Post  Reply With Quote 
Hmm. Good point about the on-off cycle Obviously you'd have to take some of the power for the electrics directly off the crankshaft, but maybe something like that would be beneficial on the highway.

Another idea that occurs to me is that, if the aforementioned pentane turbine isn't feasible, consider this: A turbocharger is simply a supercharger that is powered by a turbine driven by the exhaust gas. Suppose, instead of a supercharger, you used that turbine to do something else? In the aviation world, they experimented with applying that power directly to the crankshaft (the "turbo compound" engine used in the DC-7), but the arrival of jets and turboprops pushed the turbo compound engine aside. But suppose you fed that power into a generator of some sort? Would that produce enough juice to significantly help in propelling the car?


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Reverend Blair
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posted 26 March 2005 11:02 AM      Profile for Reverend Blair   Author's Homepage     Send New Private Message      Edit/Delete Post  Reply With Quote 
I think it would, depending on the weight of the components. A few years ago I was watching racing on TV...some kind of experimental vehicles race...and somebody had attached a generator to the drive-shaft of a Viper. The idea was to use the extra power to accelerate out of the corners. The extra weight cost him more time than he saved though.
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nister
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posted 26 March 2005 02:35 PM      Profile for nister     Send New Private Message      Edit/Delete Post  Reply With Quote 
General Motors and Chrysler have Displacement On Demand motors in the marketplace; shutting down cylinders in low-load conditions for a healthy gain in mileage. BMW brought a "white noise" exhaust system to market in one of their exotics, claiming a 5 to 7% boost in power by replacing the muffler with an interferometer. Variable valve timing engines provide flat torque curves that improve mileage and power. Constantly Variable Transmissions keep engines in their "sweet spot" of efficiency. New technologies like hydro-forming allow designers to make components thick where they need be, and lighter where not needed. Jaguar is testing unibodies they have "glued" together, rather than weld together. They are in Kapuskasing, to see what real cold will do to them.
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Agent 204
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posted 26 March 2005 05:23 PM      Profile for Agent 204   Author's Homepage     Send New Private Message      Edit/Delete Post  Reply With Quote 
Hmm. I knew about Displacement on Demand and CVTs; in fact neither of these is a new invention. GM experimented with DOD in some of their Cadillacs from the early 1980s; the engine was called the "V8-6-4", but it had so many bugs that they soon got rid of it. Presumably the new ones are better. CVTs have been around for decades in motor scooters, and the Dutch automaker DAF made a CVT in 1958. Of the others you list, variable valve timing is the only one I'd heard of.
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James
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posted 26 March 2005 06:32 PM      Profile for James        Edit/Delete Post  Reply With Quote 
What became of all the discussion around flywheel technology as a more efficient energy storage system in vehicles than storage batteries. Five years ago everyone was talking about it for busses and whatnot, then, haven't heard it mentioned in years.
From: Windsor; ON | Registered: Mar 2004  |  IP: Logged
Agent 204
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posted 26 March 2005 07:42 PM      Profile for Agent 204   Author's Homepage     Send New Private Message      Edit/Delete Post  Reply With Quote 
Flywheels are a great idea, but they have a couple of problems. One is the gyroscopic effect in a fast flywheel (the most effective kind for energy storage) that could affect the handling of the car. More serious is containment in case of failure. A 1-ft diameter flywheel, spinning at 100,000 rpm, would be very dangerous if it disintegrated (pieces would go flying at around 1500 metres per second). An effective containment for something like that would probably add quite a lot to the weight of the vehicle.

Actually, I think the best use for flywheels would be for stationary energy storage (since neither weight nor gyroscopic effects would be an issue). If each hydro substation had a bank of these flywheels, you wouldn't have problems with power surges and the like, and the system would adapt to disruptions like that one in the summer of 2003 far better.


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sid hartha
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posted 26 March 2005 08:17 PM      Profile for sid hartha     Send New Private Message      Edit/Delete Post  Reply With Quote 
Here's an interesting article on what is being done to improve the efficiency of reciprocating (piston) combustion engines.

Currently, diesel engines still produce more energy than gasoline engines - current turbo diesels are about 40 percent efficient (they convert 40% of the fuel's potential energy into usable energy), while the most efficient gasoline engines are still in the 25 percent range.

Furthermore, diesels can be run on renewable fuels, such as vegetable oils. As gasoline continues to climb over the buck-a-litre mark (sheer psychological terror for many), I think we will see more manufacturers providing diesels in the marketplace, competing with the Volks TDIs. Many european small cars are currently available with tiny turbocharged diesels.


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Agent 204
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posted 26 March 2005 09:33 PM      Profile for Agent 204   Author's Homepage     Send New Private Message      Edit/Delete Post  Reply With Quote 
Thanks for the link.

I wonder if the efficiency of diesels is enough to compensate for the greater carbon content of diesel fuel? Of course if biodiesel can be done on a big scale this will be a non-issue, but I wonder which produces more CO2 per kilometre, gas or diesel?

[ 11 May 2005: Message edited by: Agent 204 ]


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LeftRight
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posted 26 March 2005 10:17 PM      Profile for LeftRight   Author's Homepage     Send New Private Message      Edit/Delete Post  Reply With Quote 
quote:
Originally posted by Mike Keenan:

Thoughts?


Two thoughts come to mind: 1)if it is possible to convert heat directly to electricity, this would cut out a lot of the mechanisms in between. 2) instead of the piston or rotary engine, it is possible to construct an enclosed turbine engine that contrains combustion through a small narrow turbine plate that would power a forced air induction blower providing comparable internal pressure to that of a piston engine. With a bit of test measuring the blower could be geared to deliver an excess mass of oxygen (e.g. 10% surplus oxygen content) containing air. The excess oxygen would assure greater fuel burn efficiency on acceleration. Such an engine could use for fuel all gaseous and liquid fuels.


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LeftRight
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posted 26 March 2005 10:22 PM      Profile for LeftRight   Author's Homepage     Send New Private Message      Edit/Delete Post  Reply With Quote 
quote:
Originally posted by LeftRight:

Two thoughts come to mind: 1)if it is possible to convert heat directly to electricity, this would cut out a lot of the mechanisms in between.



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nister
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posted 26 March 2005 10:33 PM      Profile for nister     Send New Private Message      Edit/Delete Post  Reply With Quote 
MK, you might try googling Orbital two-stroke engines. The technology looks really promising.
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quagmire
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posted 26 March 2005 10:38 PM      Profile for quagmire   Author's Homepage     Send New Private Message      Edit/Delete Post  Reply With Quote 
quote:
Originally posted by Mike Keenan:
Thanks for the link.

I wonder if the efficiency of diesels is enough to compensate for the greater carbon content of diesel fuel? Of course if biodiesel can be done on a big scale this will be a non-issue, but I wonder which produces more CO2 per kilometre, gas or diesel?

[ 26 March 2005: Message edited by: Mike Keenan ]


I'd guess that the lower pumping losses and higher compression of the diesel would still make it more efficient in miles per pound of carbon, particularily if it was turbocharged and aftercooled.
Hydraulicaly activated valves are coming soon, they are here already on some of the monster sized marine engines. The 100,000 horsepower Sulzer uses them. It spins a whole 98 rpm.
http://www.bath.ac.uk/~ccsshb/12cyl/
http://www.wartsila.com/?_nfpb=true&_pageLabel=shippower_en
Caterpillar has a new generation of high speed and low speed diesels on the drawing board, I'm not sure what the details are but they will be electronic engines from the ground up, not just old designs with electronic fuel injection systems added. The HEUI system should be the standard for a while for Cat.

[ 28 March 2005: Message edited by: quagmire ]

[ 28 March 2005: Message edited by: quagmire ]


From: Directly above the center of the Earth | Registered: Jan 2005  |  IP: Logged
Agent 204
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posted 01 April 2005 04:44 PM      Profile for Agent 204   Author's Homepage     Send New Private Message      Edit/Delete Post  Reply With Quote 
quote:
Originally posted by quagmire:

I'd guess that the lower pumping losses and higher compression of the diesel would still make it more efficient in miles per pound of carbon, particularily if it was turbocharged and aftercooled.
Hydraulicaly activated valves are coming soon, they are here already on some of the monster sized marine engines. The 100,000 horsepower Sulzer uses them. It spins a whole 98 rpm.
http://www.bath.ac.uk/~ccsshb/12cyl/
http://www.wartsila.com/?_nfpb=true&_pageLabel=shippower_en
Caterpillar has a new generation of high speed and low speed diesels on the drawing board, I'm not sure what the details are but they will be electronic engines from the ground up, not just old designs with electronic fuel injection systems added. The HEUI system should be the standard for a while for Cat.



That Sulzer engine is amazing!

The engines at the landfill were Caterpillar engines, actually, but they were spark ignition, not diesel. (BTW, if you had a compression-ignition engine that ran on methane or the like, would it still be called a diesel engine?)

Incidentally, are all modern automotive diesels now EFI jobs, or are some of them still all-mechanical?


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quagmire
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posted 01 April 2005 05:36 PM      Profile for quagmire   Author's Homepage     Send New Private Message      Edit/Delete Post  Reply With Quote 
I'd guess that they are all electronicly controlled except maybe the quite small ones. I'm more familiar with the larger Cat mining equipment than any of the others these days.
The landfill ones you saw sound like Cat 3600 engines, they are available as Diesels or spark ignition and in 6,8,12, 16 or 18 cylinders. Most of the ones in Alberta are spark ignited and burn natural gas in the compressor stations. Caterpillar refers to them as gas engines.
The 3600 engines running generators in the north generally have exhaust gas boilers on them.
I saw some big MAN's running 12 megawatt generators, they were plenty impressive. There are a lot of interesting ideas in some of those big engines. Cooper-Besner (sp?) built some big V 12's that used a master rod and a pony rod for each pair of cylinder similar to the the aircraft radials.
There are a lot of new ideas being tried in the truck engine market to lower the pollution from them.
As a bit of interest, Detroit Diesel used to build some big two stroke diesels, the 149 series. They were 149 cubic inches per cylinder and put out a max of 125 hp per cylinder. They built two engine blocks, a V6 and a V8. The engines were available as V8's, V12's, V16's, and V20's, but not V6's.
How'd they do that?
The V8 was one engine block, the V12 was two V6's bolted together with the right amount of blowers and turbochargers, the V16 was two V8's etc, and the V20 was a V6, a V8, and another V6 bolted together with three blowers and six turbos.
I think they have gone the way of the dinosaur because of emissions and fuel economy. The 4 strokes are just more fuel efficient.
Cat builds a 3000 plus horsepower diesel called a 3524, it's two 3512 v12's coupled together and it powers the 797 mining truck, which is a big bruiser.
Cheers.

[ 01 April 2005: Message edited by: quagmire ]

[ 01 April 2005: Message edited by: quagmire ]


From: Directly above the center of the Earth | Registered: Jan 2005  |  IP: Logged
Agent 204
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posted 01 April 2005 05:53 PM      Profile for Agent 204   Author's Homepage     Send New Private Message      Edit/Delete Post  Reply With Quote 
quote:
Originally posted by quagmire:

The landfill ones you saw sound like Cat 3600 engines, they are available as Diesels or spark ignition and in 6,8,12, 16 or 18 cylinders. Most of the ones in Alberta are spark ignited and burn natural gas in the compressor stations. Caterpillar refers to them as gas engines.
The 3600 engines running generators in the north generally have exhaust gas boilers on them.


I just found my notes from the field trip. The current ones are 3516s, and are 925 kW (1240 hp). There are five of them. Probably similar to the ones you describe but aimed at a slightly different market. They plan to replace them with 3520s (1.6 MW or 2146 hp).

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