Summary of the impact

The HOTFIRE collaborative research project (2004-2008) into advanced engine combustion systems led directly to a new, high specific power output, high fuel economy, low CO₂ emissions turbocharged `down-sized' three-cylinder engine that was demonstrated in the Opel Astra car in 2008. The valuable new knowledge, understanding and techniques gained in the HOTFIRE project has directly contributed to the successful delivery of a major engine family project for an ASEAN region OEM client of Lotus Engineering.

Summary of the impact

Impact on the environment

• The adoption of cost effective CO₂ reduction technologies across a range of Ford vehicles reduced CO₂ emissions by an estimated 40,000 tonnes in 2012. This reduction applies pro rata for 2013 and becomes cumulative year on year.

Economic impact

• Improvements to vehicle engines have saved over €25M in fuel costs to the owners of Ford vehicles in 2012.
• Research has led to improvements that have been made to Ford products and processes; these improvements have been used to address upcoming legislation on CO₂ in a cost effective manner. Future penalties of up to €0.5bn have been avoided by these improved products and processes.

Impact on practitioners

• Improved monitoring processes, reducing variability in measurement of CO₂ from vehicles within Ford by 50%, facilitating the adoption of a range of new fuel saving technologies, which helped to justify a $50M investment in the Ford UK facilities.

Summary of the impact

Loughborough University's (LU) research collaboration with The Hardstaff Group has resulted in a commercial Oil-Ignition-Gas-Injection system (OIGI®), which substitutes natural gas for Diesel oil in heavy goods vehicles. Using optical diagnostics OIGI® was redesigned, increasing average substitution rates from 45% to 60%. The economic impact for Hardstaff was a fuel saving of £406k per annum. The research allowed Hardstaff to create new business with Mercedes-Benz in the UK and Volvo in Sweden. OIGI® reduces CO₂ by up to 15%, harmful nitrogen oxides and particulate emissions by 30%. The research also demonstrated, for the first time, dual fuel technology in small, high-speed diesel engines, paving the way for its application in passenger cars.

Summary of the impact

Research in Proton Exchange Membrane Fuel Cells at Loughborough University (LU) has led to commercial and innovative impacts on a global scale which have included the development of the world's first purpose-built hydrogen fuel cell motorbike, the world's first manned fuel cell aircraft and a zero emission fuel cell hybrid London taxi, with major international companies, such as Suzuki, Boeing and Lotus. These developments have arisen due to the creation of the spin out company Intelligent Energy (IE). The company currently employs some 350 personnel, has a total shareholder investment over £100M and was valued at $0.5B in 2012.

Summary of the impact

The University of Manchester and Delphi Diesel Systems jointly developed a reverse tapered micro-hole drilling technique, which has resulted in wide commercial applications for the manufacture of fuel injection nozzles in diesel engines and is used by Volkswagen, Ford and Renault in passenger cars and trucks. The technique has resulted in 1.5% fuel saving, 35-40% reduction in particulate matter emission, 20% reduction in NOx emission, 3% reduction in CO₂ emission, and allows diesel engines to satisfy the new EU emission legislation Euro 5 in 2008/2009. Delphi's diesel engine component business increased by €0.8 billion/year as a result of the new fuel injection technology.

Summary of the impact

Improved measurement of fuel behaviour in automotive engines has contributed to the success of the AJ133 V8 engine, which powers over [text removed for publication] vehicles sold since 2009. The research, carried out at the University of Oxford in collaboration with Jaguar Land Rover (JLR), developed techniques to improve the understanding of combustion dynamics in engines and consequently enabled improvements to fuel consumption, emissions and engine reliability. Impacts include contributions to (1) JLR's improved engine design process and (2) improved fuel efficiency and thus lower emissions.

Summary of the impact

Instrumentation technologies developed at Kent, in particular pulverised fuel flow metering, on-line particle sizing, on-line fuel tracking and burner flame imaging, have enabled combustion engineers to diagnose large-scale complex combustion processes and optimize the operation of coal, biomass and heavy-oil fired power plants. The technologies operate on novel sensing and advanced measurement principles and have produced real-time measurement and plant condition monitoring data that were previously unavailable. Instrumentation systems operating on the technologies have been applied successfully to a range of pilot plants and on full-scale power plants in countries including the UK, France, China and Saudi Arabia. Work has enabled the power industry to produce electricity safely while minimising environmental impact and employing a diverse range of fuels. The instrumentation technology informed the conversion of Drax power station from 100% coal firing to biomass/coal co-firing during 2011/2012 as it sought to halve its carbon footprint within five years. The technology sourced and informed the alleviation of significant vibration problems within a heavy-oil fired power plant in Saudi Arabia.

Summary of the impact

Experimental research and computer modelling in the School of Mechanical Engineering have been applied by engine and oil companies to reduce fuel consumption and noxious emissions. Studies into high pressure explosions and burn rates have helped industry improve engine efficiencies by up to 30% and contributed to the development of much improved fuels. These new products perform better, are less environmentally damaging and have generated new company revenues. Research into burn rates, detonations, and large jet-flames has also informed health and safety investigations, particularly the UK Government Inquiry into the Buncefield explosion, providing calculations and explanations of the blast, and recommendations on future safety controls.

Summary of the impact

Surface wear in moving components can endanger human lives and costs the UK economy £24 billion every year. Excellent research in this area — known as Tribology — at the University of Southampton (UoS) led to the foundation of the national Centre of Advanced Tribology (nCATS), which collaborates with over 100 companies and institutions in many sectors. Examples of nCATS impact include research findings forming an integral part of a BNFL/Sellafield Ltd's design guide for the prevention of radioactive slurry leakage. It also enhanced GE Aviation's competitive advantage by supplying novel electrostatic wear debris sensors (the only system in use), which have been integrated into new fighter aircraft engines.

Summary of the impact

Electrochemistry research in the Department of Chemistry (and associated research in Aeronautical and Automotive Engineering) at Loughborough University (LU) since 1993 has led directly to the development of a new generation of clean power systems based on advanced fuel cell technology. This resulted in the creation of a spinout company based on a license awarded by LU: Advanced Power Sources Limited (APS) in 1995. Intelligent Energy (IE) Limited (founded in 2001 upon the acquisition of APS), has a global presence: a workforce of over 350 highly skilled employees, significantly advanced technology, and investment in R&D. Environment improvements have been achieved through introduction of zero-emission fuel cell systems.