About one-third of the energy in a car's fuel tank is converted into usable power. Can this efficiency be improved? On the 15th, during the "International Symposium on Transformation and Upgrading of Traditional Fuel Vehicle Power Technologies" held at the China Science and Technology Hall, experts from around the world shared their insights, stating that achieving an engine thermal efficiency of 50% is now within reach. Minister of Science and Technology Wan Gang participated in in-depth discussions with these experts, highlighting the potential for future advancements.
Currently, the thermal efficiency of gasoline engines ranges between 25% and 35%, while diesel engines perform slightly better, typically reaching up to 40%. Over the past two decades, the highest recorded efficiency for mass-produced gasoline engines has increased by just 3 percentage points. However, despite this slow progress, many experts remain optimistic about the future of internal combustion engine technology.
"At the symposium, Su Wanhua, an academician of the Chinese Academy of Engineering and an expert in internal combustion engines, emphasized that new technologies are continuously emerging and will play a crucial role for years to come. Major engine manufacturers worldwide are investing heavily in advanced combustion techniques, intelligent control systems, small turbochargers, and other innovations aimed at reducing energy losses. There is a wealth of technical knowledge and research already in place."
The theoretical maximum thermal efficiency of internal combustion engines is estimated to be around 60%, with larger engines generally being more efficient. For comparison, power plant steam turbines have achieved over 50% efficiency, and cars are expected to approach similar levels in the near future.
Stephen Pissinger, CEO of FEV Engines in Germany, noted that German internal combustion engines have seen their thermal efficiency increase from 39% to 50% in recent years. He also predicted that exhaust gas recirculation technology will become increasingly common in the future.
Helmert Liszt, CEO of Austrian AVL, added that the global competition in internal combustion engine development is fierce, with the ultimate goal of achieving carbon neutrality. AVL has already reached 50% thermal efficiency on a truck engine supported by the U.S. Department of Energy and plans to push even further.
Su Wanhua also mentioned that his team at the University of Wisconsin has achieved a thermal efficiency of 54% using mixed fuels, with some experiments reaching as high as 57%. His lab has also developed a method to burn naphtha—a raw material used in gasoline refining—which could reduce refining costs significantly.
Wu Zhixin, deputy director of the China Automotive Technology and Research Center, pointed out that while the theoretical maximum efficiency of an engine is 50%, real-world driving conditions often fall short. To bridge this gap, electric systems can help optimize the performance of internal combustion engines. Additionally, different countries may require tailored technological approaches based on local road conditions and infrastructure.
Minister Wan Gang emphasized that China will focus its R&D efforts on high-intensity machine technology, advanced combustion methods, low-module components, and waste heat recovery systems. He also highlighted the potential of fuel cells as a complementary solution to improve engine efficiency.
Liszt noted that around 150 experts globally are working on fuel cell technology. Pissinger predicted that by 2025, the cost of vehicles equipped with both lithium batteries and fuel cells will be approximately 7,400 euros higher than that of a typical electric vehicle.
Nissan’s vice president, Takashi Kameyama, revealed that the company is integrating electric motors with internal combustion engines. By 2020, the internal combustion engine will serve as a generator in Nissan’s power platform.
Qin Yong, director of the High-tech Department at the Ministry of Science and Technology, announced that hydrogen fuel cells will be a key focus in the transformation of automotive power systems. The government aims to build a fuel cell base capable of producing 100,000 units by 2022, with the goal of deploying a million-stage fuel cell engine. The total R&D investment is expected to exceed 5 billion yuan, with thousands of fuel cell-powered vehicles planned for widespread use.
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