HAoS · Project

Simulation Software That Designs Cleaner Fuel Injectors in Less Time

energyPrototypeTRL 4Thin data (2/5)

Imagine you're designing a car engine's fuel injector — the tiny nozzle that sprays fuel into the combustion chamber. Getting that spray pattern right is the difference between clean combustion and dirty exhaust. The problem is, what happens inside that nozzle is incredibly complex and today's computers can't simulate it all at once. This project built a smarter simulation tool that captures the important small-scale physics without needing a supercomputer for every design test, so engineers can try more designs faster and hit emission targets.

By the numbers

Early Stage Researchers trained in fuel injection simulation

consortium partners across the project

countries represented in the consortium

industrial partners contributing real-world validation data

total project deliverables produced

The business problem

What needed solving

Designing fuel injectors that meet stricter emission rules requires understanding complex micro-scale physics inside the nozzle — cavitation, atomization, spray formation. Current simulation tools either cannot capture these effects or require prohibitive computing resources, forcing manufacturers into costly and slow physical prototyping cycles.

The solution

What was built

A large eddy simulation (LES) computational model with sub-grid-scale closure models for fuel atomization, validated against experimental data. One confirmed demo applied the model to MHPS oil burners. The project produced 32 deliverables across simulation development, experimental validation, and training.

Audience

Who needs this

Automotive fuel injection system manufacturers (Bosch, Delphi, Continental)Gas turbine manufacturers designing low-emission combustorsIndustrial burner companies optimizing fuel atomizationAerospace propulsion engineers designing rocket fuel injectorsCFD software companies looking to integrate advanced spray models

Business applications

Who can put this to work

Automotive engine manufacturing

enterprise

Target: Engine and fuel injection system manufacturers

If you are an engine manufacturer struggling to meet tightening emission regulations — this project developed a large eddy simulation tool that predicts how fuel sprays behave inside injector nozzles. Instead of expensive physical prototyping cycles, your engineers can digitally test injector designs and optimize spray patterns. The model was validated against benchmark experimental data and tested with industrial partner configurations.

Power generation equipment

enterprise

Target: Gas turbine and industrial burner manufacturers

If you are a power equipment company designing gas turbines or fuel burners for cleaner operation — this project delivered a simulation model specifically demonstrated on MHPS oil burners. The tool predicts fuel atomization from nozzle flow through to spray development, letting you optimize combustion efficiency digitally. With 3 industrial partners contributing real-world test data, the model bridges lab science and engineering reality.

Aerospace propulsion

enterprise

Target: Rocket engine and aviation fuel system developers

If you are an aerospace company designing fuel injectors for rocket engines or aircraft turbines — this project built a validated computational model covering cavitation, atomization, and spray dynamics. The tool runs at affordable computing time scales compared to full-resolution simulations, making it practical for iterative design work rather than one-off academic studies.

Frequently asked

Quick answers

What would it cost to use this simulation tool?

The project did not publish pricing or licensing terms. As an MSCA training network output, the software may be available through academic licensing from City St Georges University of London. A business would need to contact the coordinator to discuss commercial terms.

Can this tool work at industrial scale with real engine geometries?

Yes — the model was specifically designed as an engineering design tool for IC engines, gas turbines, fuel burners, and rocket engine fuel injectors. One demo deliverable confirms application to MHPS oil burners with real industrial geometry.

What is the IP situation — can we license this?

The project involved 14 partners across 8 countries, including 3 industrial partners. IP ownership likely follows the consortium agreement and EU grant rules. The coordinator at City St Georges University of London would be the starting point for licensing discussions.

How does this compare to existing CFD simulation tools?

Based on the project objective, the key differentiator is the sub-grid-scale closure models that capture micro-scale physics (cavitation, atomization) within a large eddy simulation at affordable computing times. The project states this validation approach is currently missing from today's state-of-the-art models.

Was this validated with real experimental data?

Yes — validation was performed against new benchmark experimental data obtained during the project, plus additional data provided by industrial partners. The demo deliverable confirms the SGS model was applied to MHPS oil burners as a concrete validation case.

What emission regulations does this help meet?

The project was specifically motivated by EU 2020 emission legislations for liquid-fueled transportation and power generation. The tool helps design fuel injection equipment that reduces pollutant emissions by optimizing spray behavior before physical prototyping.

Consortium

Who built it

The HAoS consortium brings together 14 partners from 8 countries, with a strong academic core of 8 universities and 3 research institutes, plus 3 industrial partners (21% industry ratio). The absence of SMEs and the MSCA training network format indicate this was primarily a research and talent development effort rather than a market-driven product project. The international spread (AU, DE, EL, FR, LU, SE, UK, US) ensures broad expertise in fluid dynamics and combustion, but a business partner would need to navigate multi-party IP arrangements to access the simulation tools developed.

CITY ST GEORGES UNIVERSITY OF LONDONCoordinator · UK
ETHNIKO KENTRO EREVNAS KAI TECHNOLOGIKIS ANAPTYXISparticipant · EL
IMPERIAL COLLEGE OF SCIENCE TECHNOLOGY AND MEDICINEparticipant · UK
ROLLS-ROYCE DEUTSCHLAND LTD & CO KGpartner · DE
DEUTSCHES ZENTRUM FUR LUFT - UND RAUMFAHRT EVpartner · DE
JOHNS HOPKINS UNIVERSITYpartner · US
KARLSRUHER INSTITUT FUER TECHNOLOGIEparticipant · DE
DELPHI AUTOMOTIVE SYSTEMS LUXEMBOURG SAparticipant · LU
UNIVERSITY OF MELBOURNEpartner · AU
UNIVERSITY OF STUTTGARTparticipant · DE
UNIVERSITY COLLEGE LONDONparticipant · UK
CENTRE NATIONAL DE LA RECHERCHE SCIENTIFIQUE CNRSparticipant · FR
MITSUBISHI POWER EUROPE GMBHparticipant · DE
CHALMERS TEKNISKA HOGSKOLA ABparticipant · SE

How to reach the team

City St Georges University of London, United Kingdom — search for the combustion/fluid dynamics research group lead

Order a report on this consortium See CITY ST GEORGES UNIVERSITY OF LONDON profile →

Next steps

Talk to the team behind this work.

Want to explore whether HAoS simulation tools could cut your fuel injector design cycles? SciTransfer can connect you with the research team and assess fit for your specific application.

Order a report on this topic More in Energy & Climate