Precision Combustion has created a range of novel technologies to benefit reciprocating internal combustion (IC) engine applications. In addition, we are developing solid oxide fuel cell (SOFC) based power generation systems to support hybrid automotive applications. In today’s environmentally focused world, engine manufacturers and automotive OEMs are continuously developing products that are more efficient, perform better, and create fewer emissions. PCI is helping manufacturers reach their goals with four unique categories of products.
Fuel Reformers
It is known that mixing hydrogen into the fuel stream of a hydrocarbon fueled IC engine improves fuel economy, increases power output, and reduces emissions. PCI’s extremely compact fuel reformers enable manufacturers to create hydrogen on-demand from onboard fuels for direct injection into engines. This process enhances performance while avoiding dangerous hydrogen storage given that hydrogen is only produced as needed. The technology has been developed and tested under DOE, DoW and commercial programs. The technology is scalable and has been tested with engines as small as “weed-whacker” and motorcycle engines up through 2 liter automotive engines. To learn more about our enabling reactor technology visit our Internal Combustion Engine Augmentation page.
In engine testing, on-board reformate (H2 rich syngas) has demonstrated lower brake-specific NOx and HC (up to ~50%) and CO (up to ~40%), shorter ignition delay enabling ~7-16° additional spark advance (SI), improved dilution tolerance (combined internal + external dilution up to ~77%), reduced COV of IMEP (up to ~75%), and observed BSFC improvements with fast light-off and compact packaging suited for mobile platforms.
SOFC Systems for Mobility Applications
PCI is developing ultra-compact, Microlith® reformer–enabled fuel cell systems for ground mobility applications. These systems use logistics fuels such as diesel and are designed for auxiliary power units (APUs) for ground vehicles, unmanned ground vehicles, and electric-vehicle range extension.
Fuel Processors for Mobility Fuel Cell Applications
PCI builds logistics-fuel SOFC fuel processors and integration packages sized from man-portable/1–2 kWe up to APU-class (10–20 kWe), with sulfur cleanup to <1 ppm and fast start/transient response—enabling quiet, efficient power generation for vehicles, off-road equipment, and defense platforms. Our fuel processors support diesel, JP-8/JP-5, Jet-A, gasoline, natural gas, propane, methanol/ethanol, and other conventional and future fuels. For HTPEM fuel cells, a PCI WGS reactor can be added for stack-quality reformate.
Related Future Fuels R&D
In parallel, PCI is advancing a unique hybrid fuel-cell/battery architecture under ARPA-E’s EMPoWEr program. The concept uses an electrochemical wafer fueled by liquid hydrogen coupled with a high-power lithium-ion battery to enable high energy and peak-power operation. While the project is primarily targeted at aviation, shipping, and rail, it also considers defense vehicles and unmanned ground vehicles, as well as substitute for PEM fuel cells in automotive platforms and helps inform PCI’s longer-term work on carbon-free, high-energy fuels for mobility.
Advanced Cetane Number Analyzer
PCI has developed a highly innovative advanced fuel quality analyzer for quickly and accurately measuring the cetane number (CN) of diesel, jet fuels, and bio-diesels. The analyzer performs a direct analysis of the fuel to provide an accurate measurement of the cetane number – as compared to inferring the CN with a cetane index methodology. The device is lightweight and portable, requires only microliters of sample, and delivers a result in less than one minute with low power and simple operation. The technology may be used to measure cetane number of fuel to help provide a recommendation of the need to add cetane booster or when integrated with an engine controller, may allow for advanced operating regimes to be employed to improve performance.
Catalytic Glow Plugs
Proven to significantly improve cold start capabilities in compression engines, our catalytic glow plugs are ideally suited for compression ignition engines where weight, size, and operability are primary concerns. The compact design of our catalytic glow plugs lowers the required temperature for ignition, decreases cranking time before engine start, and reduces electrical power requirements for ignition systems. A new application is focused on UAV engines where ignition and performance is enhanced in cold climates or at high altitude.
Catalytic Converters
Ultra-compact and catalyst cost-effective, PCI’s catalytic converters achieve significantly greater conversion effectiveness per unit size of material compared to conventional long channel monolith designs and can provide up to a 20-fold reduction in volume and weight. Our catalytic converters have extremely fast light off times, making them ideal for eliminating cold start emissions and have been demonstrated to exceed the Ultra Low Emission Vehicle standards (ULEV) (SAE Technical Paper # 971023).
Contact PCI to learn more about how our solutions may be adapted for your needs.
