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Experimental investigations on the performance and emissoin characteristics
1.
International Journal of
Advanced Research in Engineering and Technology (IJARET), ISSN 0976 – 6480(Print), ISSN 0976 – 6499(Online) Volume 4, Issue 3, April (2013), © IAEME 20 EXPERIMENTAL INVESTIGATIONS ON THE PERFORMANCE AND EMISSOIN CHARACTERISTICS OF A MULLITE COATED DI DIESEL ENGINE 1 Vinay Kumar Domakonda* , 2 Ravi Kumar Puli, 3 Santhosh Kumari 1,2 Department of Mechanical Engineering, National Institute of Technology, Warangal,India 3 Christu Jyothi Institute of Technology and Scienc, Jangoen, Warangal, India ABSTRACT Mullite (3Al2O3-2SiO2) ceramic powder has been used as a thermal barrier coating material to study its effect on the performance and exhaust emissions of a single cylinder diesel engine operated using diesel fuel. Mullite thermal barrier coatings have been proved to be an efficient thermal barrier coating material besides the conventional YSZ TBCs with lower thermal conductivity, high sintering resistance, low oxygen permeability. The study has shown that the performance of the engine is improved significantly on the account of brake thermal efficiency and specific fuel consumption. Emissions, on the other hand are also found to be reduced considerably, especially the smoke opacity which is significantly low at all Low Heat Rejection (LHR) operations. Key Words: Low Heat Rejection Diesel Engine, Mullite, Thermal Barrier Coatings. 1. INTRODUCTION Plasma-sprayed ceramic thermal barrier coatings (TBCs) are being extensively perused area of interest from the recent past for the improved efficiency and reduced emissions especially in diesel engines. Yttria stabilized zirconia, also called partially stabilized zirconia(Y-PSZ) material is believed to be a reliable TBC until now but the failure of the coating at elevated temperatures under continuous thermal shocks as in diesel engines lead to the investigation of new materials for TBC applications. PSZ is limited due to phase transitions and increased sintering of the porous TBC layer above 1200 °C, which leads to catastrophic delamination of the coating. The failure of the PSZ coatings is also attributed to the high concentration of oxygen vacancies which permeates the oxygen through it, leading to the oxidation of the bond coat and sintering of the coating at higher temperatures, which leads to a decrease in porosity and an increase of Young’s modulus and, hence, to higher thermally induced stresses [ HYPERLINK l "Yul10" 1 ]. In order to overcome the disadvantages of PSZ and to meet the requirements of an ideal TBC, it is needed to develop a new candidate material with even lower thermal conductivity, capability to withstand higher operating temperatures, higher sintering-resistance and phase stability at even higher temperature2]}. Among the interesting candidates for TBCs, rare earth zirconates have been INTERNATIONAL JOURNAL OF ADVANCED RESEARCH IN ENGINEERING AND TECHNOLOGY (IJARET) ISSN 0976 - 6480 (Print) ISSN 0976 - 6499 (Online) Volume 4, Issue 3, April 2013, pp. 20-25 © IAEME: www.iaeme.com/ijaret.asp Journal Impact Factor (2013): 5.8376 (Calculated by GISI) www.jifactor.com IJARET © I A E M E
2.
International Journal of
Advanced Research in Engineering and Technology (IJARET), ISSN 0976 – 6480(Print), ISSN 0976 – 6499(Online) Volume 4, Issue 3, April (2013), © IAEME 21 investigated, and they have been proved to be significant for the top coating materials [19]. Among these materials,, Mullite shows promising thermo-physical properties and has attracted great attention as candidate material for thermal barrier applications [ HYPERLINK l "Hen03" 3 ]. To this purpose, mullite (3Al2O3–2SiO2) coatings are particularly promising due to their high thermal stability, low thermal conductivity, high resistance in highly oxidative and corrosive environments, high resistance to crack propagation and high thermal shock resistance [1–6]. Previous works have demonstrated that mullite coated diesel engine components exhibited decreased surface cracking when compared to zirconia coated ones [7]. In addition, mullite coatings are suitable for environmental protection of ceramic matrix composites (CMC),i.e. SiC-based ceramics, against corrosion from molten salts and water vapour in combustion environments, due to their good density, chemical compatibility and thermal expansion coeffi-cient very close to that of the substrate [8,9]. 2. EXPERIMENTAL SETUP AND PROCEDURE The experimental setup consists of a Kirloskar made single cylinder direct injection diesel engine whose specifications are given below in Table.2 is a widely used engine for agricultural activities and water pumping in India. The set up also consists of a Kistler made pressure transduser type 7001, flush mounted on the cylinder head for the measurement of in-cylinder pressure,an optical TDC marker, a charge amplifier of type 5007 made by Kistler and an NI USB 6008 DAQ card for the conversion of pressure sensor and TDC marker analog signals into digital signal and for data acquisition. A labview based software has been used to monitor pressure and TDC signal data. Exhaust gas emissions are measured using a NETEL Made five gas analyzer model NPM-MGA-2 and smoke opacity is measured using NETEL smoke meter model no.NPM-SM-111B (Table.3). Fuel consumption is measured using a calibrated burette and volume flow rate of air is measured using an air box and U-tube manometer. The engine components viz. piston, cylinder head and valves are coated with Lanthanum zirconate and have been shown in Fig.2. Figure.1 Schematic diagram of the experimental setup Figure.2 Mullite coated engine components
3.
International Journal of
Advanced Research in Engineering and Technology (IJARET), ISSN 0976 – 6480(Print), ISSN 0976 – 6499(Online) Volume 4, Issue 3, April (2013), © IAEME 22 No. of cylinders One Bore, mm 80 Stroke, mm 110 Cubic capacity, CC 553 Rated output, kW (HP) 3.68 (5) Compression Ratio 16.5:1 Type of Injection Direct STD Inj. Timing, o BTDC 23 STD.Inj.opening pr.,kg/cm2 200 Type of cooling water Rated speed, RPM 1500 Table.2. Specifications of the test engine. Thermocouples are arranged at different locations to measure the temperatures at different engine parts viz. engine coolant outlet temperature, exhaust gas temperatures etc. . Experiments were conducted initially on the standard engine i.e. without applying coating to the engine parts at standard, manufacturer specified injection timing of 230 BTDC and at an injector opening pressure of 200 kg/cm2 using diesel fuel. Then the mullite coated parts are assembled to the engine thus making it low heat rejection engine(LHRE). Experiments are repeated same as above at standard engine operating conditions . NPM-MGA-2 Five Gas Analyzer Gases measured Method Measurement Range Resolution Accuracy HC NDIR 0-20,000 ppm 1 ppm +/- 10ppm abs CO NDIR 0-9.99 % 0.01 % +/- 0.03% abs CO2 NDIR 0-20.00 % 0.10 % +/- 0.04% abs O2 Electrochemical 0-25 % 0.01 % +/- 0.1% abs NOx Electrochemical 0-10,000 1 ppm +/- 25ppm abs NPM-SM-111B Smoke meter Type of smoke meter Partial flow Display indication Light absorption coefficient (K) and percentage opacity Display Range 0-9.99 m-1 Linearity 0.1 m-1 Repeatability 0.1 m-1
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International Journal of
Advanced Research in Engineering and Technology (IJARET), ISSN 0976 – 6480(Print), ISSN 0976 – 6499(Online) Volume 4, Issue 3, April (2013), © IAEME 23 Table.3. Technical Specifications of five gas analyzer and smoke meter Table.4. Plasma spraying parameters (Severin Seifert et al) RESULTS AND DISCUSSIONS Generally, the concentrations of pollutants in internal combustion engine exhaust differ from values calculated assuming chemical equilibrium. Thus the detailed chemical mechanisms by which these pollutants form and the kinetics of these processes are important for determining emission levels. For some pollutant species, e.g., carbon monoxide, organic compounds, and particulates, the formation and destruction reactions are intimately coupled with the primary fuel combustion process. In the diesel engine, the fuel is injected into the cylinder just before combustion starts, so throughout most of the critical parts of the cycle the fuel independent of the fuel distribution and how that distribution changes with time due to mixing. Fig.3 Variation of BSFC with brake power with and without coating Fig.4 Variation of brake thermal efficiency with brake power with and without coating using different fuels
5.
International Journal of
Advanced Research in Engineering and Technology (IJARET), ISSN 0976 – 6480(Print), ISSN 0976 – 6499(Online) Volume 4, Issue 3, April (2013), © IAEME 24 Fig.4 shows the variation of brake thermal efficiency with brake power for the standard and mullite coated LHR engine at standard operation conditions. Mullite LHR engine when run with standard diesel has shown 5.78% improvement in the brake thermal efficiency compared to the standard diesel operation. Reduced heat transfer to the cooling system in the case of LHR engine is believed to have helped in increasing the brake thermal efficiency of the engine. CONCLUSIONS 1. Mullite has been used as candidate material for TBC and a series of experiments have been conducted on a single cylinder direct injection diesel engine. 2. Experimental observations showed that the mullite has ensured in improved engine performance with reduced emissions at all engine load conditions. 3. The BSFC has been found to be 5.46% low with LHRE compared to that of standard engine operation at full load condition 4. Brake thermal efficiency of the LHR engine is improved significantly compared to that of standard engine operation resulting in over 5.78% improvement. 5. CO emissions are reduced with LHR operation significantly. Higher CO emissions from standard engine using diesel fuel are attributed to the non-favorable conditions for the oxidation of CO into CO2 especially at no load and full load conditions. This problems has been overcome using TBCs because of which rise in in-cylinder temperatures helped to oxidize the CO emissions formed within the cylinder. 6. Rise in in-cylinder temperatures because of the insulation has resulted in increased gas temperatures and thus NOx emissions. The insulation has resulted in around 4%,higher at full load. REFERENCES [1] Jianmin Chen, Huidi Zhou, Guang Liu Yulong An, "Microstructure and thermal cycle resistance of plasma sprayed mullite coatings made from secondary mullitized natural andalusite powder," Surface & Coatings Technology, 205 , pp. 1897–1903, 2010. [2] Roy Kamo, "Adiabatic Diesel-Engine Technology In Future Transportation," Energ Vol. 12, No. 10/ll,198,Pergamon Journals Ltd, pp. pp. 1073-1080, 1987. [3] Dieter Pitzer, Gerhard Pracht,Robert Vassen,and Detlef Stover Henry Lehmann, "Thermal Conductivity and Thermal Expansion Coefficients of the Lanthanum Rare-Earth-Element Zirconate System," J. Am. Ceram. Soc., 86 [8], pp. 1338–44 , 2003. [4] C M V Prasad, "Performance evaluation of non-edible vegetable oils as substitute fuels in low heat rejection diesel engines," Proc Instn Mech Engrs Vol 214 Part D, 1999. [5] Ramachandran et al, "Synthesis, spheroidization and spray deposition of lanthanum zirconate using thermal plasma process," Surface & Coatings Technology,206, pp. 3017–3035, 2012. [6] Bryzik E Kamo R, "Adiabatic turbo compound engine performance prediction.," 1978. [7] Gervin IJ, Wade WR. Havstad PH, "A ceramic insert uncooled diesel engine," 1986. [8] Ozturk U. Hazar H, "The effects of Al2O3eTiO2 coating in a diesel engine on performance and emission of corn oil methyl ester.," vol. 86,1-6, 2101. [9] S.P. Sivapirakasam,M. Udayakumar M. MohamedMusthafa, "Comparative studies on fly ash coated low heat rejection diesel engine on performa nce and emission characteristics fueled by rice bran and pongamia methyl ester and their blend with diesel," vol. 36,2343-2351, 2011. [10] Hanbey Hazar, "Characterization and effect of using cotton methyl ester as fuel in a LHR diesel engine," vol. 52,258-263, 2011. [11] Wu YG, Chang CT Lin YF, "Combustion characteristics of waste-oil produced biodiesel/diesel fuel blends," vol. 86,1772-80, 2007. [12] Miguez JL, Porteiro J, Granada E, Moran JC Murillo S, "Performance and exhaust emissions in the use of biodiesel in outboard diesel engines," vol. 86,1765-71, 2007;86. [13] Cevik I, Akcil M. Uzun A, "Effects of thermal barrier coating on a turbocharged diesel engine performance.," vol. 505–7,116–119, 1999.
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International Journal of
Advanced Research in Engineering and Technology (IJARET), ISSN 0976 – 6480(Print), ISSN 0976 – 6499(Online) Volume 4, Issue 3, April (2013), © IAEME 25 [14] Hüseyin Aydın Bahattin ş can, "Improving the usability of vegetable oils as a fuel in a low heat rejection diesel engine," vol. 98,59-64, 2012. [15] B.T. Tompkins, J.A. Bittle, T.J. Jacobs H. Song, "Comparisons of NO emissions and soot concentrations from biodiesel-fuelled diesel engine," Fuel, vol. 96, pp. 446-453, 2012. [16] N. ALAGUMURTH,C.G. SARAVANAN K. ANANDAVELU, Proceedings of the ASME 2010 International Mechanical Engineering Congress & Exposition , November 12-18, 2010, Vancouver, British Columbia, Canada. [17] P.G. Tewari N.R. Banapurmath, "Perf ormance studies of a low heat rejection engine operated on non-volatile vege table oils with exhaust gas recirculation," International Journal of Sustainable Engineering(Taylor and Francis), vol. Vol. 2, No. 4, pp. 265–274, December 2009. [18] Samria NK Prasad R, "Heat transfer and stress fields in the inlet and exhaust valves of a semi- adiabatic diesel engine," Comput Struct, vol. 35(5), pp. 765-77, 1990. [19] Fort EF, Bulumberg PN Morel T, "Effect of insulation strategy and design parameters on diesel engine heat rejection and performance," vol. SAE Paper 850506, 1985. [20] V.Narasiman, S.Jeyakumar, M. Mani and K.Rajkumar, “Impact of Combustion on Ignition Delay and Heat Release Curve of a Single Cylinder Diesel Engine using Sardine Oil as a Methyl Ester”, International Journal of Mechanical Engineering & Technology (IJMET), Volume 3, Issue 3, 2012, pp. 150 - 157, ISSN Print: 0976 – 6340, ISSN Online: 0976 – 6359. [21] Pundlik R. Ghodke and Dr. J. G. Suryawanshi, “Simulation and Optimization of HSDI Diesel Engine for Suv to Meet Bharat 4 Emission Norms in India”, International Journal of Mechanical Engineering & Technology (IJMET), Volume 3, Issue 2, 2012, pp. 494 - 510, ISSN Print: 0976 – 6340, ISSN Online: 0976 – 6359.
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