The H2-ICE project aims at developing, through numerical simulation, a new generation of hybrid powertrains featuring a hydrogen-fueled Internal Combustion Engine (ICE) suitable for 12 m urban buses in order to provide a reliable and cost-effective solution for the abatement of both CO₂ and criteria pollutant emissions. The full exploitation of the potential of such a traction system requires a substantial enhancement of the state of the art since several issues have to be addressed. In particular, the choice of a more suitable fuel injection system and the control of the combustion process are extremely challenging. Firstly, a high-fidelity 3D-CFD model will be exploited to analyze the in-cylinder H2 fuel injection through supersonic flows. Then, after the optimization of the injection and combustion process, a 1D model of the whole engine system will be built and calibrated, allowing the identification of a “sweet spot” in the ultra-lean combustion region, characterized by extremely low NOx emissions and, at the same time, high combustion efficiencies. Moreover, to further enhance the engine efficiency well above 40%, different Waste Heat Recovery (WHR) systems will be carefully scrutinized, including both Organic Rankine Cycle (ORC)-based recovery units as well as electric turbo-compounding. A Selective Catalytic Reduction (SCR) aftertreatment system will be developed to further reduce NOx emissions to near-zero levels. Finally, a dedicated torque-based control strategy for the ICE coupled with the Energy Management Systems (EMSs) of the hybrid powertrain, both optimized by exploiting Vehicle-To-Everything (V2X) connection, allows targeting H2 consumption of 0.1 kg/km. Technologies developed in the H2-ICE project will enhance the know-how necessary to design and build engines and aftertreatment systems for the efficient exploitation of H2 as a fuel, as well as for their integration into hybrid powertrains.

The H2-ICE project aims at developing, through numerical simulation, a new generation of hybrid powertrains featuring a hydrogen fueled Internal Combustion Engine (ICE) suitable for 12-meter urban buses, in order to provide a reliable and cost-effective solution for the abatement of both CO2 and criteria pollutant emissions. The full exploitation of the potential of such a traction system requires a substantial enhancement of the state of the art since several issues have to be addressed. In particular, the choice of the more suitable fuel injection system, as well as the control of the combustion process, are extremely challenging. Firstly, a high-fidelity 3D-CFD model will be exploited to analyze the in-cylinder H2 fuel injection through supersonic flows. Then, after the optimization of the injection and combustion process, a 1D model of the whole engine system will be built and calibrated allowing the identification of a “sweet spot”, in the ultra-lean combustion region, characterized by extremely low NOx emissions and, at the same time, high combustion efficiencies. Moreover, to further enhance the engine efficiency well above 40 %, different Waste Heat Recovery (WHR) systems will be carefully scrutinized, including both Organic Rankine Cycle (ORC)-based recovery units as well as electric turbo-compounding. A Selective Catalytic Reduction (SCR) aftertreatment system will be developed to further reduce NOx emissions to near-zero levels. Finally, a dedicated torque-based control strategy for the ICE coupled with the Energy Management Systems (EMS) of the hybrid powertrain, both optimized by exploiting Vehicle-To-Everything (V2X) connection, allow targeting an H2 consumption of 0.1 kg/km. Technologies developed in the H2-ICE project will enhance the know-how necessary to design and build engines and after-treatment systems for the efficient exploitation of H2 as a fuel, as well as for their integration into hybrid powertrains.

Hydrogen Internal Combustion Engines (H₂ICEs) offer significant potential in reducing the CO₂ emissions of the heavy-duty transport sector in the pursuit of the European Green Deal targets. However, the challenges associated with hydrogen energy density require advanced technologies for fuel efficiency enhancement. Hybrid powertrains, equipped with innovative energy recovery systems, allow optimizing the engine working point while recovering otherwise wasted energy. In particular, Turbocompound (TCo) systems allow recovering the energy content in the exhaust gases, improving the overall efficiency of the powertrain. Optimizing both engine operation and TCo recovery presents a significant challenge, as it requires balancing the dynamic interaction between the engine’s combustion process and TCo (which increases backpressure). This paper presents a novel approach aimed at optimizing the performance of a hybrid hydrogen-fueled internal combustion engine by integrating a TCo system. The TCo allows extracting a 9 kW extra power peak with respect to the baseline configuration. The performance assessment of the optimized working point for series hybrid powertrains underscores the capability of the strategy to reduce hydrogen consumption up to 6.8%.