Turbochargers reduce fuel consumption and CO₂ emissions from heavy-duty internal combustion engines by enabling downsizing and downspeeding through greater power density. This requires greater pressure ratios and thus air systems with multiple stages and interconnecting ducting, all subject to tight packaging constraints. This paper considers the aerodynamic optimization of the exhaust side of a two-stage air system for a Caterpillar 4.4 l heavy-duty diesel engine, focusing on the high pressure turbine (HPT) wheel and interstage duct (ISD). Using current production designs as a baseline, a genetic algorithm (GA)-based aerodynamic optimization process was carried out separately for the wheel and duct components to evaluate seven key operating points. While efficiency was a clear choice of cost function for turbine wheel optimization, different objectives were explored for ISD optimization to assess their impact. Optimized designs are influenced by the engine operating point, so each design was evaluated at every other engine operating point, to determine which should be carried forward. Prototypes of the best compromise high pressure turbine wheel and ISD designs were manufactured and tested against the baseline to validate computational fluid dynamics (CFD) predictions. The best performing high pressure turbine design was predicted to show an efficiency improvement of 2.15% points, for on-design operation. Meanwhile, the optimized ISD contributed a 0.2% and 0.5% point efficiency increase for the HPT and low pressure turbine (LPT), respectively.

The organic Rankine cycle (ORC) is low-grade heat recovery technology, for sources as diverse as geothermal, industrial, and vehicle waste heat. The working fluids used within these systems often display significant real-gas effects, especially in proximity of the thermodynamic critical point. Three-dimensional (3D) computational fluid dynamics (CFD) is commonly used for performance prediction and flow field analysis within expanders, but experimental validation with real gases is scarce within the literature. This paper therefore presents a dense-gas blowdown facility constructed at Imperial College London, for experimentally validating numerical simulations of these fluids. The system-level design process for the blowdown rig is described, including the sizing and specification of major components. Tests with refrigerant R1233zd(E) are run for multiple inlet pressures, against a nitrogen baseline case. CFD simulations are performed, with the refrigerant modeled by ideal gas, Peng–Robinson, and Helmholtz energy equations of state. It is shown that increases in fluid model fidelity lead to reduced deviation between simulation and experiment. Maximum and mean discrepancies of 9.59% and 8.12% in nozzle pressure ratio with the Helmholtz energy EoS are reported. This work demonstrates an over-prediction of pressure ratio and power output within commercial CFD packages, for turbomachines operating in non-ideal fluid environments. This suggests a need for further development and experimental validation of CFD simulations for highly non-ideal flows. The data contained within this paper are therefore of vital importance for the future validation and development of CFD methods for dense-gas turbomachinery.

Opposed-piston, two-stroke engines reveal degrees of freedom that make them excellent candidates for next generation, highly efficient internal combustion engines for hybrid electric vehicles and power systems. This article reports simulation results that explore the influence of key control and geometrical parameters, specifically crankshaft phasing and intake and exhaust port height-to-stroke ratios, in obtaining best thermal efficiency. A model of a 0.75 L, single-cylinder opposed-piston two-stroke engine is exercised to predict fuel consumption as engine speed, load, crankshaft phasing, intake and exhaust port height-to-stroke ratios, and stoichiometry are varied for medium-duty truck and range extender applications. Under stoichiometric operation, optimal crankshaft phasing is seen at 0–5°, lower than reported in the literature. If stoichiometric operation is not mandated, best fuel consumption is achieved at an air-to-fuel equivalence ratio λ = 1.25 and 5–10° crankshaft phase angle, enabling a ~10 g/kWh (~4%) improvement in average brake-specific fuel consumption across medium-duty truck operating points. In range extender form, the engine provides 30 kW output power in accordance with a survey of range extender engines. In this role, there is a clear distinction between low-speed, high-load operation and vice versa. The decision as to which is more appropriate would be based on minimizing total owning and operating cost, itself a trade-off between better thermal efficiency (and thus lower fuel cost) and greater durability.

Transport electrification is essential for reducing CO₂ emissions, and technologies such as hybrid and range-extended electric vehicles will play a crucial transitional role. Such vehicles employ an internal combustion engine for on-board chemical energy conversion. The Wankel rotary engine should be an excellent candidate for this purpose, offering a high power-to-weight ratio, simplicity, compactness, perfect balance, and low cost. Until recently, however, it has not been in production in the automotive market, due, in part, to relatively low combustion efficiency and high fuel consumption and unburnt hydrocarbon emissions, which can be traced to constraints on flame speed, an elongated combustion chamber, and relatively low compression ratios. This work used large eddy simulations to study the in-chamber flow in a peripherally ported 225cc Wankel rotary engine, providing insight into these limitations. Flow structures created during the intake phase play a key role in turbulence production but the presence of the pinch point inherent to Wankel engine combustion chambers inhibits flame propagation. Two efficiency-enhancement technologies are introduced as disruptive solutions: (i) pre-chamber jet ignition and (ii) a two-stage rotary engine. These concepts overcome the traditional efficiency limitations and show that the Wankel rotary engine design can be further enhanced for its role as a range extender in electrified vehicles.

Transport electrification is essential for reducing CO2 emissions, and technologies such as hybrid and range-extended electric vehicles will play a crucial transitional role. Such vehicles employ an internal combustion engine for on-board chemical energy conversion. The Wankel rotary engine should be an excellent candidate for this purpose, offering high power-to-weight ratio, simplicity, compactness, perfect balance, and low cost. Until recently, however, it has not been in production in the automotive market, due, in part, to relatively low combustion efficiency and high fuel consumption and unburnt hydrocarbon emissions, which can be traced to constraints on flame speed, an elongated combustion chamber, and relatively low compression ratios. This work uses large-eddy simulation to study the in-chamber flow in a peripherally ported 225cc Wankel rotary engine, providing insight into these limitations. Flow structures created during the intake phase play a key role in turbulence production but presence of the pinch point inherent to Wankel engine combustion chambers inhibits flame propagation. Two efficiency-enhancement technologies are introduced as disruptive solutions: (i) pre-chamber jet ignition and (ii) the two-stage rotary engine. These concepts overcome the traditional efficiency limitations and show that Wankel rotary engine design can be further enhanced for its role as a range extender in electrified vehicles.