Engineers from UNSW Sydney have successfully converted a diesel engine to run as a hydrogen-diesel hybrid engine – reducing CO₂ emissions by more than 85 per cent in the process.

The team, led by Professor Shawn Kook from the School of Mechanical and Manufacturing Engineering, spent around 18 months developing the Hydrogen-Diesel Direct Injection Dual-Fuel System that means existing diesel engines can run using 90 per cent hydrogen as fuel.

The researchers say that any diesel engine used in trucks and power equipment in the transportation, agriculture and mining industries could ultimately be retrofitted to the new hybrid system in just a couple of months.

Green Hydrogen

Green hydrogen, which is produced using clean renewable energy sources such as wind and solar, is much more environmentally friendly than diesel.

And in a paper published in the International Journal of Hydrogen Energy, Prof. Kook’s team show that using their patented hydrogen injection system reduces CO₂ emissions to just 90 g/kWh – 85.9 per cent below the amount produced by the diesel powered engine.

“This new technology significantly reduces CO₂ emissions from existing diesel engines, so it could play a big part in making our carbon footprint much smaller, especially in Australia with all our mining, agriculture and other heavy industries where diesel engines are widely used,” says Prof. Kook.

“We have shown that we can take those existing diesel engines and convert them into cleaner engines that burn hydrogen fuel.

“Being able to retrofit diesel engines that are already out there is much quicker than waiting for the development of completely new fuel cell systems that might not be commercially available at a larger scale for at least a decade.

“With the problem of carbon emissions and climate change, we need some more immediate solutions to deal with the issue of these many diesel engines currently in use.”

High-pressure hydrogen diesel direct injection

The UNSW team’s solution to the problem maintains the original diesel injection into the engine, but adds a hydrogen fuel injection directly into the cylinder.

The collaborative research, performed with Dr Shaun Chan and Professor Evatt Hawkes, found that specifically timed hydrogen direct injection controls the mixture condition inside the cylinder of the engine, which resolves the problem of harmful nitrogen oxide emissions that have been a major hurdle for commercialisation of hydrogen engines.

“If you just put hydrogen into the engine and let it all mix together you will get a lot of nitrogen oxide (NO_x) emissions, which is a significant cause of air pollution and acid rain,” Prof. Kook says.

“But we have shown in our system if you make it stratified – that is in some areas there is more hydrogen and in others there is less hydrogen – then we can reduce the NO_x emissions below that of a purely diesel engine.”

Importantly, the new Hydrogen-Diesel Direct Injection Dual-Fuel System does not require extremely high purity hydrogen which must be used in alternative hydrogen fuel cell systems and is more expensive to produce.

And compared to existing diesel engines, an efficiency improvement of more than 26 per cent has been shown in the diesel-hydrogen hybrid.

That improved efficiency is achieved by independent control of hydrogen direct injection timing, as well as diesel injection timing, enabling full control of combustion modes – premixed or mixing-controlled hydrogen combustion.

hydrogen diesel direct injection potential

The research team hope to be able to commercialise the new system in the next 12 to 24 months and are keen to consult with prospective investors.

They say the most immediate potential use for the new technology is in industrial locations where permanent hydrogen fuel supply lines are already in place.

That includes mining sites, where studies have shown that about 30 per cent of greenhouse-gas emissions are caused by the use of diesel engines in such items as mining vehicles and power generators.

And the Australian market for diesel-only power generators is currently estimated to be worth around $765 million.

“At mining sites, where hydrogen is piped in, we can convert the existing diesel engines that are used to generate power,” says Prof. Kook.

“In terms of applications where the hydrogen fuel would need to be stored and moved around, for example in a truck engine that currently runs purely on diesel, then we would also need to implement a hydrogen storage system to be integrated into our injection system.

“I do think the general technology with regards to mobile hydrogen storage needs to be developed further because at the moment that is quite a challenge.”

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IFAT is the largest platform worldwide for water, sewage, waste and raw materials management with around 120,0000 visitors and 3,000 exhibitors from 155 countries.

• The world’s leading trade fair for water, sewage, waste and raw materials management (IFAT 2022) shows a sharp increase in the demand for BEV and FCEV commercial vehicles especially from municipal companies and businesses
• E-mobility specialist QUANTRON records increased incoming orders and enquiries for commercial vehicles at the IFAT, especially in the heavy and light segments after the presentation of QUANTRON´s BEV and hydrogen commercial vehicles

During the four days of the trade fair, Quantron AG received various orders for new zero-emission vehicles and numerous enquiries about converting existing diesel commercial vehicles to electric drives, primarily from municipal companies.

The demand from the companies focused on all-electric vehicles from the heavy-duty segment, e.g. refuse collection vehicles such as the QUANTRON QHB 27-280 as well as light and medium-duty transporters both equipped with hydrogen fuel cell technology, realised with the exhibited QUANTRON QLI FCEV, and battery-electric driven as with the QUANTRON QARGO 4 EV.

“It is clearly noticeable that municipal companies in particular feel the pressure to act and now want to convert their fleets to be emission-free,” says Reiner Dellori, Chief Product Advisor at Quantron AG. “The problem for many companies is the implementation of the EU Clean Vehicles Directive on the one hand, with rising operating costs for diesel-powered vehicles and the inability of established manufacturers to deliver on the other. In contrast, QUANTRON is able to deliver suitable vehicles within only a few months.”

As a result, QUANTRON was able to sell additional battery-electric operated QUANTRON QARGO 4 EV Light Transporters at the fair. The vehicle was launched at the end of April 2022 and ideally suited for sustainable transportation tasks in inner-city areas and for last-mile deliveries.

Fully-electric refuse collection trucks in particular are of great interest to local authorities. With the QUANTRON QHB 27-280, which is based on the Mercedes-Benz Econic, QUANTRON is producing a vehicle that is particularly pleasant for residents and vehicle personnel alike thanks to its emission-free and low-noise mode of operation. Featuring a battery capacity of 280 kWh, the refuse collection truck effortlessly manages a complete shift and can simply be charged overnight for everyday use.

Furthermore, QUANTRON was also able to inspire customers regarding its hydrogen-powered vehicles. The QUANTRON QLI FCEV Light Transporter, based on the Iveco Daily, was developed in close cooperation with QUANTRON partner and fuel cell expert, AE Driven Solutions.

The tremendous interest shown by trade fair visitors in the hydrogen fuel cell vehicle demonstrates that municipal companies are very open-minded when it comes to the innovative energy source.

Together with its partner, Ballard Power Systems, QUANTRON is working on the development of hydrogen-powered vehicles in the heavy sector. The first vehicle of the joint hydrogen offensive will be presented at the IAA Transportation Fair in September 2022.

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