Long Term Assessment Trial on a Slow Speed Diesel
Engine fuelled with Straight Jatropha Oil
PARTIAL REPORT
(THIRD PHASE)
October 2007 – January 2009
Submitted to
The GAIA-Movement,
International Environment House,
9 chemin de Balexert
1219 Châtelaine (Geneva)
From
Humana People to People India
C-183, Madhuban, New Delhi – 110092, INDIA
1
1.Title of the Project
:
Development of Dual Fuel System and Long Term
Assessment of Utilization of Straight Vegetable Oil in
Diesel Engine
Humana People to People India
C-183, Madhuban, New Delhi – 110092, INDIA
2. Name of the Implementing :
agency
3. Collaborating Institute, if any
:
4. Project Commencement after :
completion of formalities
5. Duration of the Project
Delhi College of Engineering, Delhi, India
September
:
2008
Six Months
6. Objectives of the Project
:
• Carry out endurance test of another 512 hours on high speed diesel engine with pre-heating
arrangement (The test rig was already developed during the second phase and 512 hours of
trial was conducted on pre-heated JO which proved to be satisfactory.
• Commissioning of a slow speed diesel engine for SVO application (dual fuel system without
heating)
• Endurance Test of diesel engine running on SVO with dual fuel system
• Provision of heating arrangement through exhaust gases in slow speed diesel engine and
carry out endurance test of 512 hours on pre-heated JO
• Analysis of wear after the endurance test(s) and preparation of report
2
1.0
EXECUTIVE SUMMARY
Jatropha activities are attractive because they are viable in adverse conditions and may
help to counter drought, desertification, soil degradation, and climate change and to increase
permanent crops and protection of biodiversity in tropical and subtropical developing countries.
Additionally, jatropha undertakings provide a synergy of rural energy production, environmental
protection and food security by erosion control, acting as a living fence to protect from water and
wind, increasing income of rural dwellers, promoting women and providing renewable fuel. The
fact that a huge amount of foreign exchange is used to import mineral fuels from oil exporting
countries raises the demand for using an alternative, locally produced fuel as an extender or
substitute to mineral diesel in developing countries. Furthermore, the high number of unpaved
roads, particularly in remote areas, makes transporting petroleum products to rural areas very
difficult. This increases the need for seeking a local fuel solution. The present study investigates
doing a new 512 hours endurance test on a high speed diesel engine on pre-heated jatropha oil (a
512 hours of endurance test has already been completed during second phase) and conduct of
512 hours trial on a slow speed diesel engine on neat jatropha oil (unheated) using a dual fuel
tank approach. Both the engines were run for 512 hours on neat jatropha oil (preheated and
unheated) and analysis of wear of various vital engine parts during the endurance tests was
carried. The results obtained on high speed diesel engine fuelled with pre-heated Jatropha Oil
suggest that in longer term; even pre-heated jatropha oil has not performed that well. The ring
sticking was found to occur. However, other features were satisfactorily. Therefore, in the light of
two successive endurance tests of 512 hours each, it can be concluded that problems associated
with neat vegetable utilization (with preheating) in high speed diesel engine have been delayed
but not completely eliminated.
The long term trial on slow speed diesel engine has been very encouraging and no untoward
failure was encountered except heavy carbon deposits on engine parts.
In the light of the endurance test of 512 hours, it can be concluded that problems associated
with neat vegetable utilization are minimal in slow speed, IDI, diesel engine as compared to high
speed diesel engine.
3
4.0 STATEMENT OF THE PROBLEM
As Jatropha is becoming a sustainable source for diesel replacement in India, its high viscosity
issue is resolved by adapting two strategies; first to modify the engine to adapt to the fuel and the
second for processing the fuel to adapt to the engine. The literature suggests that modifying
existing diesel engines to preheat Jatropha oil to reduce viscosity and could achieve the first
strategy. The adaptation of Jatropha oil to the diesel engine could be done by blending the
Jatropha oil with diesel or converting into biodiesel through transesterification process as a part
of second strategy. As transesterification process requires expertise and equipments are not easily
understandable to rural community and blending still require diesel, it shall be advisable to
formulate the strategy in which neat Jatropha oil could be used in diesel engine with out
detrimental effect on engine health. In this regard, it was found that very little quantum of work
has been done on potential suitability of Jatropha oil in slow speed diesel engine and no work has
been reported on assessing the aptness of neat Jatropha oil in slow speed IDI Engine.
The following objectives have been set for the third phase of the project.
•
Carry out endurance test of another 512 hours on high speed diesel engine with pre-heating
arrangement (The test rig was already developed during the second phase and 512 hours of
trial was conducted on pre-heated JO which proved to be satisfactory.
•
Commissioning of a slow speed diesel engine for SVO application (dual fuel system without
heating)
•
Endurance Test of diesel engine running on SVO with dual fuel system
•
Provision of heating arrangement through exhaust gases in slow speed diesel engine and
carry out endurance test of 512 hours on pre-heated JO
•
Analysis of wear after the endurance test(s) and preparation of report
19
5.0
SYSTEM DEVELOPMENT
5.1
High Speed Diesel Engine Test Rig with pre-heating
The high speed diesel engine test rig was developed during second phase of the project and the
specification of the test engine is listed below in table 8.
Table 8:
Specifications of the Diesel Engine
Make
Kirloskar
Model
DAF 8
Rated Brake Power (bhp/kW)
8 / 5.9
Rated Speed (rpm)
1500
Number of Cylinder
One
Bore X Stroke (mm)
95 x 110
Compression Ratio
17.5:1
Cooling System
Air Cooled (Radial Cooled)
Lubrication System
Forced Feed
Cubic Capacity
0.78 Lit
Inlet Valve Open (Degree)
4.5 BTDC
Inlet Valve Closed (Degree)
35.5 ABDC
Exhaust Valve Open (Degree)
35.5 BBDC
Exhaust Valve Closed (Degree)
4.5 ATDC
Fuel Injection Timing (Degree)
26 BTDC
For conducting the desired set of experiments and together required data from the engine,
it is essential to get the various instruments mounted at the appropriate location on the
experimental setup. Apart from this, a dual fuel system has been developed for diesel and
jatropha oil.
The schematic diagram of the experimental setup with heat exchanger and along with all
instrumentation is shown in Figure 6. Overall pictorial view of the test rig along with
instrumentation
used
in
the
present
investigations
20
is
shown
in
Plate
1
&
2.
Figure 6: Schematic Diagram of the Experimental Set Up
Plate 1: Photograph of the Experimental Set Up
21
Plate 2: Photograph of Heat Exchanger Arrangement for Preheating by Exhaust Gases
5.2
High vs. Slow Speed Diesel Engine
The high speed diesel engine used during the first & second phase of the project was a DI
(Direct Injection) diesel engine. In this type of diesel engine, the fuel is squirted at a very high
pressure into the combustion chamber (a bowl in the piston). The slow speed diesel engine used
during the third phase of the project is an IDI (Indirect Injection) diesel engine. In IDI diesel
engine, the fuel is not directly injected in to the combustion chamber. An IDI diesel engine
delivers fuel into a chamber off the combustion chamber called a prechamber. The prechamber is
carefully designed to ensure adequate mixing of the atomized fuel with the compressed heated
air.
5.3
Selection of Engine
Diesel engines play an indispensable role in agriculture and transportation sector and as
such diesel consumption is expected to increase multi fold in future. The diesel engine continues
to dominate the agriculture sector in our country in comparison to spark ignition engine and have
always been preferred widely because of power developed, specific fuel consumption and
durability. In India, almost all irrigation pump sets, tractors, mechanized farm machinery and
heavy transportation vehicle are powered by direct injection diesel engines. However, they are
22
not considered suitable for vegetable oil adaptation on a long term basis. Considering the wide
application of a small capacity diesel engine which has got great dominance in Indian agriculture
sector, a slow speed, IDI, lister type, 4 stroke diesel engine was selected for the present study as
the maintenance of this engine is very simple and due to its slow speed potential suitability of
neat JO is more in this kind of engine.
5.4
Development of Experimental Test Rig
The indirect injection (IDI) diesel engine used for this study is manufactured by Rolex
Industries Engines Limited. It is widely used in India in agriculture for running the irrigation
pump sets, running agriculture machinery and for driving different machines in industrial sector
and shown in Plate 3.
Plate 3: Slow Speed Diesel Engine
It is a single cylinder, naturally aspirated, four stroke, vertical, water-cooled engine. It has a
provision of loading electrically since it is coupled with single phase alternator through belt and
pulley arrangement. The cylinder is made of cast alloy and fitted with a hardened highphosphorus cast iron liner. The lubrication system used in this engine is of splash type. The
engine can be hand started using decompression lever and is provided with spring loaded
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governor. The engine was started on diesel engine and after some time (10-15 minutes) it was
switched on to the neat Jatropha mode. The detailed technical specifications of the engine are
given in Table 9.
Table 9:
Specifications of the Lister type Diesel Engine
Make
Rated Brake Power (bhp/kW)
Rated Speed (rpm)
Number of Cylinder
Bore X Stroke (mm)
Compression Ratio
Cooling System
Lubrication System
Cubic Capacity
Inlet Valve Open (Degree)
Inlet Valve Closed (Degree)
Exhaust Valve Open (Degree)
Exhaust Valve Closed (Degree)
Fuel Injection Timing (Degree)
Flywheel Dimension & Face
Foundation Stud Hole Center
Distance
Crankshaft Center Dist. from Base
Engine Total Height
Rolex
5 / 3.725
600
One
114.3 x 139.7
18:1
Water Cooled
Splash
1.43 Lit
5 BTDC
15 ABDC
45 BBDC
5 ATDC
20 BTDC
600 X 89
330 X 330
318
1016
For conducting the desired set of experiments and together required data from the engine,
it is essential to get the various instruments mounted at the appropriate location on the
experimental setup. Apart from this, a dual fuel system has been developed for diesel and
Jatropha oil.
The schematic diagram of the experimental setup along with all instrumentation is shown
in Figure 7. Overall pictorial view of the test rig along with instrumentation used in the present
investigations is shown in Plate 4.
24
Figure 7: Schematic Block Diagram of Engine Setup
Plate 4: Photograph of the Test Rig
25
5.5
Installation of the Instrument Control Panel
After finalizing the procedures for data collection and procurement of the desired
instruments, they were put on a panel. A MS Control panel was fabricated and Instruments such
as voltmeter, ammeter, watt meter, speed counter, six channels digital temperature display was
mounted on the front side of the control panel (Plate 5). Electrical load bank, i.e. 16 bulbs each
of 500 watts, were mounted on the rear side of the control panel which is shown in Plate 6 and
their switches provided on the front side of the control panel.
Plate 5: Control Panel
Plate 6: Incandescent Bulbs on the Control Panel
One 50ml burette with stop cocks was also mounted on the front side of the panel for fuel flow
26
measurements of either diesel fuel or Jatropha oil. The two fuel tanks were mounted on the rear
side of the panel at highest position with stop cocks as shown in plate 7 & 8.
Plate 7: Two Tanks System
Plate 8: Valves for Controlling Supply of Jatropha Oil and Diesel
A voltmeter, ammeter and wattmeter were connected between alternator and load bank. A
nut was welded on the flywheel and the photo reflective sensor was mounted on a bracket
attached to engine body. The thermocouples were mounted in the exhaust manifold to measure
the exhaust temperature. The AVL 437 smoke meter and AVL Di Gas Analyzer were also kept in
proximity for the measurements of various exhaust gas parameters.
27
Thus such a system was chosen to examine the practical utility of Jatropha oil in such
applications. Besides being a single cylinder system it was light and easy to maintain. The engine
was provided with suitable arrangement, which permitted wide variation of controlling
parameters. Being a water cooled engine it was suitable for hot climate. Absence of radiator,
water body and pump made the system more suitable for the tests.
5.6
Experimental Approach
The high speed diesel was subjected to long term endurance test straight away since 512
hours of trial was already done on the engine on pre-heated Jatropha oil. For slow speed diesel
engine, preliminary run was conducted at rated speed of 600 rpm to ensure that the engines is
made trouble free for its exhaustive test run. This was done in accordance with IS: 10,000 Part
V. During the preliminary run, engines are subjected to preliminary run of 49 hours at the
operating temperature specified by the manufacturer, in a non stop cycles of seven hours each
confirming to the following cycle pattern, the period of each run being a minimum of one cycle.
Accordingly, after commissioning of the engine test rig, the engine was initially run for 49 hours
on diesel fuel. The details of loading cycle are given in Table 10.
Table 10: Loading cycle for preliminary run of constant speed engine
Load (% of rated load)
Running Time (hours)
25
1.5
50
2
75
1.5
100
2
After completion of preliminary 49 hrs test on the engine, long term endurance test was
started on the slow speed diesel engine with Jatropha oil as a fuel in a dual tank operation
method. The cycle adopted for long term endurance test is mentioned in Table 11. The total trial
on the diesel engine has been kept as 8 hrs per day. The same cycle was also adopted for high
speed diesel engine with preheated Jatropha oil.
Table11: Test cycle for long term endurance test
Load (% of rated load)
Running time (hours)
100
2(including warm-up period for 0.25hours)
50
2
28
110
No load (idling)
100
50
0.5
0.25
1.5
1.75
6.0
Photograph Showing Results of the Long Term Endurance Test for High
Diesel Engine
Speed
Plate 9: Cylinder Head of High Speed Diesel Engine after Completion of Endurance Test
Plate 10: Upper Face of the Piston of High Speed Diesel Engine after Completion of
Endurance Test
29
Plate 11: Photograph of the Piston of High Speed Diesel Engine after Completion of
Endurance Test
Plate 12: Piston Rings of High Speed Diesel Engine after Completion of Endurance Test
Plate 13: Injector of High Speed Diesel Engine after Completion of Endurance Test
30
Plate 14: Fuel Filter of High Speed Diesel Engine after Completion of Endurance Test
The long term trial 512 hours of endurance test was completed and a total of 512 hours was
accumulated with pre heated jatropha oil as a fuel. The engine was opened on 09.01.2009 to
assess the wear and tear of vital engine parts and condition of the fuel filter. Major findings after
completion of trial are as follows:
1. It was found that sticking of top two compression ring have taken place.
2. The remaining third compression ring and two oil scrapping rings were found to be in
good condition. As Jatropha oil has high viscosity and results in sticking of the piston
rings. In the first phase of the project, the ring sticking occurred many times on neat
Jatropha oil (without preheating). However, with the preheating the viscosity of Jatropha
oil has been reduced and frequency of ring sticking has been drastically reduced. It is
relevant to mention that ring sticking has been observed only after 1024 hours of
endurance test.
3. The inlet and exhaust valves were in good condition.
4. Moderate carbon deposit was noticed at the upper face of the piston and cylinder head.
5. The space for the piston ring on the piston was found to be reduced.
6. Excessive carbon deposits were noticed at the tip of the injectors. However, all the holes
of the injector were working satisfactorily.
7. The sedimentation was found on the fuel filter and housing. This is due to un-saturation
and presence of wax in the jatropha oil. It is relevant to mention that preheating reduces
viscosity. However; it has no control over unsaturation and wax particles. Therefore,
31
sedimentation is expected to occur even with preheating.
8. Some scratches on the cylinder were observed which are due to ring sticking.
In the light of two endurance tests of 512 hours each, it can be concluded that problems
associated with neat vegetable utilization (with preheating) in high speed diesel engine have been
delayed but not completely eliminated.
7.0
Photograph of the New Piston & Piston Ring of Slow Speed Diesel Engine
32
8.0
Photograph Showing Results of the Endurance Test for Slow Speed Diesel
Engine
Plate 15: Cylinder Head of Slow Speed Diesel Engine after Completion of Endurance Test
Plate 16: Upper Face of Piston Head of Slow Speed Diesel Engine after Completion of
Endurance Test
33
Plate 17: Photograph of the Piston & Piston Ring of Slow Speed Diesel Engine after
Completion of Endurance Test
Plate 18: Injector of Slow Speed Diesel Engine after Completion of Endurance Test
Plate 19: Fuel Filter of Slow Speed Diesel Engine after Completion of Endurance Test
The long term trial 512hrs of endurance test was completed on Jatropha oil (unheated) as a
34
fuel in slow speed diesel engine. The engine was opened on 18.01.2009 to assess the wear and
tear of vital engine parts and condition of the fuel filter. Major findings after completion of trial
are as follows:
1. It was found that no ring sticking has taken place which was experienced in high speed
diesel engine.
2. The slow speed of the diesel engine under investigation has actually given favorable
results because due to slow speed more time was available for the combustion and very
less fuel was unburnt.
3. The inlet and exhaust valves were in good condition.
4. Heavy carbon deposit was noticed at the upper face of the piston and cylinder head.
5. The piston was found in a good condition. It is relevant to mention that the piston used in
high speed diesel engine is made up of aluminum alloy and that of slow speed diesel
engine is of cast steel. Since, steel is stronger than aluminum therefore, no damage was
found in slow speed diesel engine piston.
6. Excessive carbon deposits were noticed at the tip of the injectors. However, all the holes
of the injector were working satisfactorily.
7. The sedimentation was found on the fuel filter and housing. This is due to un-saturation
and presence of wax in the jatropha oil.
In the light of the endurance test of 512 hours, it can be concluded that problems associated
with neat vegetable utilization are minimal in slow speed diesel engine as compared to high
speed diesel engine.
8.0
RECOMMENDATIONS
Despite using preheating of Jatropha oil in high speed diesel engine, the results have not
been very favorable in a longer term, whereas the endurance test on slow speed diesel engine
(without preheating) has clearly established the suitability of adaptation of neat vegetable in slow
speed, IDI, diesel engine. Therefore, the first part of the third phase advocates utilization of
Jatropha oil in slow speed diesel engine either for rural electrification or driving many
agriculture equipments. In the second part of the third phase, the long term suitability of
preheated Jatropha oil (Using exhaust heat of the engine) shall be investigated.
35
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