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.

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

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

Professor Jostins' research has produced dual electric/hydrogen-powered vehicles to address urban pollution. The research has delivered impact by pushing the boundaries of alternative fuels design and technology, by supporting the economic prosperity of the automotive industry and its supply chain and by influencing policy makers to invest in hydrogen. From a quarter scale model in 1998, it and subsequent iterations have had significant impact. Highlights include deployment of the UK's first hydrogen vehicle fleet in 2009, nomination for the Condé Nast Award: Innovation & Design in 2012 and the invitation to join the SWARM project (a demonstration of small four- wheeled fuel cell vehicles, http://swarm-project.eu/home.html) as a pan-European hybrid vehicle demonstrator, 2012. Beneficiaries include Horizon Fuel Cell, Westfield and Lotus (new products developed), and the South African and Scottish Governments (hydrogen economy developed).

Summary of the impact

University of Huddersfield research into engine technologies has resulted in a major new partnership with the UK arm of engineering multinational BorgWarner, leading to the company increasing R&D capabilities in the UK. This collaboration, funded partly by parent company BorgWarner US and partly by the government's Regional Growth Fund, involves multi-million-pound investment, as well as significant job creation and safeguarding. It was a key factor in the company securing a substantial contract with Jaguar Land Rover, whose decision was informed by the University's capacity to help BorgWarner further its R&D activities and upskill its workforce for the benefit of the UK automotive supply chain and the local and national economy.

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

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

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

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

Reducing vehicle noise and vibration is a key quality objective in the automotive industry. Historically, the approach has been costly palliation late in the manufacturing process; now a new approach applied earlier in the vehicle development cycle has been devised by Loughborough University and Ford and implemented at Ford that has led to savings of $7 per vehicle with respect to clutch in-cycle vibration (whoop). Ford has reported savings of $10M over 5 years, whilst reductions in transmission rattle have led to 5% fuel efficiency gains [5.1]. Ford has made an investment of £240M in its engine and transmission work at Bridgend, which includes aspects of work reported here and has created 600 new jobs [5.2].