Exhaust Gas Analysis of CI engine with Co-generation

Abstract

Exhaust system plays most effective role on the environment as it is that portion of an automobile through which exhaust gases get out from the combustion chamber to pollute the air by their harmful gases. The exhaust system components like catalytic converter, muffler, resonator and co-generation make it possible to let out the least possible harmful gases from the engine exhaust manifold. The performance of the emission control system particularly by the Analysis of exhaust gases with co-generation by help of Heat exchanger are the main concern of this paper. To make a comparison of the exhaust gas emission providing with cogeneration and single generation, and exhaust gas analyzer was used to collect experimental data. All the experimental data and graphical representation concludes that the CO, CO 2, NOx in the exhaust gas from CI engine has been reduced to a great extent with the help of cogeneration process. The experimental results obtained from the present work shows that the idea of recovery of waste heat by using compact type heat exchanger is feasible. The experimental results show that the design of the co-generation system is successful and more effective to utilize the resources efficiently.

Full text

International Journal on Recent Technologies in Mechanical and Electrical Engineering (IJRMEE) ISSN: 2349-7947
Volume: 2 Issue: 12 22 – 30
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Exhaust Gas Analysis of CI engine with Co-generation
1. Janak Suthar, 2. Himanshu Tetarwal, 3. Chetan Thakur, 4. Amit Patil
Assistant Professor at SCOE kharghar, 2.Production Engg. at hawa pvt.ltd.,3,4. Assistant Professor at SCOE kharghar
Abstract:- Exhaust system plays most effective role on the environment as it is that portion of an automobile through which exhaust gases get
out from the combustion chamber to pollute the air by their harmful gases. The exhaust system components like catalytic converter, muffler,
resonator and co-generation make it possible to let out the least possible harmful gases from the engine exhaust manifold. The performance of
the emission control system particularly by the Analysis of exhaust gases with co-generation by help of Heat exchanger are the main concern of
this paper. To make a comparison of the exhaust gas emission providing with cogeneration and single generation, and exhaust gas analyzer was
used to collect experimental data. All the experimental data and graphical representation concludes that the CO, CO2, NOx in the exhaust gas
from CI engine has been reduced to a great extent with the help of cogeneration process. The experimental results obtained from the present
work shows that the idea of recovery of waste heat by using compact type heat exchanger is feasible. The experimental results show that the
design of the co-generation system is successful and more effective to utilize the resources efficiently.
Keywords - Exhaust system, exhaustGases, compact heat exchanger, Gas Analyser.
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Introduction
Demand of energy is growing day by day in the world.
According to limited resources and continuous growing
demand there is great need to find out alternative sources
and energy conservation technique which enhance the
efficiency of the system and to reduced the primary energy
consumption and pollution. The huge amount of flue gases
are generated from Engines, Boilers, Ovens and Furnaces
etc and goes as a waste if it is not utilized properly. If some
of heat could be recovered then loss of primary fuel can be
saved. The recovery and utilization of waste heat not only
conserves the primary fuel (fossil fuel) but also reduces the
huge amount of waste heat & greenhouse gases damped to
environment. The essential quality of heat is not the amount
but rather its value. So cogeneration technology emerges as
the most effective technique for achieving the goal of energy
conservation and sustainability.So a experiment setup for
completion.
Experimental Setup and Procedure
An experimental setup was developed to utilize the waste
heat of engine exhaust for heating purpose.The schematic
layout of the experimental setup for the present investigation
is shown in Figure 1.1. It consists of a test-bed, having a
diesel engine, rope brake dynamometer, heat exchanger for
heating the water, fuel tank, air box, operation panel having
controls and displays for different thermocouples for
measurement of temperature, tachometer and flow meters.
Fuel supply is measured using burette flow meter

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Figure 1.1 Schematic diagram of Experimental Setup for Cogeneration System
A typical engine system widely used in the agricultural field
has been selected for present experimental investigations. A
stationery single cylinder, four stroke, water cooled, direct
injection diesel engine was procured for the experiments.
Rope brake dynamometer was used to measure the load or
brake power. The Experiments were carried out in two
stages. In first stage the Engine was not integrated with heat
exchanger than the various parameters like Brake Thermal
Efficiency, Specific fuel consumption, and Mass flow rate
of air etc. evaluated at that time. After in second stage the
heat exchanger or waste heat recovery system was
integrated with the engine and at this condition various
parameters like BTE, BSFC, BSEC and various
temperatures were evaluated.
Specification of Engine
For this Experimental investigation Kirloskar made single
cylinder Water cooled diesel engine used. The complete
specification of engine is shown in Table.
SPECIFICATIONS OF THE ENGINE
S.No.
Component of
Engine
Unit
Description
1
Name of the
engine
-
Kirloskar Oil
Engine
Model AV1
2
Type of engine
-
Vertical, four
stroke cycle,
single acting,
totally enclosed,
high speed, C.I.
engine
3
No. of cylinders
-
1
4
Direction of
rotation
Counter
clockwise
(When looking at
flywheel )
5
IS Rating at
1500 rpm
kW(bhp)
3.7 (5.0)
6
Bore
Mm
80
7
Stroke
Mm
110
8
Cubic Capacity
Liters
0.553
9
Compression
Ratio
-
16.5 : 1

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10
No. of Injection
Pumps and Type
-
1 number, Single
cylinder, flange
mounted without
camshaft
11
Governor type
-
Mechanical
centrifugal type
12
Class of
governing
-
B1
13
Filter type
Dry oil bath type
paper element
Air
-
Bypass filter with
paper element
Fuel
-
Bypass filter with
paper element
Lubricating Oil
-
14
Recommended
fuel specification
-
Diesel as per IS :
1460
15
Fuel Oil Tank
Capacity
Liters
6.5
16
Lubricating Oil
specification
-
HD- type 3 as per
IS : 496–1982
17
Mode of Starting
-
Gear end /
Flywheel end
Hand start
18
Apparatus
required for
starting
-
Extension shaft
Starting Handle
Decompression
arrangement
19
Weight of engine
Kg
160
Engine alone
kg
114
Flywheel
kg
33
20
Maximum
permissible back
pressure
Pa
2.5
21
Maximum
permissible
intake
depression
Pa
1
22
Method of
Cooling
-
Cooling Water
Cooling water
flow rate
(For run through
system cooling)
lit/min
7
(Attached with
water flow
meter)
23
Lubricating oil
sump capacity
lit.
3.3
24
Lubricating oil
consumption
lit.
1.0% of sfc
maximum
25
Sfc at rated hp
per 1500rpm
245 g/kWh(180
g/bhp/hr)
26
Fuel refilling
time
6 hrs (When
engine running at
rated output)
27
Injection timing
Degree
crank
angle
23 Degree BTDC
28
Thermocouple
-
„J‟ Type
Dynamometer and Loading arrangement
Dynamometer (dyno for short), is a device for
measuring force, moment of force (torque), or Brake power.
Figure 1.2 Rope Brake Dynamometer
Specifications of rope brake dynamometer
SPECIFICATIONS OF ROPE BRAKE
DYNAMOMETER
Type
Rope Brake Dynamometer
Diameter of brake
drum (db),
0.3 m

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Diameter of rope
(dR)
0.012 m
Material
C.I.
Cooling system
Water cooling
The brake power is given by
B.P. = 2𝜋𝑁𝑇
60×1000 KW
and Torque is Given by
T= (W1- W2)×g×Re N-m
Measurement of Speed
One of the simplest and basic measurements is that of speed.
A wide variety of speed measurements devices are available
but in this experiment electrical tachometer was used to
measuring speed.
Measurement of exhaust emission
Figure 1.3 Gas Analyzer
The detailed specifications of the exhaust gas analyzer are
given in Table.
SPECIFICATIONS OF THE EXHAUST GAS
ANALYZER
Type
EPM1601
Object of measurement
CO
HC
O2
CO2
NOx
Range of measurement
CO = 15%
HC = 0-15000 ppm
O2 = 0-25%
CO2 = 0-20%
Warm up time
120 Seconds
RPM
400-10000
OT
0-150 0C
Flow
1000cc/Mint.
I/P Voltage
11-13 VDC
Experimental Procedure
The engine used in this experimental method was a single
cylinder, 4-storke, water cooled Kirloskar oil engine. The
specifications of the engine are presented in the table .The
engine was coupled with a rope brake dynamometer. The
schematic diagram of experimental setup as shown in figure
1.3.A nozzle was mounted at the inlet of engine to measured
air flow rate. The pressure difference was measured with the
help of U-tube manometer. Burette method was used for
fuel flow measurement with the help of stop watch. By
using fuel mass flow rate and air mass flow rate, exhaust
mass flow rate was calculated. A flow meter was used for
water flow rate, „J‟ type thermocouple for temperature
measurement at different points and a gas analyser was used
for emissions measurement. A compact type designed heat
exchanger used for cogeneration and this heat exchanger
and exhaust piping system were well insulated to prevent
heat losses. To insulate exhaust pipe and heat exchanger,
glass wool fibre with reflective aluminium foil was used.
First of all the engine was tested at different loads and
speeds. The exhaust gas temperature, fuel flow rate, air flow
rate, emissions etc. were recorded to calculate the available
heat energy from exhaust gas of the engine. According to its
exhaust heat availability a compact type heat exchanger was
designed and connected to exhaust of the engine. The
exhaust gas of engine was passed through shell and water
flowed through tubes. The effectiveness compact type heat
exchanger is more compare to other type heat exchanger so
it was selected for this experimental setup. The performance
of with integrated system also examined and as per
requirement some modification were also done in the heat
exchanger. View of experimental setup as shown in below
figure 1.4

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Figure 1.4 View of the Experimental Setup in Laboratory
RESULTS AND DISCUSSION
After developing the whole experimental system
experimentation was carried out.
Engine performance parameters
27.0644% (Single generation)and 26.90% when engine was
integrated with heat exchanger.
Observed by gas analyzer.
U-tube
Manometer
Temperatur
e Indicator
Fuel to
Engine
Orifice
Engine
Exhaust
Pipe
Dynamometer
Fuel Tank
Fuel Burette

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0
100
200
300
400
500
600
700
0 2 4 6
Oxides of Nitrogen, ppm
Load (kW)
Single
Generation
Cogeneration
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0 2 4 6
Brake Specific fuel Consumption
(kg/kW-hr)
Load (kW)
Single
generation
Cogeneration
0
0.5
1
1.5
2
2.5
3
3.5
0123456
Carbon dioxide (CO2)
Load (kW)
Single Generation
Cogeneration
0
5
10
15
20
25
30
35
40
45
0 2 4 6
Brake Thermal Efficiency (%)
Load (kW)
Single
Generation
Cogeneratio
n
0
0.002
0.004
0.006
0.008
0.01
0.012
0.014
0.016
0.018
0.02
0 2 4 6
CarbonMonoxide (CO)
Load (kW)
Single Generation
Cogeneration

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.
Effectiveness parameter of Heat Exchanger
Effectiveness of the system
The effectiveness of heat exchanger was calculated and a
variation between effectiveness and load has been shown in
Figure 5.8. It has been observed from the variation that
effectiveness was found maximum at a load of 4.38 kW and
was 0.3635 and minimum 0.2921 at a load of 1.753 kW.
Initially there was a continuous rise in the effectiveness up
to a load of 4.38 kW then it was decreased at a load of 5.33
kW although the temperature difference was quite high than
that of at a load of 4.38 kW.
Figure Variations in Effectiveness and Load
This decrement may be due to increased in heat loss to the
surroundings of the system. Due to the heat loss the less
amount of heat was transferred to cold fluid (water) hence
time taken to achieve the boiling temperature increased. As
the time heat available also increased and availability of
amount of heat gained was fixed hence effectiveness of the
system decreases.
CONCLUSIONS AND FUTURE WORK
Conclusions
In this paper, Performance investigation of the compact type
heat exchangerutilization of waste heat from diesel engine
exhaust. Performance and emission parameters of the heat
exchanger and diesel engine system were measured and
16.4
16.6
16.8
17
17.2
17.4
17.6
17.8
0 2 4 6
Oxygen (%)
Load (kW)
Single Generation
Cogeneration
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0123456
Effectiveness
Load (kW)
Effectiveness

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analyzed. The Following conclusions can be drawn from the
thesis
1. Waste heat exchanger developed was feasible.
2. Brake thermal efficiency and brake specific fuel
consumption for the CI engine was found to be
nearly same for both the cases (with and without
cogeneration) which indicate that there is no effect
on the performance of the engine.
3. The exhaust CO emissions of the engine with
cogeneration were found slightly low than that of
single generation. There was no more difference in
CO2 and NOx emissions.
4. It was found that with increasing in load the heat
rate was also increases, and again there is an
increment in heat rate when modification was done.
The heat rate was found minimum at 1.75 kW load
and was found maximum at 4.34 kW load.
5. The effectiveness of heat exchanger was found
0.3650 without baffle and after modification it has
increased to 0.3850.
6. From above conclusion available energy of the
waste heat was recovered by the cogeneration
system and it has been increased when
modification was done.
The experimental results obtained from the present work
shows that the idea of recovery of waste heat by using
compact type heat exchanger is feasible. The experimental
results show that the design of the co-generation system is
successful and more effective to utilize the resources
efficiently.
Future work in research field
In order to promote the waste heat recovery system the
following research field can be carried out:
1. To design and develop a micro tri-generation
system for cooling/heating purpose.
2. To develop simulation model to predict the
performance of other tri-generation systems.
3. To study the effect on the performance of engine
and heat exchanger using other type heat exchanger
and its sizes.
4. To design a cogeneration system by using ANSYS
software can be done.
5. To analyze other performance and emission
characteristics of cogeneration system
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Volume: 2 Issue: 12 22 – 30
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