Use of waste hydrogen for energy purposes

Authors: Marek Brzezanski, Michal Mareczek, Tadeusz Papuga, Marcin Noga

The aim of the project was to use flammable waste gases from the chemical industry for energy purposes. Previously, this type of post-production waste was burned on so-called torches, which caused a burden on the environment and was associated with energy losses and additional environmental fees for the industrial unit. The team from the Krakow University of Technology developed piston combustion engines adapted to be powered by waste gases from the technological line for the production of artificial fertilizers. These were various types of gases with a variable chemical composition, which contain a large share of hydrogen, ranging from 50 to 90% by volume, and the rest was mainly nitrogen, carbon monoxide and various types of hydrocarbons. The project also developed a system that allows for additional powering of combustion engines with waste, flammable liquid fractions (mainly alcohol fractions), which were created as a result of the condensation of waste gases.

The result of the research and development work was the development and implementation of an innovative control system and a unique engine power supply system, which allow for simultaneous supply with waste fuels of variable chemical composition, occurring in the liquid and gas phase. As part of this project, an innovative system for continuous control and supervision of the engine power injection supply system and ignition system was created, which was developed in the LabView program. A characteristic feature of the developed system is the ability to automatically adjust the engine control parameters (ignition advance angle and excess air coefficient) to changes in fuel parameters and changes in engine load.

This unique, adaptive engine operation supervision system also allowed for ongoing interference in the engine control system settings, carried out remotely via the Internet from the control panel located outside the place where the engines were installed. The project, which was successfully implemented in the years 2012 – 2018 in chemical plants, included the implementation of the above systems for three engines (2x 12-cylinder engines, 1x 6-cylinder engine), used in generators with a total electrical power of approx. 1 MW. Currently, none of the European and global manufacturers and suppliers of so-called gas generators offers on the market a similar installation using waste gases of variable chemical composition, originating from the technological line of chemical plants, for energy purposes.

For the most important part of the project, developed at the Krakow University of Technology, patent No. 222462 was received for the invention titled “Method of controlling regulatory parameters in a spark-ignition internal combustion engine”.

Thanks to the experience gained in this project, since 2020, a project to adapt a modern industrial engine to be powered by pure hydrogen or hydrogen-natural gas mixtures has been implemented at the Cracow University of Technology. For this purpose, a system for burning this type of fuel and a modern power supply system operating in adaptive mode were developed. In addition, new safety systems for powering piston combustion engines have been used, protecting the system against flame flashback. Preliminary results indicate a high implementation potential of the project.