Home > Research Projects
With a growing portfolio of projects, FLEET research continues to expand its focus in several key areas. Currently, projects are centered on technological advancements in hydrogen engines, high-efficiency clean-fuel engines, advanced lubricants, and low-emission maritime systems. Each project has a one-year turnaround time.
Inverted and Closed Joule Cycle for Waste Heat Recovery in Marine Engines
Objective
To identify and evaluate the most efficient Joule or Ericsson cycle configurations for recovering waste heat from marine engine exhaust gases, improving overall system efficiency and supporting decarbonization goals.
Key Outcomes
- Analyzed multiple waste heat recovery (WHR) cycle designs, including Inverted Joule Cycle, Closed Joule Cycle (CJC), CJC with heat recuperation, and two-stage CJC approximating an Ericsson Cycle.
- Evaluated various working fluids (air, argon, carbon dioxide) for closed-cycle applications.
- Conducted sensitivity studies on exhaust gas temperature, pressure ratios, and component sizing to understand their impact on efficiency.
- Developed detailed system models incorporating component efficiency maps to estimate realistic performance gains.
- Found that complex cycles can theoretically achieve efficiencies of up to 40% with high exhaust gas temperatures (around 600°C).
- Prepared for experimental validation of the most promising cycle configuration.
Spray and Combustion Modeling: Marine
Objective
To develop a robust spray model capable of reproducing cavitation effects under a Lagrangian framework, enabling more accurate simulation of fuel spray dynamics in large-bore marine engines.
Key Outcomes
- Conducted cavitation studies using the Eulerian approach to evaluate nozzle design parameters and injection conditions.
- Extracted detailed spray data from Eulerian simulations to inform model development.
- Developed a correlation model to account for cavitation effects and integrated it into a Lagrangian spray framework.
- Improved prediction accuracy of spray dynamics under high-pressure, supercritical engine conditions.
Minimizing Climate Impact of Saudi Arabian Port Routes and “Grid-to-Propeller” Solutions
Objective
To enhance sustainability in shipping by optimizing port routes, reducing emissions through alternative fuels, and exploring “grid to propeller” solutions for renewable port fuel production and use.
Key Outcomes
- Route optimization achieved up to 5% fuel savings per trip.
- Feasibility of e-methanol production and onshore power demonstrated at Yanbu port.
- Switching to alternative fuels reduced overall carbon emissions.
Techno-Economic Study of Hydrogen-Powered Cruise and Cargo Ships
Objective
To evaluate the techno-economic feasibility of hydrogen-based fuels (methanol, ammonia, MCH, and LH₂) for cruise and cargo ship propulsion systems in Saudi Arabia.
Key Outcomes
- Identified ICE-methanol as the most feasible propulsion system for cruise and cargo ships.
- Demonstrated that ICE-methanol provides a balanced trade-off between cost, maturity, and environmental impact.
Bridging the Gap to Zero Emission / Aftertreatment
Objective
To integrate advanced aftertreatment systems (DOC, DPF, SCR) onto a diesel generator in the 100–200 kW range, targeting significant reductions in CO, HC, NOx, and PM emissions, while aligning with EPA Tier 4 Final / Stage V standards and the Kingdom of Saudi Arabia’s future emissions framework.
Shockwave-Assisted Ballast Water Treatment System
Objective
To develop and optimize a shockwave-assisted treatment method for ballast water that overcomes the limitations of conventional techniques (filtration, UV, electrochlorination, ozonation). The project aims to use short-duration high-pressure waves to physically disrupt aquatic organisms, disinfect water, and degrade contaminants without producing harmful by-products or allowing microbial regrowth. The approach will be tested experimentally and via simulations to refine shockwave parameters, with the goal of achieving a scalable, energy-efficient, and regulation-compliant solution for the shipping industry.
Onboard Carbon Capture for Marine Vessels
Objective
To validate and optimize a shipboard carbon capture system that uses alkaline reagents and seawater to absorb CO₂, eliminating the need for onboard carbon storage while reducing energy and space requirements. The project will focus on lab-scale validation and advance toward a pilot-scale demonstration. Key investigations include seawater intake temperature, exhaust gas composition, reagent concentration, and mixing efficiency, alongside testing alternative low-cost reagents. A critical component is evaluating the environmental impact of discharging CO₂-enriched seawater. The end goal is to demonstrate the system at KAUST on a 100 kWe generator, providing proof-of-concept for scalable carbon capture on marine vessels.
Lowering Carbon Footprint of Marine Transport
Objective
To reduce the carbon footprint of maritime transport through the integration of alternative fuels, advanced propulsion technologies, and operational efficiency measures. The project focuses on hydrogen-powered vessel design, e-Diesel production facility development, and testing Proton Exchange Membrane Fuel Cells (PEM-FC) under real marine conditions, with specific attention to Saudi Arabia’s environmental factors such as temperature and humidity. It also emphasizes route optimization using high-resolution forecasting of wind, wave, and current data to improve energy efficiency. Additionally, it explores innovative shore power solutions in Saudi Arabia to reduce emissions from vessels at berth. By combining alternative fuels, fuel cell technology, and smart navigation systems, the initiative aims to enable more sustainable and climate-aligned marine transportation.
MtG, EtG and Their Blends: Fuels
Objective
To study the ignition behavior of renewable-derived gasolines (MtG and EtG) and their blends with petroleum and renewable additives, to develop simple, reliable fuel surrogates and improve KAUST’s gasoline kinetics model.
Key Outcomes
- Measured ignition delay times for neat renewable-derived gasoline fuels.
- Studied reactivity of improved MtG 35A blends with both renewable and petroleum octane enhancers.
- Proposed and validated fuel surrogates for MtG, EtG, and MtG A35 blends.
- Enhanced the KAUST kinetic gasoline surrogate model.
- Conducted experiments across a wide temperature and pressure range using high-pressure shock tube and rapid compression machine facilities.
Life Cycle Assessment of PEM Fuel Cell Vehicles Using Grey and Blue Hydrogen in Saudi Arabia
Objective
To evaluate the life-cycle greenhouse gas emissions and environmental impacts of proton-exchange membrane (PEM) fuel cell vehicles powered by grey and blue hydrogen in Saudi Arabia, using heavy-duty buses in the Makkah region as a case study. Results will be compared with diesel and battery electric vehicles operating under similar conditions.
Key Outcomes
- Conducted a cradle-to-grave environmental impact assessment following ISO 14040 and 14044 LCA standards.
- Used the GREET Model to quantify energy use and emissions for fuel production, transportation, vehicle manufacturing, operation, and disposal.
- Incorporated Saudi-specific data from FLEET members (including Aramco, Hyundai, Toyota, and SAPTCO) and adapted GREET datasets where necessary.
- Identified that total emissions are distributed differently between vehicle types:
- ICEVs: majority of emissions from the usage stage.
- BEVs: high emissions from vehicle production; usage phase highly dependent on the carbon intensity of the electricity grid.
- PEM FCVs: near-zero emissions in the usage phase, but significant upstream emissions from hydrogen production and transport.
- Determined that blue hydrogen is expected to deliver lower life-cycle emissions than grey hydrogen due to carbon capture, though performance depends on CCS efficiency.
- Highlighted that the shift in Saudi power generation from oil to natural gas and renewables will influence future BEV and PEM FCV results.
MtG Refinery: Fuels
Objective
To evaluate the technical and economic feasibility of producing gasoline from green methanol (MTG) using repurposed conventional refinery equipment, with focus on applicability in Europe.
Key Outcomes
- Developed refinery process simulations for MTG using Aspen Plus, Aspen PIMS, and HYSYS.
- Constructed and validated a surrogate-based MTG kinetic model with existing experimental data.
- Assessed compatibility of MTG process conditions (temperature, pressure, catalyst, materials) with conventional refinery infrastructure.
- Demonstrated proof-of-concept for integrating MTG in conventional refineries and analysed economic feasibility in the European context.
- Initiated patent draft for a novel non-catalytic MTG process.
1-D Fuel Cell Modeling: PEMFC
Objective
To develop a 1-D model of a hydrogen-powered Proton Exchange Membrane Fuel Cell (PEMFC) for low-temperature operation (up to 120 °C), enabling analysis of performance under varying operating conditions and the influence of impurities.
Key Outcomes
- Developed a COMSOL-based 1-D PEMFC model to study the impact of temperature, pressure, relative humidity, catalyst loading, and gas diffusion layer morphology.
- Conducted parametric studies using polarization curves to evaluate performance trends under varying conditions.
- Modeled the effects of hydrogen contaminants (e.g., toluene traces from methyl cyclohexane carriers) and metal cation impurities on catalyst activity and membrane ionic conductivity.
- Established a framework to predict PEMFC voltage, current response, and degradation under realistic fuel quality scenarios.
2-Stroke HCCI Engine with Variable Compression Ratio for Improved Efficiency and Fuel Flexibility
Objective
To assess the viability of a novel 2-stroke HCCI engine capable of operating on multiple fuels with high indicated efficiency and low emissions, without requiring hardware modifications between fuels.
Key Outcomes
- Evaluated engine performance and emissions across different fuels using CFD simulations.
- Prepared for subsequent validation through experimental test cell activities.
- Identified suitability of the engine concept for range extender applications due to high power density and lightness.
Development of Predictive Models for Hydrogen Combustion in Spark-Ignition Engines
Objective
To evaluate and improve hydrogen combustion mechanisms and models for spark-ignition engines, with a focus on incorporating diffusive-thermal instability effects and applying the models to Ferrari engine simulations.
Key Outcomes
- Evaluated fifteen detailed H₂ combustion mechanisms and optimized them using in-house codes.
- Incorporated diffusive-thermal instability effects for accurate H₂ flame speed predictions under lean conditions.
- Achieved significant improvements in modeling H₂ PFI-SI, DISI, and TJI engine combustion.
Publications
- Evaluation of H₂ combustion mechanisms at high-pressure and lean combustion modeling.
- A Computational Study of H₂ Mixing and Combustion in a High-Speed DISI Engine.
- A Computational Study of H₂ Mixing and Combustion in a High-Speed DI TJI Engine.
- Numerical Analysis of the Combustion Process in a Hydrogen-Fueled Pre-Chamber Combustion Engine
e-Gasoline Combustion Characteristics and Plant Optimization
Objective
To support the integration of e-gasoline (MtGs) into transportation systems by studying its combustion properties and optimizing its production via the methanol-to-gasoline (MtG) process.
Key Outcomes
- Measured ignition delay times (IDT) and laminar flame speeds (LFS) using a shock tube and rapid compression machine (RCM).
- Optimized the methanol-to-gasoline (MtG) production process using Aspen Plus simulations.
- Conducted a comparative reactivity analysis of various MtG fuels.
- Determined that, despite chemical composition and RON/MON differences, MtG fuels have similar high-temperature reactivity and laminar flame speeds comparable to established MtG fuels (MTG E0 and MTG E10).
Implementation of a Lambda Leap Control Strategy in High-Specific-Output Hydrogen SI Engines
Objective
To develop and implement a control strategy in a high-performance gasoline engine to enable operation on hydrogen, allowing the engine to switch between different air-to-fuel ratios (λ) to improve efficiency and reduce NOx emissions.
Key Outcomes
- Achieved a significant increase in the high-efficiency operating range of the engine using the λLeap strategy.
- Vehicle simulations demonstrated fuel consumption reductions of more than 5% and engine-out NOx emissions less than half compared to single λ operation.
Hydrogen Combustion Kinetics Under Extreme Conditions
Objective
To reduce uncertainty in predicting hydrogen combustion under engine-relevant conditions, with a focus on laminar burning velocities (LBV).
Key Outcomes
- Conducted comprehensive ignition delay time (IDT) and LBV measurements for hydrogen combustion under extreme conditions.
- Identified that NOx chemistry, thermochemical properties, and transport properties have minimal impact on predictions.
- Developed and improved a chemical kinetic model compatible with high-pressure and high-temperature conditions.
Experiments of PEM Fuel Cells
Objective
To optimize the performance of a 65 kW PEM fuel cell system through experiments and develop simulation and data-driven models at single-cell and stack levels for predictive analysis and design improvement.
Key Outcomes
- Successfully installed and commissioned the 65 kW PEM fuel cell system across multiple power levels.
- Developed machine learning models for single-cell PEM fuel cells to enable accurate predictive modeling.
Simulation and Characterization of Hydrogen Injectors for Heavy-duty Engines
Objective
To develop simplified hydrogen injector geometries and evaluate cap designs for heavy-duty engines, enabling better control of H₂ jet dynamics and mixing performance.
Key Outcomes
- Established relationships between cap design parameters and key macroscopic jet metrics.
- Developed a computationally efficient simplified H₂ injection model accounting for cap-induced flow variations.
Development of Combustion Models for Hydrogen ICE
Objective
To develop advanced combustion models for hydrogen internal combustion engines (pre-chamber and spark-ignition), enabling accurate prediction of combustion behavior and NOx formation across a wide range of operating conditions. The work includes a high-performance computational framework for direct-injection H₂ engines, evaluation of EGR impacts on efficiency and emissions, and integration of physics-based and data-driven control strategies.
Comprehensive Characterization of Hydrogen Pre-Ignition
Objective
To systematically investigate the mechanisms and influencing factors of hydrogen pre-ignition, focusing on lube oil interactions, hot surface ignition, mixture inhomogeneity, and wall quenching effects. The project will combine experimental investigations in controlled combustion vessels with modeling approaches to capture key pre-ignition characteristics under varying conditions, enabling the development of mitigation strategies to improve H₂ICE reliability and efficiency.
e-Fuel Comparative Combustion Analysis
Objective
To evaluate and compare the combustion characteristics of at least two types of e-fuels with distinct manufacturing focuses—one prioritizing production yield and the other ease of combustion. The study will also assess performance with and without ethanol mixtures. Flame propagation dynamics and lean flammability limits of Methanol-to-Gasoline (MTG) blends enhanced with octane boosters (ethanol, triptane, ETBE) will be investigated to determine their effectiveness in improving anti-knock resistance, extending lean limits, and enhancing engine efficiency. Experiments will utilize a constant volume spherical reactor (CVSR), shock tube, and rapid compression machine (RCM) under engine-relevant conditions (600–1400 K, 15–30 bar).
DLC Lubrication with GQDs
Objective
To simulate MoDTC-induced wear on DLC coatings and investigate the mitigation potential of functionalized graphene quantum dots (GQDs), while characterizing the tribofilm and understanding the lubrication mechanism.
Key Outcomes
- GQDs reduced friction and wear compared to MoDTC.
- XPS analysis showed evidence of carbon layer formation on the DLC surface.
Development of a Graphene Ceramic Hybrid Lubricant Additive for Enhanced Friction Reduction and Surface Regeneration
Objective
To develop a graphene-ceramic hybrid lubricant additive that leverages the ultra-low friction properties of graphene and the self-healing characteristics of ceramic nanoparticles (SiO₂, Al₂O₃, ZrO₂) to improve internal combustion engine (ICE) performance. The project will determine the optimal graphene-to-ceramic nanoparticle ratio, evaluate effective dispersion techniques, and assess impacts on friction reduction, wear resistance, oxidative stability, and thermal stability. By enhancing lubricant performance, the initiative aims to improve fuel efficiency, reduce frictional losses, extend engine life, and lower overall carbon emissions in high-load applications. The technology has cross-sector relevance, including marine vessels, automobiles, and stationary generators.
e-Aviation Fuel Production in Saudi Arabia: Techno Economic and Environmental Perspectives
Objective
To assess the feasibility, efficiency, and techno-economic performance of e-Fischer–Tropsch (FT) and Methanol-to-Jet (MtJ) pathways for jet fuel production using renewable hydrogen and captured CO₂, combined with a Well-to-Wake life cycle assessment (LCA) to evaluate environmental impacts.
Key Outcomes
- Evaluated costs and environmental impacts of aviation electro-fuels (e-fuels) as sustainable alternatives to conventional jet fuels.
- Modeled e-fuel production using detailed process simulations in Aspen Plus.
- Analyzed various hydrogen production pathways and carbon capture technologies to determine the most efficient and environmentally viable options.
- Found that MtJ produces lower greenhouse gas (GHG) emissions than FTJ but at higher production cost.
- Determined that transporting CO₂ for production results in lower emissions than transporting hydrogen.
- Both MtJ and FTJ pathways show significantly lower life-cycle GHG emissions compared to conventional aviation fuel in Saudi Arabia.
H₂ Swirled Flames at Aircraft Engine Pressures
Objective
To experimentally validate H₂ gas turbine injector concepts, provide data for realistic numerical simulations of H₂ flames, and improve understanding of pollutant emissions and flame stabilization mechanisms.
Key Outcomes
- Characterized flame stabilization regimes and pollutant emissions (NO, NO₂, N₂O, and H₂) over a wide range of operating conditions.
- Identified mechanisms controlling H₂ release and transitions between flame stabilization regimes.
- Determined operating conditions to achieve low-NOx emissions and prevent unburnt hydrogen above a critical equivalence ratio.
Publications
- Flame stabilization and pollutant emissions from a H /air dual swirl coaxial injector at elevated pressure
- On the bifurcation of flame stabilization of a H$_2$/air dual swirl flame at elevated pressure - (in progress)
- On the mechanisms behind the release of unburnt fuel from swirled partially premixed hydrogen flames at elevated pressure - in progress)
Property Prediction for SAF Blends
Objective
To develop property prediction models for sustainable aviation fuel (SAF) blends, enabling rapid screening, optimization, and accurate kinetic modeling.
Key Outcomes
- Modeled combustion characteristics of SAF, Jet A-1, and hydrogen blends.
- Developed machine learning models using spectra of fuel components.
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