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

Two related research activities 1) on low NOx burners and 2) on co-firing of biomass have led to combined economic savings estimated to be in the region £40M-£70Mpa.

The fitting of low NOx burners to power station boilers reduced the NOx emissions but resulted in a reduced amount of saleable bottom slag and a finer pulverised fuel ash (pfa), which placed an increased load on the electrostatic precipitators. Additions of pfa to the power station coals were found to increase the overall combustion efficiency, while at the same time providing an increased amount of a saleable boiler slag and a pfa that could be used as a cement replacement material.

Despite the very different nature of the ashes produced from the combustion of biomass and coals, a detailed characterisation of the residues demonstrated that, with an appropriate choice of both biomass type and coal, a successful co-firing at up to 50% of coal replacement with biomass was possible. Co-combustion with increased levels of coal replacement has produced significant reductions in power station emissions, resulting in both environmental and economic benefits.

Summary of the impact

Coal fired power stations will be a major element of global power generation for the foreseeable future. Measurement, and hence control, of pulverised fuel flow is a vital technology for the efficient and green operation of coal fired power stations. Balancing fuel delivery and combustion stoichiometry increases boiler efficiency and reduces emissions. Research in this area carried out at Teesside University was adopted by ABB Ltd and led to the commercial development of new powder flow measurement systems (PfMaster technology) installed in power stations around the world. Quantifiable economic benefits of the installations to date amount to >£3.4 M with concomitant environmental benefits of significant reduction in CO₂ and NO_xemissions and solid waste disposal burdens.

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

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

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

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

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.