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american journal of applied sciences 6 5 929 936 2009 issn 1546 9239 2009 science publications development of dual fuel single cylinder natural gas engine an analysis and experimental investigation ...

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                   American Journal of Applied Sciences 6 (5): 929-936, 2009 
                   ISSN 1546-9239                          
                   © 2009 Science Publications 
                    
                           Development of Dual Fuel Single Cylinder Natural Gas Engine an Analysis and 
                                         Experimental Investigation for Performance and Emission 
                    
                                                                                                           
                                                      Syed Kaleemuddin and G. Amba Prasad Rao
                            Department of Mechanical Engineering, National Institute of Technology Warangal, India 
                    
                          Abstract: The present study reports the experimental investigations carried and upgradation of 395 cc 
                          air  cooled  engine  to  dual  fuel  (CNG/Gasoline)  application.  The  original  395  cc  direct  injection 
                          naturally aspirated, air cooled diesel engine was first converted to run on Gasoline by addition of 
                          electronic  ignition  system  and  reduction  in  compression  ratio  to  suit  both  gasoline  and  CNG 
                          application. CFX software has been employed to calculate and improve the cooling capacity of engine 
                          with the use of CNG. Materials of major engine components were reviewed to suit CNG application. 
                          The engine was subsequently tuned with dual multi-mapped ignition timing for bi-fuel stoichiometric 
                          operation on engine dynamometer and then fitted on a 3-Wheeler vehicle. The vehicle was optimized 
                          on a chassis dynamometer to meet the proposed Bharat Stage-III norms. The engine has passed current 
                          BS-II emission norms with 48% margin in CO emission and 76% margin in NMHC (Non-Methane 
                          Hydrocarbons) and Extensive trials were conducted on engine and vehicle to optimize with CNG kit 
                          and minimum loaded three way cat-con to finally to met proposed BS-III norms. 
                           
                          Key words: Dual fuel CNG, performance, emission 
                    
                                                                                                                       o
                                      INTRODUCTION                                in  a  liquid  (LNG)  form  at  -160 C,  has  an  research 
                                                                                  octane number (RON) of about 127, is good suited for 
                        Extensive Research has given a way for a number           SI  engines,  can  be  run  on  without  knocking  on  high 
                   of alternate fuels to mitigate the problems of fuel crisis     compression  ratios.  Due  its  high  auto  ignition 
                   and associated environmental degradation. It is not an         temperature it is readily suited for SI engines. Table 1 
                   exaggeration that automotive population has given rise         depicts the important properties of CNG, gasoline and 
                   to  severe  air  pollution.  The  liquid  dominated  prime     diesel fuel. 
                   movers have driven the vehicles  for  many  years and               Natural gas is pressurized to 22MPa in vehicular 
                   leaving the danger of its existence. Use of gaseous fuels      storage tanks, so that it has about 1/3 of the volumetric 
                   in   for   fueling    the   Engines    reduces    reactive     energy  density  of  gasoline.  The  storage  pressure  is 
                   hydrocarbons  and  do  not  pose  the  problem  of             about 20 times that of propane. Combustion of methane 
                   vaporization as with the liquid fuels. Two gaseous fuels       is different from that of liquid hydrocarbon combustion 
                   viz.   LPG  (Liquid  Petroleum  Gas)  and  CNG                 since  only  carbon-hydrogen bonds are involved and no 
                   (Compressed Natural Gas) have attracted the attention          carbon-carbon  bonds,  so  the  combustion  process  is 
                                                                      [1]
                   of  both  industry  and  transportation  sectors .  As         more likely to be complete, producing less non-methane 
                   domestic  sector  is  dominated  by  the  use  of  LPG  for    hydrocarbons. Natural gas has a lower adiabatic flame 
                   meting cooking and other allied applications, attention        temperature (~2240K) than gasoline (~2310K), due to 
                   is  being diverted towards the use of natural gas on a         its higher product water content. Operation under lean 
                   large  scale.  Natural  gas,  a  naturally  occurring  fuel    conditions  will  also  lower  the  peak  combustion 
                                                                                                [2]
                   found in oil fields (one of the world’s most abundant          temperatures .  The  lower  combustion  temperatures 
                   fossil fuel). It is primarily composed of about 90-95%         lower the NO formation rate and produce less engine-
                   methane  (CH4),  with  small  traces  of  additional           out NO . Natural gas can replace diesel fuel in heavy 
                                                                                          x
                   compounds such as 0-4% Nitrogen, 4% ethane and 1-              duty  engines  with  the  addition  of  a  spark  ignition 
                   2% propane Methane has a lower carbon to hydrogen              system.  A  number  of  heavy  duty  diesel  engine 
                   ratio relative to gasoline, so its CO  emissions are about     manufacturers  are  also  producing  a  dedicated  natural 
                                                        2
                   22-25% lower than gasoline. Natural gas is stored in a         gas heavy duty engines. The natural gas fueled engines 
                   compressed (CNG) state at room temperatures and also           are  operated  lean  with  an  equivalence ratio as low as  
                   Corresponding Author:  Syed Kaleemuddin, Department of Mechanical Engineering, 
                                            National Institute of Technology Warangal, India   Tel: +91- 0240-2479340  Fax: +91 -0240 -2479334 
                                                                              929 
                                                                                         Am. J. Applied Sci., 6 (5): 929-936, 2009 
                                                                                                                           
                             Table 1: Fuel properties                                                                         Table 2: Diesel engine specification and vehicle details 
                             Property                            Gasoline             Diesel              CNG                 Parameter                                   Specification 
                             Chemical formula                    CH                   C H                 CH                  Engine type                                 DI, Naturally aspirated, Air cooled 
                                                                   8  16                12  26                 4
                             State                               Liquid               Liquid              Gas                 Bore×Stroke, mm                             86×68 
                             Energy content                      100%                 110%                25%                 Number of cylinders                         1 
                             Octane rating                       87∼93                                    120∼130             Displacement, cc                            395 
                             Auto ignition temp.                 225°C                220°C               450°C               Compression ratio                           18:1 
                             Stoichiometric ratio                14.7                 15                  17.3                Fuel pump                                   PFE 1Q 
                                                                                                                              Injector nozzle type                        P type DSLA 
                             0.7.  The  resulting  lower  in-cylinder  temperatures                                           Vehicles                                    Load carrier 
                             reduce the NO  levels. In the literature, it is observed                                         Unladen mass, kg                            384 
                                                     x                                                                        Reference mass, kg                          534 
                             most of the work on the use of CNG has been carried                                              Gross Vehicle Weight, kg                    995  
                             out on the multi-cylinder water cooled engines or single                                         Gear box                                    Four speed  
                             cylinder          water         cooled          engines           experimentally                 Differential ratio                          2.385 
                                                                                                                              Tyre size                                   4.5×10” 8PR  
                             investigated the effect of advanced injection timing on                                           
                             emission characteristics of a diesel engine running on                                                  Spark  ignition  engine  design  was  done  by 
                             natural  gas.  The  test  results  showed  that  alternative                                     modifying  existing  cylinder  head,  Piston  assembly, 
                             fuels  exhibit  longer  ignition  delay,  with  slow  burning                                    Flywheel  and  replacing  fuel  injection  system  with 
                                     [3]
                             rates .  The  ignition  delay  was  reduced  through                                             electronic ignition  system on engine. Valve timing of 
                             advanced injection timing but tended to incur a slight                                           existing  diesel  was  found  suitable  for  spark  ignition 
                             increase  in  fuel  consumption.  The  CO  and  CO2                                              engine and was unaltered. 
                             emissions  were  reduced  through  advanced  injection                                            
                             timing.                                                                                          Cylinder head: Diesel engine intake and exhaust port 
                                    Due  to  the  threat  posed  by  the  automotive                                          with average flow coefficient of 0.274 for intake port 
                             population,  different  nations  have  gone  in  for  setting                                    and  0.308  for  exhaust  port  was  retained  in  order  to 
                             different  stringent  emission  norms.  Thus  the  engine                                        build a gasoline engine with typical swirl cylinder head. 
                             manufacturing  is  put  under  enormous  pressure  to                                            The flow coefficients were measure in accordance with 
                             comply with stringent emission norms.                                                            procedure  laid  down  by  Ricardo[4,5],  The  decision  of 
                                    Present          research          reports          the       experimental                same  cylinder  head  adopting  was  taken  in  order  to 
                             investigations  carried  out  on  light  duty  automotive                                        commonise  machining  of  cylinder  head  for  both 
                             engine  to  employ  CNG  and  to  comply  with  the                                              production running diesel engine and newly developed 
                             proposed new emissions standards. The investigations                                             spark-ignition engine also it reduces tooling cost. Spark 
                                                                                                                                                                                         o
                             include:                                                                                         plug thread tapping was made at 20  inclination in the 
                                                                                                                              cylinder  head  was  in  place  of  diesel  injector,  so  that 
                             •      Conversion of 395cc high speed diesel engine into                                         spark plug is located centrally with required spark plug 
                                    spark-ignition engine                                                                     protrusion in order to produce short flame travel which 
                             •      Design  modification  was  carried  for  CNG                                              reflect in rapid and relatively complete combustion.  
                                    compatible solution                                                                        
                             •      CFD analysis to improve the cooling system                                                Flywheel weight reduction: Since gasoline engine is 
                             •      Spark  ignition  engine  was  tuned  for  bi-fuel                                         quantity  governed  lightweight  flywheel  is  preferred 
                                    stoichiometric operation on CNG as fuel                                                   hence  additional  base  diesel  engine  flywheel  was 
                             •      Performance and emission tests  were  carried  out                                        machined to reduce its weight to 6.25kg from existing 
                                                                                                                              14 kg.  
                                    engine dynamometer and chassis dynamometer and                                             
                             •      Finally,  CNG  fueled  engine  was  optimized  for                                        Compression ratio: Diesel engine compression ratio of 
                                    emission on reference 3-wheeler vehicle to achieve                                        18:1  was  changed  to  optimum  working  compression 
                                    equivalent mileage as diesel                                                              ratio  of  9:1  for  spark  ignition  engine.  Piston  toping 
                                                                                                                              clearance was increased from 0.75-7.4 mm to achieve 
                                                MATERIAL AND METHODS                                                          spark ignition compression ratio as illustrated in Fig. 1. 
                                                                                                                              Spark ignition engine working compression ratio of 9:1 
                                    The diesel engine complying with BS-II emission                                           was kept on higher side in order to adopt it for CNG as 
                             norms  was  adopted  to  convert  it  into  spark-ignition                                       a fuel, which demands for higher compression ratio due 
                             engine  whose  specification  along  with  test  vehicle                                         to its high auto ignition temperature and low calorific 
                             details is illustrated in below Table 2.                                                         value[6].  9:1    compression    ratio    was   achieved   by  
                                                                                                                       930 
                                                               Am. J. Applied Sci., 6 (5): 929-936, 2009 
                                                                                      
                                                                                        compactable  for  electromagnetic  interference.  The 
                                                                                        spark plug temperature was recorded on engine and as 
                                                                                        well on the vehicle by running the vehicle at different 
                                                                                        speeds. The temperature was found 200°C higher but 
                                                                                        within acceptable range for CNG application. This is 
                                                                                        because of more heat losses compared to diesel engine 
                                                                                        even after increasing cooling surface area.  
                                                                                         
                                                                                        Cooling      system       improvement-CFD           analysis: 
                                                                                        Gasoline  engines  mostly  run  hotter  as  compared  to 
                                                                                        diesel engine due its homogeneous combustion process 
                     Fig. 1: Pan cake combustion chamber                                as compared to lean burn heterogeneous nature of diesel 
                                                                                        combustion  process.  Further,  CNG  engine  will  run 
                     modifying existing reentrant piston crown to pan cake              hotter than gasoline engine due to delay in combustion 
                     combustion  chamber.  Pan   cake  combustion  chamber              process because of its higher auto ignition temperature 
                     piston  was  adopted  to  avoid  hot  spot  during  spark          and lower specific weight. To make CNG compatible 
                     ignition combustion as cylinder was having intake swirl            analysis  was  done  on  existing  diesel  engine  cooling 
                     port.                                                              system  through  CFX (Computational Fluid Dynamic) 
                                                                                        software. From the CFD analysis it was concluded that 
                     Carburetor selection: Mechanical controlled variable               existing    surface   area    was  adequate  for  diesel 
                     depression  carburetor  with  piston  type  throttle  was          application  only.  Specially  for  CNG  application 
                     selected.  Were  the  throttle  is  situated  in  the  venture     additional  surface  area  of  15%  was  required  for 
                     zone  itself,  area  of  venturi  was  varied  by  throttling      adequate cooling. To achieve increase in surface area 
                     carburetor  piston  up  and  down  to  provide  the  right         for effective cooling, the number of fins on the cylinder 
                     quantity  of  mixture  to  meet  the  engine  operating            head and cylinder barrel was increased without major 
                                [7]
                     conditions .  The  quantity  of  fuel  delivered  was              decrease in space between the fins hence the thermal 
                     controlled  by  various  jets  and  passages  and  metering        balancing of the cylinder head and block were retained. 
                     needle  moving  inside  the  calibrated  orifices.  The            The  flow  rate  of  fan  is  increased  by  10-15%,  by 
                     metering needle is attached to throttle itself. Carburetor         modifying the blade design. The changes are made in 
                     piston was anodized in order to take care of wear and              the  air-shroud  and  back-plate  for  accommodating  the 
                     abrasion during dry run of CNG.                                    fan design as shown in Fig. 2.  
                                                                                             Turbulent Kinetic Energy profile of CFD analysis 
                     Electronic  ignition  system:  From  the  base  diesel             of  existing  system is shown in Fig. 3 where poor air 
                     engine, fuel injection system and governing mechanism              velocity is causing excess heat energy loss leading to 
                     were  removed  and  spark  ignition  system  was                   over heating of engine and drop in performance. Figure 
                     introduced  with  electronic  multi  mapped  DC  Igniter           4  shows  for  improved  system  where  air  velocity  has 
                                           [7,8]
                     with  pulsar  pickup     .  High  tension  coil  with  high        improved  engine  cooling  reducing  hot  spot  from 
                     energy  capacity  was  used  in  order  to  care  delay            turbulent kinetic energy profile. The analysis has given 
                     combustion  due  to  high  auto  ignition  temperature  of         10-12%  improvement  in  engine  cooling  on  actual 
                     CNG fuel. In order to take care valve train mechanical             engine. 
                     safety higher engine speed cut off was introduce in DC              
                     igniter which cut off spark from spark plug as soon as             CNG compactable material: As CNG operated engine 
                     engine reaches 4100 rpm.                                           was  running  hotter  by  hundred  degree  centigrade  in 
                                                                                        CNG  as  compared  to  gasoline.  Engine  material  of 
                     Spark plug selection:  On  assessment  twin  electrode             cylinder  head,  valve  and  valve  seat  insert  were 
                     resistive spark plug was adopted on engine in case of                                                     [9,10]
                                                                                        reviewed  for  CNG  compatibility          .  Cylinder  head 
                     twin electrode plugs ignition spark selects the best route         material was upgraded with silicon copper high alloy 
                     to  take  from  the  centre  electrode  to  the  ground            material  to  retain  hardness  at  elevated  temperature, 
                     electrode[7,8]. The possible spark path are four as against        valves material was reviewed from mono metal with bi-
                     one  in  single  electrode  spark  plug.  This  increase  the      metal valve with satellite coating on valve head in order 
                     probability  of  ignition  and  improve  the  acceleration         to  avoid  premature  wear  due  dryness  of  CNG  fuel. 
                     startability even for delayed fuel characteristic of CNG.          Cobalt base alloy was used in valve seat inserts which 
                     On  assessment,  resistive  spark  plug  has  shown                remain intact even at elevated temperatures. 
                                                                                   931 
                                                                                                                    Am. J. Applied Sci., 6 (5): 929-936, 2009 
                                                                                                                                                                
                                                                                                                Air shroud 
                                       Back plate 
                                                                                                                            Flywheel 
                                                                                                                                             
                                      Fig. 2: Cooling system of engine 
                                                                                                                                                                                                                                                                                 
                                                                                                                                                                   Fig. 4: Improved system turbulent kinetic energy profile 
                                                                                                                                                                                                                                       
                                                                                                                                                                                                        Air filter                  Pressure guage 
                                                                                                                                                                                       Carburetor 
                                                                                                                                                                                                                 CNG regulator 
                                                                                                                                                                            Petrol tank 
                                                                                                                                                                                                 Engine                               CNG bottle 
                                                                                                                                                                                                                                                                   Ignition switch 
                                                                                                                                                                                                                                                                        
                                                                                                                                                                                                                                                 Fuse 
                                                                                                                                                                                                       Vacuum pipe CNG solenoid                                     Relay 
                                                                                                                                                                      Petrol solenoid valve                          Controller 
                                                                                                                                                                                                                               Selector switch                      Battery           
                                                                                                                                                                    
                                                                                                                                                                   Fig. 5: Schematic layout of engine with CNG system 
                                                                                                                                                                    
                                                                                                                                                                   system was becoming more sensitive especially in part 
                                      Fig. 3: Existing system turbulent kinetic energy profile                                                                     load  condition  where  effective  compression  ratio 
                                                                                                                                                                   decrease  due  to  homogenous  combustion  process. To 
                                      Experimental method                                                                                                          study on stoichiometric air to fuel ratio in gasoline and 
                                      Ignition  timing  optimization:  Ignition  timing  was                                                                       CNG intake  system  was  optimized[11].  During  initial 
                                      mapped  for  each  engine  speed  and  load  for  better                                                                     engine  performance  there  was  drop  in  volumetric 
                                      engine performance and fuel economy. Figure 5 shows                                                                          efficiency observed, drop in volumetric efficiency was 
                                      schematic layout of engine setup use for experimental                                                                        mostly due to poor CNG fuel and pulsation effect at 
                                      research.                                                                                                                    higher  engine  speed.  Many  trials was done by adding 
                                               To  compensate  for  dual  Gasoline  and  CNG                                                                       volume  in  intake  system  to  reduce  pulsation  effect 
                                      application, dual ignition timing curve was mapped to                                                                        which  results  in  increasing  volumetric  efficiency. 
                                      achieve better power, torque and over all performance                                                                        Resonator optimum volume of 5 L could achieve nearly 
                                      and  also  to  meet  the  engineering  target  for  mass                                                                     equivalent volumetric efficiency as of diesel. Figure 7 
                                      emission test on chassis dynamometer. Variable ignition                                                                      shows the trends of volumetric efficiency with different 
                                      timing of 15° btdc at low idling engine speed to 25°                                                                         volume in intake system.  
                                      btdc at rated engine speed was optimized for gasoline                                                                         
                                      mode and 29° btdc at rated speed was optimized for                                                                           Combustion  pressure  measurement:  Combustion 
                                      CNG mode as shown in Fig. 6. Selection of respective                                                                         pressure  measurement  was  done  by  AVL  endoscope. 
                                      curve is sensed through change over switch of CNG kit.                                                                       With  CNG  as  fuel  there  was  drop  in  combustion 
                                                                                                                                                                   pressure to 36 bar as against 55 bar of diesel as show in 
                                      Engine  optimization  on  engine  dynamometer:                                                                               Fig. 8.This drop in combustion pressure is significance 
                                      During   engine   optimization   in   CNG   mode  intake                                                                     as   compression   ratio  for  CNG  is  lesser  then  diesel  
                                                                                                                                                           932 
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...American journal of applied sciences issn science publications development dual fuel single cylinder natural gas engine an analysis and experimental investigation for performance emission syed kaleemuddin g amba prasad rao department mechanical engineering national institute technology warangal india abstract the present study reports investigations carried upgradation cc air cooled to cng gasoline application original direct injection naturally aspirated diesel was first converted run on by addition electronic ignition system reduction in compression ratio suit both cfx software has been employed calculate improve cooling capacity with use materials major components were reviewed subsequently tuned multi mapped timing bi stoichiometric operation dynamometer then fitted a wheeler vehicle optimized chassis meet proposed bharat stage iii norms passed current bs ii margin co nmhc non methane hydrocarbons extensive trials conducted optimize kit minimum loaded three way cat con finally met ...

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