Improved Internal Combustion Engines: Zajac Motors

Teaching the old diesel engine new tricks

Meetings with greentech start-ups are usually cordial affairs.  

Unlike my meeting with Zajac Motors, in which the management team alternately tried to burn and asphyxiate me. 

Zajac Motors had a point to prove.  The firm is developing a wildly efficient and innovative twist on the diesel engine and is using a new insulating material as part of the design.  Mr. John Zajac, founder and CTO of the company, placed a small square of this ceramic material on my palm and proceeded to direct the flame of a 2,000-degrees-Celsius blow torch on the material.  I suffered mild anxiety but no immolation.  It's this material that allows the company's engine to be a "hot wall reactor with ten times the duration for a complete and clean combustion," according to Zajac.

Later on, during a tour of the plant, Zajac's management team locked me in a small room while their modified internal combustion engine (ICE) ran at full speed.  The engine is so efficient at burning fuel that its emissions are minimal and one can't even detect the odor of exhaust.  Luckily, I survived another segment of the interview. 

Here's what I learned from my near-death experience:

With a longer "residence time" and a constant temperature of 1425 degrees C, their split-cycle engine can make carbon fuels "virtually clean."  The engine certainly emits CO2, although only half as much as conventional diesels.  The emissions of CO, NOx, and particulates is negligible due to the high heat in the "green combustion" chamber.

Instead of intake, combustion and exhaust taking place in one location, Zajac performs these separate functions in separate places.  The distinct combustion chamber leads to better efficiency and much better emissions performance.  The secret to making the engine work is in the design of the valves --  the patented Zajec variable timing valves require much less power to operate than conventional valves, which can use up to 10 percent of a conventional engine's horsepower.

The design of this engine allows Zajac to jettison timing chains, mufflers, plugs and catalytic converters.  The new design actually adds eight new components but removes 29 other parts.

The constant temperature of 1425 degrees C and constant pressure of 600 psi make this an engine which is "self-cleaning"  and one in which the valves "can't get dirty." 

According to the firm, the new technology also promises a dramatic increase in fuel efficiency (up to 50 percent more than conventional gas engines) and the ability to change fuels on the fly, without any alterations to the engine or its power rating.  Modifications to the engine are entirely above the cylinder head.




The U.S. diesel engine market is worth $12.7 billion, according to the Fredonia Group.  The first market target for the early stage firm is the substantial off-road engine sector -- construction, oil, mining and marine.  The firm envisions a mix of revenue from sales of valves and chambers, as well as a licensing/royalty stream.  There is the potential to move into on-road vehicles after that.  The worldwide internal combustion engine market represents a $400 billion opportunity.

The Zajac Motors team members are hands-on entrepreneurs with varied backgrounds, albeit with a mildly homicidal mien.  They've raised $3.5 million from angel investors and have a working prototype with which they are currently threatening journalists.  They are in the process of raising their next round.

The team claims that their invention can "establish U.S. leadership in clean ICE technology."  Other start-ups working on internal combustion engines are Achates Power and Transonic Combustion.   

In the words of the Zajac team, "We are not making engines, we are making them better." 

 

7 Comments

  • Shauna 02/16/10 2:45 PM

    Seems awfully similar to the Scuderi engine.  Power density and packaging must suffer from the split combustion process, too.

    Reply
  • Andy R 02/16/10 3:15 PM

    This concept is basically a gas turbine with reciprocating compression and expansion stages instead of turbomachines. It seems likely to me that the only way to overcome the material limitations of the expansion cylinder is to downgrade the power density dramatically with respect to a conventional diesel engine. In which case it might achieve attractive efficiency in a stationary test, but if it has to haul its own weight around then the result could be different.
    What was the power density (kW/kg) of the prototype?
    PS. NOx formation does not decrease with combustion temperature, it increases.

    Reply
  • SF 02/16/10 4:36 PM

    They never said how efficient. seems like there wouldn’t be that big of an efficiency gain in a car for the same power range.

    Reply
  • Tamza 02/16/10 7:33 PM

    It certainly is a simplified system, therefore one would expect a more reliable one? As well as easier/cheaper to maintain. However, the high temp material (the ceramic you note) complicates the marketability of the idea.

    Reply
  • Meton 03/31/10 12:26 AM

    In addition to the excellent points made by the other comments:  What about the rotary valves?  They have never achieved much market success because they have not been able to compete with poppet valves.
    I seriously doubt the assertion that poppet valve trains consume 10% of an engines output.  Maybe it is so when the engine is idling and not producing any useful work, anyway.
    One of the many advantages of poppet valves is their low power requirement which does not increase with increasing cylinder pressure, unlike rotary valves.

    Reply
  • DaveO 06/1/10 7:52 PM

    Sorry folks, this one is just an expensive experiment.  The VC’s have invested in “people” instead of “technology” again.  They have given up the best parts of the Otto cycle, which are the near constant volume combustion and high peak cycle pressures, as mentioned above, which reduces it to a brayton cycle with pistons, which has a much lower thermodynamic efficiency.  The slight increase in combustion efficiency can’t offset that.  The lower peak pressures will only increase heat transfer losses and reduce the effective expansion ratio - especially at part-load where 99% of fuel is consumed.  Similar problem in the Scuderi design.  The Scuderi folks haven’t published efficiency numbers even though they’ve spent millions!  The disadvantage of pistons machinery is that it has higher friction and heat losses at low pressures.  Since the specific power output is dramatically reduced due to the lower fuel-air ratio, the losses due to friction and heat will increase as a percentage of energy input.  Engine out hydrocarbon emissions should decrease, but carbon emissions will increase due to lower efficiency.  There are ways to achieve large gains in IC engines, but this isn’t it.

    Reply
  • Carlos Barrera 07/29/10 9:02 PM

    Tip Info / New Technology Submission - Gearturbine - Atypical

    http://gearturbine.260mb.com

    You Tube Video; Atypical New * GEARTURBINE / Retrodynamic = DextroRPM VS LevoInFlow + Ying Yang Thrust Way Type - Non Waste Looses

    http://www.youtube.com/watch?v=0cPo9Lf44TE

    GEARTURBINE -Atypical Combustion Turbine Engine, -State of the Art, -New Thermodynamic Technology, -With Retrodynamic “Dextrogiro vs Levogiro” Effect, is when the inflow direction moves is against [VS] of the circular rotary dynamic, When the inflow have more velocity the rotor have more RPM / because push the single turbine with the planetary gear, (an a example is like to move the head to the side of the strike hit) / RPM Rotor Move VS Inflow Conduits Way /ACTION VS REACTION / Front to Front / Velocity vs Velocity, making in a simple way a very strong concept of power thrust, a unique technical quality. -Wide cylindrical shape dynamic mass (continue Inertia cinetic positive tendens motion / all the motor weight is goin with the power thrust direction), -Non Waste, parasitic losses form-function engine system for; cooling, lubrication & combustion; -Lubrication & Combustion inside a conduit radial position, out way direction, activated by centrifugal force Fueled Injected (centripetal to in) , -Cooling in & out; In by Thermomix flow & Out by air Thermo transference, activated by the dynamic rotary move, -Increase the first compression by going of reduction of one big circumference fan blades going to, -2two very long distance captive compression inflow propulsion conduits (like a digestive system) (long interaction) in perfect equilibrium well balanced start were end like a snake bite his own tale, -Inside active rotor with 4 pairs of retrodynamic turbos (complete regeneration power system), -Mechanical direct “Planetary Gear” power thrust like a Ying Yang (very strong torque) (friendly loose friction) 2two small gears in polar position inside a bigger shell gear, wide out the rotor circumference were have much more lever power thrust, lower RPM in a simple way solution for turbines, to make possible for a some new work application (land). -3 Stages of inflow turbo compression before the combustion. -3 points united of power thrust; 1- Rocket Flames, 2-Planetary Gear & 3-Exhaust Propulsion, all in one system. -2two continuous circular moving inside combustion (rocket flames) like two dragons trying to bite the tail of the opposite other. -Hybrid flow system different kind of aerolasticity thermoplastic inflow propulsion types; single, action & reaction turbines applied in one same system, -Military benefits, No blade erosion by sand & very low heat target profile. -Power thrust by barr (tube); air sea land & generation application, -A pretender of very high % porcent efficient power plant engine. -Patent; Dic 1991 IMPI Mexico #197187

    Reply
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