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Volume 6, Issue 11, Nov 2015, pp. 132-144, Article ID: IJMET_06_11_016
Available online at
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=6&IType=11
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
IAEME Publication
AN EXPERIMENTAL INVESTIGATION ON
ENGINE PERFORMANCE OF A LOW HEAT
REJECTION (MULLITE COATED) SINGLE
CYLINDER DIESEL ENGINE WITH AND
WITHOUT TURBOCHARGER
Parvezalam Shaikh and S.P. Yeole
Department of Mechanical Engineering,
P.R Pote (Patil) Group of Educational Institutions, Amravati, India
ABSTRACT
In Present Investigation at the first stage, experiments were conducted on
baseline (Conventional) engine and hence combustion and emission
Parameters were recorded. At second stage Mullite, which is a compound of
SiO2 and Al2O3 with composition 3Al2O3.2SiO2 (Aluminium oxide 60% and
Silicon dioxide 40%), was used as a (TBC) thermal barrier coating material.
The piston crown, cylinder valves and cylinder head of diesel engine were
coated with a 0.5 mm thickness of 3Al2O3.2SiO2 (mullite) over a 150-m
thickness of Nickel Chrome Aluminium Yttrium (NiCrAlY) bond coat using
plasma spray technique to achieve less heat loss and combustion and emission
Parameters were recorded for LHR engine. The operational parameters i.e.
air-fuel ratio and engine speed conditions were maintained constant for both
conventional as well as Low Heat rejection engines. In Third stage, the
experiments were conducted on turbocharged low heat rejection (LHR) single
cylinder diesel engine with advanced injection timing. The main objective of
the study was to evaluate combustion parameters and overall engine
performance of these engines. The experiments were carried out for various
loads via. 0%, 25%, 50%, 75% and maximum loads, then the results were
compared. The evaluation of experimental data showed that the brake thermal
efficiency and brake power values of Low heat rejection (LHR) engine were
slightly higher than that of conventional diesel engine. It was also found that
heat lost to coolant is reduced and there is increase in energy of exhaust gases
for Low heat rejection (LHR) engine when compared with the conventional
single cylinder diesel engine. Emission characteristics such as NOx are
increased and there is decrease in HC and CO in case of LHR Engine when
compared with conventional engine. Whereas Low heat rejection (LHR)
engine with turbocharger showed deterioration in the engine performance
when compared with Low heat rejection (LHR) diesel engine without
turbocharger.
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1. INTRODUCTION
Because of increasing requirements of governments and customers, car manufacturers
and researchers are always trying to reduce fuel consumption while maintaining the
best engine performance. The insulation of the combustion chamber surfaces strongly
influences the performance and exhaust emissions of direct injection diesel engines.
Thermal barrier coatings (TBCs) have been a topic of great scientific interest
worldwide for several decades. They have been used for engine components, in
turbines and aircraft engines in order to achieve improved engine performance and
fuel efficiency by increasing the actual temperature of engine operation.
In the present investigation, Mullite, which is a compound of SiO 2 and Al2O3 with
composition 3Al2O3.2SiO2 (Al2O3= 60%, SiO2= 40%), is used as a thermal barrier
coating material for single cylinder diesel engine. Mullite is an important ceramic
material because of its low density, high thermal stability, stability in severe chemical
environments, low thermal conductivity and favorable strength and creep behavior. It
is a compound of SiO2 and Al2O3 with composition 3Al2O3.2SiO2. Compared with
YSZ, mullite has a much lower thermal expansion coefficient and higher thermal
conductivity, and is much more oxygen-resistant than YSZ. Yttria-stabilized zirconia
(YSZ) has emerged as the preferred TBC material due to its low thermal conductivity
(~1 W/mK) over a range of temperatures. The ceramic, mullite, though, has the
advantage of having reduced thermally activated time-dependent behavior compared
to YSZ [1]. Diesel engine rig tests performed in the past have demonstrated that
mullite coatings on pistons experienced decreased surface cracking and increased life
compared to YSZ coatings on pistons [2]. For the applications such as diesel engines
where the surface temperatures are lower than those encountered in gas turbines and
where the temperature variations across the coating are large, mullite is an excellent
alternative to zirconia as a TBC material. Life of Mullite coating is more than the
zirconia coating tested under same condition. Mullite is most promising coating
material for the SiC substrate because their thermal expansion coefficients are similar.
The objective of this investigation have been also to evaluate the effect of thin
mullite coating on engine exhaust emissions for both the LHR and conventionally
cooled diesel engines.
In the present research work, the concept of an adiabatic turbo compound diesel
engine has been introduced. The pulse turbocharger (suits to the specification of given
diesel engine), which utilized the kinetic energy of exhaust gases of low heat rejection
(LHR) diesel engine, has been used for experimentation. The objective of this
investigation has been to study the effect of pulse turbocharger on the engine
performance parameters of low heat rejection (LHR) diesel engine. The thermal
barrier coatings (TBCs) enable to lower temperature (Fig.2.1) (at approx. 170C) of
operating elements, exposed to creeping, in a hot section of gas turbine (e. g.
combustion chambers and directing and rotating blades) to a range, which enables to
operate for a long time in conditions of high temperature influence and prolongs
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2. EXPERIMENTAL SETUP
A four stroke, direct injected, water-cooled, single cylinder, naturally aspirated diesel
engine was used for investigation. Details of the engine specifications are given in
Table 1.
Table 1 Engine specifications
Engine type
Kirloskar AV1, DI
Stroke number
Cylinder number
Stroke (mm)
110
Compression ratio
16.5:1
3.7
1500
245
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4.5
Conventional
Engine
LHR Engine
3.5
3
2.5
2
No Load 1/4 Load 1/2 Load 3/4 Load Full Load
Load (Kg)
Conventional
Engine
Load (Kg)
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Load Vs BSFC
BSFC (Kg/Kwhr)
0.8
Conventional Engine
0.7
LHR Engine
0.6
0.5
0.4
0.3
0.2
0.1
0
No Load 1/4 Load 1/2 Load 3/4 Load Full Load
Load (Kg)
35
Conventional Engine
30
LHR Engine
25
20
15
10
5
0
No Load 1/4 Load 1/2 Load 3/4 Load Full Load
Load (Kg)
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low and medium loads thermal efficiency shows less variation for LHR engine when
compared to the conventional engine. This is because that heat recovered by
insulation which is generally lost to the cooling, is converted into useful work
(indicated work). But all the heat recovered by the insulation may or may not be able
to get converted into some useful work. Therefore, the rate of increasing thermal
efficiency for LHR engine is minor compared to conventional engine.
3.2 Comparisons of experimental results such as engine exhaust emissions of the
conventional (without coating) and LHR (mullite coated) diesel engines under
identical conditions
After conducting long-term experimental investigations on a single cylinder, four
stroke, direct injection, conventional (without coating) and LHR (mullite coated)
diesel engines, the engine exhaust emissions such as carbon monoxide (CO),
Nitrogen-oxides (NOx), Unburned hydrocarbons (UHC), and exhaust gas temperature
all as a function of load for both the Conventional and LHR engines are calculated.
The engine exhaust emissions are found for 25%, 50%, 75% of full engine load and
full engine load condition for both conventional and LHR diesel engines.
Fig.8 shows the comparison of NOx variations as a function of engine load for
conventional and LHR engine. It is found that the NOx emission for LHR engine is
more as compared to conventional engine. The NOx emission for LHR engine at full
engine load is 20.19 % higher than conventional engine. The increase of NOx
emission for in the LHR engine may be due increase in after-combustion temperature
due to the mullite coating. This is due to higher combustion temperature and having
longer combustion duration.
Conventional Engine
LHR Engine
5
4
3
2
1
0
No Load
1/4 Load
1/2 Load
Load (Kg)
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temperatures in the gases and at the combustion chamber walls of the LHR engine
allows the oxidation reactions to close to completion results in decreasing the
Hydrocarbon (HC) emissions.
Conventional Engine
LHR Engine
Load (Kg)
Conventional Engine
LHR Engine
4
3
2
1
0
No Load 1/4 Load 1/2 Load 3/4 Load Full Load
Load (Kg)
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Conventional Engine
LHR Engine
Load (Kg)
0.7
LHR Engine without
Turbocharger
0.6
0.5
0.4
0.3
0.2
No Load 1/4 Load 1/2 Load 3/4 Load Full Load
Load (Kg)
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compared with the LHR engine without turbocharger. The increase in brake specific
consumption at low engine load is 2.89 % while the increase in brake specific
consumption at full engine load is 2.10 % for LHR engine with turbocharger
compared with the LHR engine without turbocharger. This is due to fact that the
increase of back pressure on the engine due to turbocharger. As the back pressure
goes on increasing, the engine must work harder to pump the gases out of the cylinder
against the higher pressure. The pressure ratios across the turbocharger compressor
and turbine decrease, reducing the mass flow of air through these components and
thus the air available to the engine. At the same time, the fuel flow to the engine
increases so as to provide the extra power required to overcome the increased
pumping losses while maintaining a brake power output constant. As a result the
brake thermal efficiency decreases and brake specific fuel consumption increases
above that for a LHR engine without Turbocharger. Also it is observed that at low and
medium loads the brake thermal efficiency decreases due to the effect of "turbo lag".
At low and medium engine loads of the engine, the "turbo lag" occurs in exhaust gas
turbocharger because the mechanical power transmitted from the turbine wheel to the
compressor rotor of the exhaust gas turbocharger is at all no longer sufficient for the
engine to increase the pressure in the intake tract of the engine due to the low exhaust
gas volume flow.
3
2.5
2
1.5
1
0.5
0
No Load
Load (Kg)
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4. CONCLUSION
The main conclusions of these experimental investigations are summarized as
follows.
Exhaust gas temperature increases as the engine load increases for both conventional
and LHR engines. The increase in exhaust gas temperature in the LHR engine,
compared with the conventional engine is 22 % at full load condition
5. REFERENCES
[1]
[2]
[3]
[4]
Brunauer G., Frey F., Boysen H. and Schneider H., High temperature thermal
Expansion of mullite: an in-situ neutron diffraction study up to 1600 oC, J. Eur.
Ceram. Soc., Vol. 21, pp 25632567, 2001.
Vassen R., Cao X.Q., Tietz F., Basu D., and Stover D. Zirconates as new
Materials for thermal barrier coatings, Journal of the American Ceramic Society,
Vol. 83, pp 2023-2028, 2000.
Meier S.M., Gupta D.K., The evolution of thermal barrier coatings in gas turbine
Applications, Journal of Engineering for Gas Turbines and Power, Vol.116, pp
250257, 1994.
Gilbert A., Kokini K., Sankarasubramanian S., Surf. Coating Technol., Vol.202
pp 2152, 2008.
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[8]
[9]
[10]
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