Search Results (62)

In the era of depletion of fossil fuels, there is an intensive search for renewable fuels for the internal combustion engine, which is the most efficient thermal machine in the power range of several kW to several MW. Hence, this article discusses the results of research on the combustion of renewable fuels such as hydrotreated vegetable oil (HVO) and the rapeseed methyl ester (RME) with the addition of hydrogen, injected in its gaseous form into the intake manifold. The thermodynamic analysis presented in the article discusses progress in the combustion process of these fuels depending on the hydrogen content. The parameters for diesel fuel combustion are given as a reference point. Based on the obtained results, one can conclude that adding hydrogen increases the maximum combustion pressure in the cylinder and significantly accelerates the combustion process in the premixed combustion phase, thus reducing the share of the diffusion combustion phase. This significantly affects exhaust toxic emissions. In connection with this, a shortening of the flame kernels development phase was observed, calculated as the time expressed by the crank angle, to release heat of 10%, and a slight extension of the main combustion phase, managed as the period of the heat released from 10 to 90% was observed as well. Full article

Thermoelectric generator (TEG) has emerged as a critical technology for automotive exhaust energy recovery, yet there is still a lack of reviews analyzing automotive TEG structure design and optimization methods simultaneously. Therefore, this review consolidates structure design and methods for improving thermoelectric conversion efficiency, focusing on three core components: thermoelectric module (TEM), heat exchanger (HEX), and heat sink (HSK). For TEM, research and development efforts have primarily centered on material innovation and structural optimization, with segmented, non-segmented, and multi-stage configurations emerging as the three primary structural types. HEX development spans external geometries, including plate, polygonal, and annular designs, and internal enhancements such as fin, heat pipe, metal foam, and baffle to augment heat transfer. HSK leverages active, passive, or hybrid cooling systems, with water-cooling designs prevalent in automotive TEG for cold-side thermal management. Optimization methods encompass theoretical analysis, numerical simulation, experimental testing, and hybrid methods, with strategies devised to balance computational efficiency and accuracy based on system complexity and resource availability. This review provides a systematic framework to guide the design and optimization of automotive TEG. Full article

High-temperature and high-pollution mobile sources are frequently encountered in industrial environments. Fixed-position exhaust outlets often fail to promptly remove heat and contaminants when these sources are in motion, leading to local accumulation and reduced indoor air quality. This study proposes a novel mobile exhaust system capable of tracking and dynamically aligning with moving emission sources to improve heat removal and cooling efficiency. Three configurations were evaluated: (1) a fixed exhaust outlet, (2) an exhaust vent moving synchronously with the heat source, and (3) a buoyancy-driven tracking exhaust outlet. Small-scale experiments and CFD simulations using dynamic mesh techniques were conducted. The results showed that the synchronous system reduced ambient temperature by an average of 0.25 to 2.3 °C compared to the fixed outlet, while the buoyancy-tracking system achieved an additional 0.15 to 2.5 °C reduction. The study also introduces a correlation between thermal plume inclination and the Archimedes number, providing a predictive basis for exhaust positioning. Given the similar dispersion patterns of heat and airborne pollutants, the proposed system holds promise for both thermal management and contaminant control in dynamic industrial environments. Furthermore, the system may offer critical advantages in emergency ventilation scenarios involving intense heat or hazardous pollutant outbreaks. Full article

Compressed natural gas (CNG) in dual-fuel diesel engines offers environmental benefits but significantly increases unburned methane (CH₄) emissions, especially at low engine loads. This study investigates the effectiveness of different catalytic converters in methane oxidation under transient test conditions (WHTC). Three types of catalysts (Pt-, Rh-, and Pd-based) were evaluated using a combined approach of empirical engine bench tests and mathematical modelling. The results showed that, under actual exhaust gas temperature conditions, the average methane conversion efficiencies were 3.7% for Pt, 17.7% for Rh, and 31.3% for Pd catalysts. Increasing the exhaust gas temperature by 50% improved the conversion efficiencies to 7.3%, 51.8%, and 69.2%, respectively. Despite this enhancement, none of the catalysts reached the 90% efficiency threshold required to increase the CNG content of the fuel beyond 6% without exceeding emission limits. The results highlight the need for high-activity Pd-based catalysts and optimised thermal management strategies to enable the broader adoption of dual-fuel engines, while complying with Euro VI standards. Full article

Faults of heating, ventilation, and air-conditioning (HVAC) systems can cause significant consequences, such as negatively affecting thermal comfort of occupants, energy demand, indoor air quality, etc. Several methods of fault detection and diagnosis (FDD) in building energy systems have been proposed since the late 1980s in order to reduce the consequences of faults in heating, ventilation, and air-conditioning (HVAC) systems. All the proposed FDD methods require laboratory data, or simulated data, or field data. Furthermore, the majority of the recently proposed FDD methods require labelled faulty and normal data to be developed. Thus, providing reliable ground truth data of HVAC systems with different technical characteristics is of great importance for advances in FDD methods for HVAC units. The primary objective of this study is to examine the operational behaviour of a typical single-duct dual-fan constant air volume air-handling unit (AHU) in both faulty and fault-free conditions. The investigation encompasses a series of experiments conducted under Mediterranean climatic conditions in southern Italy during summer and winter. This study investigates the performance of the AHU by artificially introducing seven distinct typical faults: (1) return air damper kept always closed (stuck at 0%); (2) fresh air damper kept always closed (stuck at 0%); (3) fresh air damper kept always opened (stuck at 100%); (4) exhaust air damper kept always closed (stuck at 0%); (5) supply air filter partially clogged at 50%; (6) fresh air filter partially clogged at 50%; and (7) return air filter partially clogged at 50%. The collected data from the faulty scenarios are compared to the corresponding data obtained from fault-free performance measurements conducted under similar boundary conditions. Indoor thermo-hygrometric conditions, electrical power and energy consumption, operation time of AHU components, and all key operating parameters are measured for all the aforementioned faulty tests and their corresponding normal tests. In particular, the experimental results demonstrated that the exhaust air damper stuck at 0% significantly reduces the percentage of time with indoor air relative humidity kept within the defined deadbands by about 29% (together with a reduction in the percentage of time with indoor air temperature kept within the defined deadbands by 7.2%) and increases electric energy consumption by about 13% during winter. Moreover, the measured data underlined that the effects on electrical energy demand and indoor thermo-hygrometric conditions are minimal (with deviations not exceeding 5.6% during both summer and winter) in the cases of 50% clogging of supply air filter, fresh air filter, and return air filter. The results of this study can be exploited by researchers, facility managers, and building operators to better recognize root causes of faulty evidences in AHUs and also to develop and test new FDD tools. Full article

Fatigue management is critical for high-risk professions such as pilots, firefighters, and healthcare workers, where physical and mental exhaustion can lead to catastrophic accidents and loss of life. Traditional fatigue assessment methods, including surveys and physiological measurements, are limited in real-time monitoring and user convenience. To address these issues, this study introduces a novel contactless fatigue level diagnosis system leveraging multimodal sensor data, including video, thermal imaging, and audio. The system integrates non-contact biometric data collection with an AI-driven classification model capable of diagnosing fatigue levels on a 1 to 5 scale with an average accuracy of 89%. Key features include real-time feedback, adaptive retraining for personalized accuracy improvement, and compatibility with high-stress environments. Experimental results demonstrate that retraining with user feedback enhances classification accuracy by 11 percentage points. The system’s hardware is validated for robustness under diverse operational conditions, including temperature and electromagnetic compliance. This innovation provides a practical solution for improving operational safety and performance in critical sectors by enabling precise, non-invasive, and efficient fatigue monitoring. Full article

With the rapid development of China’s economy, urban domestic sewage and industrial wastewater treatment efficiency has improved, resulting in a significant increase in sludge production. Thermal drying is essential for reducing, safely disposing of, and resourcefully utilizing sludge. However, this drying process inevitably releases harmful pollutants, posing potential environmental risks that necessitate careful management. This work focused on the thermal drying of municipal sludge at five temperature intervals (90–210 °C) and examined the impact of calcium oxide on sludge drying properties. The results indicated that higher temperatures increased sludge drying rates, with optimal efficiency achieved at a 15% calcium oxide addition. Online detection of NH₃, H₂S, CO, and CH₄ in the exhaust gas revealed that pollutant generation was temperature-dependent. While calcium oxide addition had no significant effect on CH₄ and CO emissions, it significantly inhibited the generation of H₂S and NH₃. This work provided crucial insights into optimizing sludge treatment, which improved drying efficiency and mitigated the release of hazardous pollutants, thereby reducing potential environmental and health risks associated with sludge disposal. Full article

Thermal management presents a significant challenge in electric design, particularly in densely packed electronic systems. This study proposes a theoretical model for radiative bionic skin that emulates human skin, enabling the self-adaptive modulation of the thermal exhaustion rate to maintain homeostasis for objects covered by the skin in fluctuating thermal environments. The proposed artificial skin consists of phase change material (VO₂) nanoparticles embedded in a low-loss matrix situated on a metallic substrate with a minimal thickness of several micrometers. The findings from our theoretical analyses indicate that substantial alterations in thermal radiation power around the phase transition temperature of 340 K enable a silicone substrate to sustain a relatively stable temperature, with variations confined to ±6 K, despite external heat fluxes ranging from 150 to 450 W/m². Furthermore, to improve the spectral resemblance to natural skin, a plasmonic surface composed of self-assembled silver nanocubes is incorporated, allowing for modifications to the visible light properties of the bionic skin while maintaining its infrared characteristics. This theoretical investigation offers a cost-effective and conformal approach to the design of ultra-compact, fully passive, and versatile thermal management solutions for robotic systems and related technologies. Full article

Over 50% of an engine’s energy dissipates via the exhaust and cooling systems, leading to considerable energy loss. Effectively harnessing the waste heat generated by the engine is a critical avenue for enhancing energy efficiency. Traditional exhaust heat recovery systems are limited to real-time recovery of exhaust heat primarily for engine warm-up and fail to fully optimize exhaust heat utilization. This paper introduces a novel exhaust heat recovery system leveraging thermal battery technology, which utilizes phase change materials for both heat storage and reutilization. This innovation significantly minimizes the engine’s cold start duration and provides necessary heating for the cabin during start-up. Dynamic models and thermal management system models were constructed. Parameter optimization and calculations for essential components were conducted, and the fidelity of the simulation model was confirmed through experiments conducted under idle warm-up conditions. Four distinct operational modes for engine warm-up are proposed, and strategies for transitioning between these heating modes are established. A simulation analysis was performed across four varying operational scenarios: WLTC, NEDC, 40 km/h, and 80 km/h. The results indicated that the thermal battery-based exhaust heat recovery system notably reduces warm-up time and fuel consumption. In comparison to the cold start mode, the constant speed condition at 40 km/h showcased the most significant reduction in warm-up time, achieving an impressive 22.52% saving; the highest cumulative fuel consumption reduction was observed at a constant speed of 80 km/h, totaling 24.7%. This study offers theoretical foundations for further exploration of thermal management systems in new energy vehicles that incorporate heat storage and reutilization strategies utilizing thermal batteries. Full article

This study investigates the enhancement of vehicle warm-up performance using phase-change materials (PCMs) and various thermal storage methods. The primary objective is to utilize the thermal energy lost during engine cooling to improve the cold-start performance, thereby reducing fuel consumption and emissions. Thermal storage devices incorporating PCMs were developed and tested by measuring temperature changes and energy transfer over soaking periods of 4, 8, 16, and 24 h. The results show energy transfers of 591, 489, 446, and 315 kJ at 4, 8, 16, and 24 h, respectively. In terms of the warm-up time, the use of thermal storage devices reduced the time required to reach 70 °C by up to 24.45%, with significant reductions observed across all soaking periods. This reduction in the warm-up time directly contributes to faster engine stabilization, leading to proportional improvements in fuel efficiency and a corresponding decrease in exhaust emissions, including CO₂. The findings highlight the effectiveness of PCMs in improving the engine warm-up performance and emphasize the importance of optimizing thermal storage systems to balance energy efficiency and practical application considerations. Additionally, the experimental data provide useful benchmark information for computational simulation validation, enabling the further optimization of automotive thermal management systems. Integrating a PCM-based thermal storage device can significantly enhance a vehicle’s warm-up performance, leading to reduced fuel consumption and lower emissions. Full article

Electrification of aircraft is a very challenging task as the demand for energy and power is high. While the storage and generation of electrical energy are widely studied due to the limited specific energy and specific power of batteries and fuel cells, electric machines (power electronics and motors) which have years of experience in many industrial fields must be improved when applied to aviation: they generally have a high efficiency but the increase in power levels determines significant thermal loads which, unlike internal combustion engines (ICE), cannot be rejected with the exhaust. There is therefore a need for thermal management systems (TMSs) with the main objective of maintaining operating temperatures below the maximum level required by electric machines. Turboprop aircraft, such as the ATR 72 or the Dash 8-Q400, are commonly used for regional transport and are equipped with two gas turbine engines whose combined power is in the order of 4 MW. Electric and hybrid propulsion systems for these aircraft are being studied by several leading commercial aviation industries and start-ups, and the 1MW motor size seems to be the main option as it could be used in different aircraft configurations, particularly those that exploit distributed electric propulsion. With reference to the topics mentioned above, the present work presents the design of a TMS for a high-power motor/generator whose electrical architecture is known. Once integrated with the electrical part, the TMS must allow a weight/power ratio of 14 kW/kg (or 20 kW/kg at peak power) while maintaining the temperature below the limit temperature with reasonable safety margins. Submerged jet oil is the cooling technique here applied with a focus on diathermic oil. Parameters affecting cooling, like rotor speed and filling factor, are analysed with advanced CFD. Full article

This paper presents a comprehensive investigation into the design of a methane oxidation catalyst aftertreatment system specifically tailored for the Wärtsilä W31DF natural gas engine which has been converted to a reactivity-controlled compression ignition NG/Diesel engine. A GT-Power model was coupled with a predictive physical base chemical kinetic multizone model (MZM) as a combustion object. In this MZM simulation, a set of 54 species and 269 reactions as chemical kinetic mechanism were used for modelling combustion and emissions. Aftertreatment simulations were conducted using a 1D air-path model in the same GT-Power model, integrated with a chemical kinetic model featuring 15 catalytic reactions, based on activation energy and species concentrations from combustion outputs. The latter offered detailed exhaust composition and exhaust thermodynamic data under specific operating conditions, effectively capturing the intricate interactions between the investigated aftertreatment system, combustion, and exhaust composition. Special emphasis was placed on the formation of intermediate hydrocarbons such as C₂H₄ and C₂H₆, despite their concentrations being lower than that of CH₄. The analysis of catalytic conversion focused on key species, including H₂O, CO₂, CO, CH₄, C₂H₄, and C₂H₆, examining their interactions. After consideration of thermal management and pressure drop, a practical choice of a 400 mm long catalyst with a density of 10 cells per cm² was selected. Investigations of this catalyst’s specification revealed complete CO conversion and a minimum of 89% hydrocarbon conversion efficiency. Integrating the exhaust aftertreatment system into the air path resulted in a reduction in engine-indicated efficiency by up to 2.65% but did not affect in-cylinder combustion. Full article

The ORC-based micro-cogeneration systems exploiting a solar source to generate electricity and domestic hot water (DHW) simultaneously are a promising solution to reduce CO₂ emissions in the residential sector. In recent years, a huge amount of attention was focused on the development of a technological solution allowing improved performance of solar ORC-based systems frequently working under off-design conditions due to the intermittence of the solar source availability and to the variability in domestic hot water demand. The optimization efforts are focused on the improvement of component technology and plant architecture. The expander is retained as the key component of such micro-cogeneration units. Generally, volumetric machines are adopted thanks to their better capability to deal with severe off-design conditions. Among the volumetric expanders, scroll machines are one of the best candidates thanks to their reliability and to their flexibility in managing two-phase working fluid. Their good efficiency adds further interest to place them among the best candidate machines to be considered. Nevertheless, similarly to other volumetric expanders, an additional research effort is needed toward efficiency improvement. The fixed built-in volume ratio, in fact, could produce an unsteady under- or over-expansion during vane filling and emptying, mainly when the operating conditions depart from the designed ones. To overcome this phenomenon, a dual intake port (DIP) technology was also introduced for the scroll expander. Such technology allows widening the angular extension of the intake phase, thus adapting the ratio between the intake and exhaust volume (so called built-in volume ratio) to the operating condition. Moreover, DIP technology allows increasing the permeability of the machine, ensuring a resulting higher mass flow rate for a given pressure difference at the expander side. On the other hand, for a given mass flow rate, the expander intake pressure diminishes with a positive benefit on scroll efficiency. DIP benefits were already proven experimentally and theoretically in previous works by the authors for Sliding Rotary Vane Expanders (SVRE). In the present paper, the impact of the DIP technology was assessed in a solar-assisted ORC-based micro-cogeneration system operating with scroll expanders and being characterized by reduced power (hundreds of W). It was found that the DIP Scroll allows elaboration of a 32% higher mass flow rate for a given pressure difference between intake and expander sides for the application at hand. This leads to an average power increase of 10% and to an improvement of up to 5% of the expander mechanical efficiency. Such results are particularly interesting for micro-cogeneration ORC-based units that are solar-assisted. Indeed, the high variability of hot source and DHW demand makes the operation of the DIP expander at a wide range of operating conditions. The experimental activity conducted confirms the suitability of the DIP expander to exploit as much as possible the thermal power available from a hot source even when at variable temperatures during operation. Full article

Solid Oxide Fuel Cells (SOFCs) are emerging as a leading solution in sustainable power generation, boasting high power-to-energy density and minimal emissions. With efficiencies potentially exceeding 60% for electricity generation alone and up to 85% when in cogeneration applications, SOFCs significantly outperform traditional combustion-based technologies, which typically achieve efficiencies of around 35–40%. Operating effectively at elevated temperatures (600 °C to 1000 °C), SOFCs not only offer superior efficiency but also generate high-grade waste heat, making them ideal for cogeneration applications. However, these high operational temperatures pose significant thermal management challenges, necessitating innovative solutions to maintain system stability and longevity. This review aims to address these challenges by offering an exhaustive analysis of the latest advancements in SOFC thermal management. We begin by contextualizing the significance of thermal management in SOFC performance, focusing on its role in enhancing operational stability and minimizing thermal stresses. The core of this review delves into various thermal management subsystems such as afterburners, heat exchangers, and advanced thermal regulation strategies. A comprehensive examination of the recent literature is presented, highlighting innovations in subsystem design, fuel management, flow channel configuration, heat pipe integration, and efficient waste heat recovery techniques. In conclusion, we provide a forward-looking perspective on the state of research in SOFC thermal management, identifying potential avenues for future advancements and their implications for the broader field of sustainable energy technologies. Full article

Grade 91 steel is widely used in the boilers and piping of thermal power plants. There has been significant research interest in understanding the variations in creep characteristics among different heats of this steel for effective plant management. In recent years, thermal power plants have been subjected to frequent load changes and startup/shutdown to adjust power supply and demand and stabilize frequencies. These operational shifts have raised concerns regarding the potential for creep-fatigue damage in high-temperature components. Therefore, this research focuses on creep-fatigue properties of Grade 91 steel and their predictability. Tensile, creep, strain-controlled fatigue, and strain-controlled creep-fatigue tests were performed on six Grade 91 steels with different heats and/or histories, and the characteristics in each test were compared. As a result, the variations in creep-fatigue life among the materials were found to be correlated with the difference in creep characteristics and stress level during stress relaxation. Furthermore, the study involved a comparative assessment of the predictive performance of creep-fatigue life using five different approaches: time fraction, classical ductility exhaustion, modified ductility exhaustion, energy-based, and hybrid approaches. Among these approaches, the hybrid approach, based on inelastic strain energy density at fracture formulated as a function of inelastic strain rate, exhibited the most accurate predictive performance. Full article