1. Powering a VW Golf With A Hydrogen-Gasoline Bi-Fuel
Omri Flaisher, Weitai Hu, Grant Raymond
Worcester Polytechnic Institute – October 16th, 2013
Project Goals
Candidate Solutions
Design Analysis Results
Conclusions
References
Challenges
Gate Valve
Side Front
Rotary Valve
Side Front
*Hydrogen Thermal Pre-charged
163.3
Inches
30
Inches
*Hydrogen Thermal Pre-charged
**For 180 inch long tube
Calculated Required Wall Thickness
•¼” diameter tubing
•Set yield strength equal to hoop
and longitudinal stress [6]
•Safety factor of 3
Leak Safety Check
•Set flaw size equal to wall
thickness [6]
•Checked fracture toughness for
each material
•Safety factor of 3 applies to flaw
size
Material Analysis
•Each material met safety requirements
•Tubing length of 180 inches used to
determine weight contribution
Fuel Supply Lines
•Dimensions taken from
current gen. Golf
• Used dimensions to
determine length of tubing
•(approximated in blue)
Hydrogen Operation Gasoline Operation
Emissions (g/km CO2) 0 299
Horse Power 107 206
Torque (ft*lb) 103 163
Driving Range (miles) 61 341
•JBK-75 Steel was selected for the hydrogen fuel lines, due to
its known hydrogen compatibility, moderate price and weight.
• JBK-75 Steel does not require additional coatings or special
treatment.
•Determine the feasibility of converting the Volkswagen
Golf to run on a hydrogen/gasoline bi-fuel.
•Outline a hydrogen delivery system to be used on the
Volkswagen Golf.
•Analysis fuel injection and supply line components
extensively.
•Hydrogen embrittlement can adversely effect many
metals, causing them to become brittle and fracture after
hydrogen exposure.
•Depending on hydrogen state, vast temperature and
pressure gradients occur.
Hydrogen Gas
• Minimal temperature
extremes compared to
liquid.
•Does not require
atomization.
Port injection [4]
•Injects the hydrogen gas
into air intake manifold.
•Less risk of knock.
•Combusts more
predictably.
Gate Valves
•Less susceptible to
thermal expansion sealing
issues.
•Withstands stresses
caused by pressure forces.
•Lacks even pressure
distribution during
throttling like rotary valve.
Machining
Turning: Use Carbide Tooling and water base coolant
Drilling: High speed steel drills
Milling: Rigid Machines and Fixtures are essential
Grinding: Aluminum Oxide Grinding Wheels
*Readily machined by standard methods [5].
•Converting the VW Golf is a plausible challenge. Based on
performance specifications of other hydrogen bi-fuel vehicles,
the technology reduces emissions at the cost of available
engine power.
•Hydrogen fuel poses great potential in terms of sustainability
and availability. Ideally, the most efficient use of hydrogen for
power is through fuel cells but our focus is an important
intermediate step in hydrogen advancements.
•To further advance the study, we would recommend to
scope the effects of fatigue in long term cycles.
•Expected VW Golf performance is based on performance
specifications of the Mazda RX-8 Hydrogen RE [2][3] running
on a 5076 psi hydrogen supply and standard gasoline tank
pressure (psi) Safety Factor
5076 3
Material Yield Stress (ksi)
Min. Fracture Toughness
(psi in
0.5
)
Actual Fracture
Toughness (psi in
0.5
)
JBK-75 Steel* 30 4465 70075
Stainless Steel 24.7 12153 56400
High Carbon Steel 58 6208 24600
Nickel Chromium Alloy 52.9 5929 72800
Copper 43.5 5376 27300
Cost Analysis
•Price per pound used to determine cost
of piping
[1] United States. Sandia National Laboratories and B.P. Somerday. Livermore, California.Technical
Reference on Hydrogen Compatibility of Materials. By San C. Marchi. N.p., n.d. Web. 14 Oct. 2013.
<http://www.sandia.gov/matlsTechRef/chapters/1100TechRef_FeCMn.pdf>.
[2] Wakayama, Norihira, Kenji Morimoto, Akihiro Kashiwagi, and Tomoaki Saito. Development of
Hydrogen Rotary Engine Vehicle. Mazda Motor Corporation, June 2006. Web. 14 Oct. 2013.
<http://www.cder.dz/A2H2/Medias/Download/Proc%20PDF/PARALLEL%20SESSIONS/%5BS22%5D%
20Internal%20Combustion%20Engines/13-06-06/169.pdf>.
[3] Bickerstaffe, Simon. "Mazda RX-8 Hydrogen RE." Automotive Engineer 34.10 (2009):
31. ProQuest. Web. 14 Oct. 2013.
[4] Sebastian Verhelst, Thomas Wallner, Hydrogen-fueled internal combustion engines, Progress in
Energy and Combustion Science, Volume 35, Issue 6, December 2009, Pages 490-527, ISSN 0360-
1285, http://dx.doi.org/10.1016/j.pecs.2009.08.001.
(http://www.sciencedirect.com/science/article/pii/S0360128509000422)
[5] "A-286 Super Alloy Material Property Data Sheet - Product Availability and Request a Quote." A-
286 Super Alloy Material Property Data Sheet - Product Availability and Request a Quote. N.p., n.d.
Web. 14 Oct. 2013. <http://www.suppliersonline.com/propertypages/A-286.asp>.
[6] Hibbeler, R. C. Mechanics of Materials. Boston: Prentice Hall, 2011. Print.
Material Thickness Req'd (inches) Weight (lbs) Price (USD)
JBK-75 Steel* 0.0635 0.101 0.30
Stainless Steel 0.0771 0.123 0.35
High Carbon Steel 0.0328 0.052 0.01
Nickel Chromium Alloy 0.0360 0.057 0.70
Copper 0.0438 0.070 0.31