59 CHAPTER 5 EXPERIMENTAL PERFOMANCE ANALYSIS WITH EGR 5.1 EXHAUST GAS RECIRCULATION SYSTEM 5.1.1 Introduction to EGR The most effective way of reducing NOx emissions is to hold combustion chamber temperatures down. Although practically, this is a commonly used method in that it also reduces the thermal efficiency of the engine. Probably the simplest and practical method of reducing maximum flame temperature is to dilute the air-fuel mixture with a non-reacting gas. This gas absorbs energy during combustion without contributing any energy input. The net result is a lower flame temperature. Any non-reacting gas would work as diluents. Those gases with larger specific heats would absorb the most energy per unit mass and would therefore require the least amount, thus less CO2 would be required than argon for the same maximum temperature. However, neither CO2 nor argon is readily available for use in an engine. Air is available as diluents but is not totally non-reacting. Adding air changes the air-fuel ratio and combustion characteristics. The one nonreacting gas that is available to use in an engine is exhaust gas and this is used in all modern automobile and other medium-size to large engines. Adding any non-reacting neutral gas to the inlet air-fuel mixture reduces flame 60 temperature and NOx generation. Exhaust gas is the one gas that is readily available for engine use. 5.1.2 EGR Operation The purpose of the EGR system is to precisely regulate exhaust gas to engine under different operating conditions, which would compromise good engine performance. The precise amount of exhaust gas, which must be metered into the intake manifold, varies significantly as engine load changes. This results in the EGR system operating on a fine line between good NO x control and engine performance. If too much exhaust is metered in the engine the performance will suffer, if too little EGR flows, the engine may knock. 5.1.3 Classification of EGR Systems EGR systems have been classified on the basis of EGR temperature, configuration and pressure. 5.1.3.1 Classification Based on Temperature Hot EGR Exhaust gas is re-circulated without being cooled, resulting in increased intake charge temperature. Fully Cooled EGR Exhaust gas is fully cooled before mixing with fresh intake air, using a water-cooled heat exchanger. In this case, the moisture present in the exhaust gas may condense and the resulting water droplets may cause undesirable effects inside the engine cylinder. 61 Partly Cooled EGR To avoid water condensation, the temperature of the exhaust gas is kept just above its dew point temperature. 5.1.3.2 Classification Based on Configuration Long Route System In a long route system the pressure drop across the air intake and the stagnation pressure in the exhaust gas stream make the EGR possible. The exhaust gas velocity creates a small stagnation pressure, which in combination with low pressure after the intake air, gives rise to a pressure difference to accomplish EGR across the entire torque/speed envelope of the engine. Short Route System This system differs mainly in the method used to setup a positive pressure difference across the EGR circuit. Another way of controlling the EGR-rate is to use Variable Nozzle Turbine (VNT). Most of the VNT systems have single entrance, which reduces the efficiency of the system by exhaust pulse separation. Cooled EGR should be supplied effectively. 5.1.3.3 Classification Based on Pressure There are two different routes for EGR, namely low-pressure and high-pressure route systems. Low Pressure Route System The passage for EGR is provided from downstream of the turbine to the upstream side of the compressor. It is found that by using the low-pressure 62 route method EGR is possible up to a high load region, with significant reduction in NOx. High Pressure Route System The EGR is passed from upstream of the turbine to downstream of the compressor. In the high-pressure route EGR system, although EGR is possible in the high load regions, the excess air ratio decreases and fuel consumption increases remarkably. 5.1.4 Advantages and Disadvantages of using EGR With the use of EGR, there is a trade-off between reduction in NO x on one hand and increase in products of incomplete combustion like soot, CO and unburned hydrocarbon emissions on the other hand. It is seen that HC continued to decrease until the EGR rate reached a certain level and the fuel economy decreased. It has been indicated that for more than 60% EGR particulate emission increased significantly. Therefore EGR must be coupled with a particulate filtration system not only to lower the emission of soot to the atmosphere, but also to provide an exhaust stream that is clean enough to be re-circulated. The changes in the oxygen concentration cause the change in the flame and hence changes the duration of combustion. It was suggested that the flame temperature suppression is the most important factor influencing the NOx formation. Implementation of EGR in diesel engine has problems like increased soot emission. A particulate matter may be introduced in to the engine cylinders. When the engine components come into contact with a high velocity soot particulates, particulate abrasion occurs. Moreover when much soot builds up on the interior of the air intake manifold, the air pressure drop increases and the volume of intake air decreases, thereby decreasing the 63 power of the engine. Much of the soot content in the exhaust enters the engine and the soot adheres to the surface of the combustion chamber. Soot build-up on the surface of the combustion chamber impedes heat transfer at high temperature; the strength of the combustion chamber weakens. Soot carried in the blow-by gas deteriorates the properties of the lubricating oil in the crankcase. This in turn increases friction losses and requires more frequent oil changes. The percentage of exhaust gas re-circulated in the engine is given by Equation (5.1). % 5.2 = 100 (5.1) EXPERIMENTAL METHOD The test engine is a single cylinder, direct injection, water cooled Compression Ignition engine. The experimental setup is shown in Figure 5.1. An orifice box is connected to the inlet manifold and the air mass flow rate is measured using the manometer connected to the orifice box. The EGR system consists of a piping system taken from the engine exhaust pipe and an orifice meter is to used measure the flow rate of the exhaust gases. The amount of exhaust gas recycling into the inlet manifold is controlled by means of two valves, one in the inlet pipe and the other in the pipe line connecting the exhaust line and the inlet manifold. The re-circulated exhaust gas flows through another orifice meter with inclined manometer for measuring the flow rate, before mixing with the fresh air. Cold EGR is attained by cooling the recirculated exhaust gas. The exhaust gas recirculation line is connected to a parallel flow heat exchanger having water as the cold fluid. Thermometers are connected to inlet and exit of the cold and hot fluids in the heat exchanger. The probe of exhaust gas analyzer is inserted into the exhaust pipe for emission measurement. The engine is loaded using rope brake dynamometer. The load on the engine as well as the time taken to consume 25 cc fuel was 64 noted and the remaining performance parameters were calculated using the standard formulae mentioned in chapter 4. At the same time the emission values were recorded for all engines and for all conditions by changing the percentage of EGR. 5.2.1 Experimental Setup Figure 5.1 Experimental Setup 1. Air inlet 2.Air inlet Orifice box 3. Air inlet manometer 4.Air inlet control valve 5. CI engine 6.Exhaust gas control valve 7. EGR control valve 8.Heat exchanger 9. Water inlet 10.Water outlet 11. Exhaust gas Orifice box 12.Exhaust gas manometer 13. EGR pipe 14.Particulate filter 65 5.3 EXHAUST GAS ANALYSER The Kane automotive range of emission analysers has been designed to be used for Petrol, LPG and Diesel powered vehicles. It can measure carbon monoxide, unburned hydrocarbons, Oxygen, Carbon dioxide and Nitrous oxide. The analyser is supplied with an RS232 output enabling communication between the analyser and a PC. It is battery powered to give true portability in the workshop environment. The battery can be charged via an adapter or 12V capacity battery and the specifications are listed in Table 5.1. Table 5.1 Exhaust Gas Analyser Specifications Parameter Resolution Accuracy Range Carbon monoxide 0.01% +/-5% of reading +/-5% volume 0-10% Over-range 20% Oxygen 0.01% +/-5% of reading +/-0.1% volume 0-21% Over-range 48% Hydrocarbon 1ppm +/-5% of reading +/-12ppm volume 0-5000ppm Over-range: 10000ppm Carbon Dioxide 0. 1% +/-5% of reading +/-0.5% volume 0-16% Over-range 25% Nitrous oxide 1ppm 0-4000ppm+/-4%or 25ppm;40005000ppm +/-5% 0-5000ppm Oil temperature 1.0oC +/-2.0oC±0.3%of reading+/-3.6oF±of reading 0-150oC 32-302oC Carbon monoxide corrected CO 0.01% Calculated 0-15% 66 5.4 RESULTS AND DISCUSSION The trends of thermal efficiency are shown in Figures 5.3, 5.8, 5.13 and 5.18. Thermal efficiency is found to have slightly increased with EGR at lower engine loads. The possible reason may be re-burning of hydrocarbons that enter the combustion chamber with the re-circulated exhaust gas. At part loads, the exhaust gas has less CO2 and fairly high amount of O2. Also, partlycooled EGR acts like a pre-heater of the intake mixture. When this exhaust gas is re-circulated in the cylinder, the unburned HC in the exhaust gas was burned because of sufficient O2 available in the combustion chamber and reasonably increasing intake temperatures. At higher engine loads, the thermal efficiency remains unaffected by EGR. At higher loads, the exhaust gas has higher amount of CO2, which reduces the maximum temperature in the combustion chamber along with oxygen availability, therefore re-burning of HC is not significant. Figures 5.2, 5.7, 5.12 and 5.17 represent comparison of SFC for all piston engines performance with different percentage of EGR. SFC is lower at lower loads for engine operated with EGR compared to without EGR. However, at higher engine loads, SFC with EGR is almost similar to that of without EGR. At higher loads, the amount of fuel supplied to the cylinder is increased at higher rate and the oxygen available for combustion gets reduced. Thus, the air fuel ratio is changed and this increases the BSFC. The exhaust gas temperatures have been increased with load. Exhaust gas temperature decreases with increase in EGR rate. The reasons for temperature reduction are relatively lower availability of oxygen for combustion and higher specific heat of intake air mixture. The effect of EGR on unburned HC and CO emissions are incremental with increasing EGR. Lower excess oxygen concentration results in rich air-fuel mixtures at different locations inside the combustion chamber. 67 This heterogeneous mixture does not burn completely and results in higher HC and CO emissions. At part loads, lean mixtures are harder to ignite because of heterogeneous mixture and produce higher amount of HC and CO. Figures 5.22 to 5.25 shows the main benefit of EGR in reducing NO x emissions from a diesel engine. The degree of reduction in NO x is higher at maximum loads. The reasons for reduction in NOx emissions using EGR in diesel engines are reduced oxygen concentration and decreased flame temperatures in the combustible mixture. At the part load, O 2 is available in sufficient quantity but at high loads, the availability of O 2 reduces drastically, therefore NOx is reduced more at higher loads compared to part loads. The NOx values were decreased due to the EGR addition up to 15% but if increasing beyond this limit, NO x values were increasing slowly and exceed the initial EGR percentage benefits. HEMISPHERE 0.6 0.5 0.4 Without EGR 0.3 5% EGR 0.2 10% EGR 15% EGR 0.1 20% EGR 0 0 5 10 Load kg 15 20 Figure 5.2 Specific Fuel Consumption of Hemisphere Piston Engine with EGR 68 HEMISPHERE 50 45 40 35 30 25 20 15 10 5 0 Without EGR 5% EGR 10% EGR 15% EGR 20% EGR 0 Figure 5.3 5 10 Load kg 15 20 Brake Thermal Efficiency of Hemisphere Piston Engine with EGR HEMISPHERE 80 70 60 50 Without EGR 40 5% EGR 30 10% EGR 20 15% EGR 10 20% EGR 0 0 Figure 5.4 5 10 Load kg 15 20 Indicated Thermal Efficiency of Hemisphere Piston Engine with EGR 69 HEMISPHERE 80 70 60 50 Without EGR 40 5% EGR 30 10% EGR 20 15% EGR 10 20% EGR 0 0 5 10 Load kg 15 20 Figure 5.5 Mechanical Efficiency of Hemisphere Piston Engine with EGR HEMISPHERE 8 7 6 5 Without EGR 4 5% EGR 3 10% EGR 2 15% EGR 20% EGR 1 0 0 Figure 5.6 5 10 Load kg 15 20 Indicated Mean Effective Pressure of Hemisphere Piston Engine with EGR 70 Table 5.2 Performance tabulation for Hemisphere piston engine with 5% EGR Load kg SFC kg/kW-hr 0 30.9051 0 IMEP bar 2.170296 46.89555 39.767 3.603168 56.90471 5.036039 65.37374 66.45037 6.468911 BT 0 % IT % 5 0.445306 18.64895 10 0.266557 31.15472 54.74893 15 0.191167 43.44109 Table 5.3 mech % Performance tabulation for Elliptical piston engine with 5% EGR Load kg SFC kg/kW-hr BT 0 % 0 IT % 27.66505 mech % 0 IMEP bar 1.953266 5 0.440128 18.86835 44.58937 42.31581 3.386138 10 0.266557 31.15472 52.38951 59.46748 4.81901 15 0.233648 35.54271 51.69311 68.75714 6.251882 Table 5.4 Performance tabulation for Ellipsoid piston engine with 5% EGR Load kg SFC kg/kW-hr 0 BT % IT % mech % IMEP bar 0 31.40356 0 2.170296 5 0.427695 19.41685 48.82654 39.767 3.603168 10 0.259254 32.03232 56.29116 56.90471 5.036039 15 0.221351 37.5173 56.45914 66.45037 6.468911 71 Table 5.5 Performance tabulation for Double concave piston engine with 5% EGR Load kg SFC kg/kW-hr 0 BT % 0 IT % 31.07125 mech % IMEP bar 0 2.170296 39.767 3.603168 5 0.437584 18.97805 47.72311 10 0.259254 32.03232 56.29116 56.90471 5.036039 15 0.210284 39.4919 6.468911 59.43067 66.45037 ELLIPTICAL 0.5 0.45 0.4 0.35 0.3 0.25 0.2 0.15 0.1 0.05 0 Without EGR 5% EGR 10% EGR 15% EGR 20% EGR 0 5 10 Load kg 15 20 Figure 5.7 Specific Fuel Consumption of Elliptical Piston Engine with EGR 72 ELLIPTICAL 45 40 35 30 Without EGR 25 20 15 10 5 5% EGR 10% EGR 15% EGR 20% EGR 0 0 Figure 5.8 5 10 Load kg 15 20 Brake Thermal Efficiency of Elliptical Piston Engine with EGR ELLIPTICAL 70 60 50 Without EGR 40 5% EGR 30 10% EGR 20 15% EGR 10 20% EGR 0 0 Figure 5.9 5 10 Load kg 15 20 Indicated Thermal Efficiency of Elliptical Piston Engine EGR 73 ELLIPTICAL 90 80 70 60 Without EGR 50 40 30 20 10 5% EGR 10% EGR 15% EGR 20% EGR 0 0 5 10 Load kg 15 20 Figure 5.10 Mechanical Efficiency of Elliptical Piston Engine with EGR ELLIPTICAL 7 6 5 Without EGR 4 5% EGR 3 10% EGR 2 15% EGR 1 20% EGR 0 0 5 10 Load kg 15 20 Figure 5.11 Indicated Mean Effective Pressure of Elliptical Piston Engine with EGR 74 Table 5.6 Performance tabulation for Hemisphere piston engine with 10% EGR Load kg SFC kg/kW-hr ther 0 % 0 IT % 40.32063 mech % IMEP bar 0 2.893728 5 0.461598 17.99075 54.32363 33.11773 4.3266 10 0.270365 30.71592 61.73179 49.75706 5.759471 15 0.2035 40.8083 68.27949 59.76655 7.192343 Table 5.7 Performance tabulation for Elliptical piston engine with 10% EGR Load kg SFC kg/kW-hr 0 % ther IT % mech % IMEP bar 0 26.44656 0 1.80858 5 0.411424 20.18475 45.66207 44.20463 3.241452 10 0.25749 32.25172 52.60588 61.3082 4.674323 15 0.217535 38.1755 54.23729 70.38608 6.107195 Table 5.8 Performance tabulation for Ellipsoid piston engine with 10% EGR Load kg SFC kg/kW-hr 0 ther % IT % mech % IMEP bar 0 36.53226 0 2.459669 5 0.402671 20.62355 56.02594 36.81071 3.89254 10 0.250669 33.12932 61.56422 53.81261 5.325412 15 0.212051 39.1628 61.57176 63.60513 6.758284 75 Table 5.9 Performance tabulation for Double concave piston engine with 10% EGR Load kg SFC kg/kW-hr 0 % ther 0 IT % 33.49714 mech % IMEP bar 0 2.314982 5 0.430126 19.30715 50.50025 38.23179 3.747854 10 0.25575 32.47112 58.70168 55.31548 5.180726 15 0.208546 39.821 61.26625 64.99663 6.613598 ELLIPSOID 0.5 0.45 0.4 0.35 0.3 Without EGR 0.25 5% EGR 0.2 10% EGR 0.15 0.1 15% EGR 20% EGR 0.05 0 0 5 10 Load kg 15 20 Figure 5.12 Specific Fuel Consumption of Ellipsoid Piston with EGR 76 ELLIPSOID 45 40 35 30 Without EGR 25 20 15 10 5 5% EGR 10% EGR 15% EGR 20% EGR 0 0 5 10 Load kg 15 20 Figure 5.13 Brake Thermal Efficiency of Ellipsoid Piston Engine with EGR ELLIPSOID 70 60 50 Without EGR 40 5% EGR 30 10% EGR 20 15% EGR 10 20% EGR 0 0 5 10 Load kg 15 20 Figure 5.14 Indicated Thermal Efficiency of Ellipsoid Piston Engine with EGR 77 ELLIPSOID 80 70 60 50 Without EGR 40 5% EGR 30 10% EGR 15% EGR 20 20% EGR 10 0 0 5 10 Load kg 15 20 Figure 5.15 Mechanical Efficiency of Ellipsoid Piston Engine with EGR ELLIPSOID 8 7 6 5 Without EGR 4 5% EGR 3 10% EGR 2 15% EGR 1 20% EGR 0 0 5 10 Load kg 15 20 Figure 5.16 Indicated Mean Effective Pressure of Ellipsoid Piston Engine with EGR 78 Table 5.10 Performance tabulation for Hemisphere piston engine with 15% EGR Load kg SFC kg/kW-hr 0 ther % IT % mech % IMEP bar 0 30.57278 0 2.170296 5 0.473138 17.55196 44.13698 39.767 3.603168 10 0.276285 30.05772 52.82115 56.90471 5.036039 15 0.221351 37.5173 56.45914 66.45037 6.468911 Table 5.11 Performance tabulation for Elliptical piston engine with 15% EGR Load kg SFC kg/kW-hr 0 ther % IT % mech % IMEP bar 0 28.08044 0 1.880923 5 0.407 20.40415 47.18856 43.2396 3.313795 10 0.242635 34.22631 56.69066 60.37381 4.746667 15 0.208546 39.821 57.24527 69.56208 6.179538 Table 5.12 Performance tabulation for Ellipsoid piston engine with 15% EGR Load kg SFC kg/kW-hr 0 ther % 0 IT % 38.8806 mech % 0 IMEP bar 2.604355 5 0.407 20.40415 57.49026 35.49149 4.037227 10 0.242635 34.22631 65.3308 52.38925 5.470099 15 0.208546 39.821 63.94691 62.27196 6.90297 79 Table 5.13 Performance tabulation for Double concave piston engine with 15% EGR Load kg SFC kg/kW-hr 0 ther % IT % mech % IMEP bar 0 33.14267 0 2.459669 5 0.450608 18.42955 50.06574 36.81071 3.89254 10 0.25575 32.47112 60.34109 53.81261 5.325412 15 0.213848 38.8337 61.05435 63.60513 6.758284 DOUBLE CONCAVE 0.6 0.5 0.4 Without EGR 0.3 5% EGR 0.2 10% EGR 15% EGR 0.1 20% EGR 0 0 5 10 Load kg 15 20 Figure 5.17 Specific Fuel Consumption of Double concave Piston Engine with EGR 80 DOUBLE CONCAVE 45 40 35 30 Without EGR 25 20 15 10 5 5% EGR 10% EGR 15% EGR 20% EGR 0 0 5 10 Load kg 15 20 Figure 5.18 Brake Thermal Efficiency of Double concave Piston Engine with EGR DOUBLE CONCAVE 70 60 50 Without EGR 40 5% EGR 30 10% EGR 20 15% EGR 10 20% EGR 0 0 5 10 Load kg 15 20 Figure 5.19 Indicated Thermal Efficiency of Double concave Piston Engine with EGR 81 DOUBLE CONCAVE 80 70 60 50 Without EGR 40 5% EGR 30 10% EGR 20 15% EGR 10 20% EGR 0 0 5 10 Load kg 15 20 Figure 5.20 Mechanical Efficiency of Double concave Piston Engine with EGR DOUBLE CONCAVE 8 7 6 5 Without EGR 4 5% EGR 3 10% EGR 2 15% EGR 20% EGR 1 0 0 5 10 Load kg 15 20 Figure 5.21 Indicated Mean Effective Pressure of Double concave Piston Engine with EGR 82 Table.5.14 Performance tabulation for Hemisphere piston engine with 20% EGR Load kg SFC kg/kW-hr 0 ther % 0 IT % 37.68428 mech % 0 IMEP bar 2.604355 5 0.479127 17.33256 48.83581 35.49149 4.037227 10 0.278317 29.83832 56.95505 52.38925 5.470099 15 0.233648 35.54271 57.07658 62.27196 6.90297 Table 5.15 Performance tabulation for Elliptical piston engine with 20% EGR Load kg SFC kg/kW-hr 0 ther % 0 IT % 18.74245 mech % 0 IMEP bar 1.302178 5 0.415946 19.96535 38.10963 52.38925 2.735049 10 0.264693 31.37412 45.63034 68.75714 4.167921 15 0.213848 38.8337 5.600793 Table 5.16 50.59758 76.75012 Performance tabulation for Ellipsoid piston engine with 20% EGR Load kg SFC kg/kW-hr 0 ther % IT % mech % IMEP bar 0 38.09413 0 2.749041 5 0.427695 19.41685 56.66912 34.26355 4.181913 10 0.268447 30.93532 60.61086 51.03924 5.614785 15 0.219426 37.8464 62.04986 60.99354 7.047657 83 Table 5.17 Performance tabulation for Double concave piston engine with 20% EGR Load kg SFC kg/kW-hr 0 ther % 0 IT % 32.83251 mech % 0 IMEP bar 2.749041 5 0.494785 16.78406 48.98517 34.26355 4.181913 10 0.27231 30.49652 59.75113 51.03924 5.614785 15 0.227334 36.53001 7.047657 59.8916 60.99354 Hemisphere 550 500 450 400 5 % EGR 350 10 % EGR 15 % EGR 300 20 % EGR 250 200 0 5 10 15 Load kg 20 25 Figure 5.22 NOx emission of Hemisphere Piston Engine 84 Elliptical 550 500 450 400 5 % EGR 350 10 % EGR 15 % EGR 300 20 % EGR 250 200 0 5 10 15 Load kg 20 25 Figure 5.23 NOx emission of Elliptical Piston Engine Ellipsoid 500 450 400 5 % EGR 350 10 % EGR 15 % EGR 300 20 % EGR 250 200 0 5 10 15 Load kg 20 25 Figure 5.24 NOx emission of Ellipsoid Piston Engine 85 Double concave 600 550 500 450 5 % EGR 400 10 % EGR 350 15 % EGR 300 20 % EGR 250 200 0 5 10 15 Load kg 20 25 Figure 5.25 NOx emission of Double concave Piston Engine Table 5.18 Emission of NOx for all engines with 5% EGR Hemisphere Elliptical Ellipsoid Double concave NOx ppm Vol NOx ppm Vol NOx ppm Vol NOx ppm Vol 0 382 376 348 395 5 418 410 390 432 10 458 451 436 470 15 520 494 467 532 Load kg 86 Table 5.19 Emission of NOx for all engines with 10% EGR Load kg 0 5 10 15 Hemisphere NOx ppm Vol 364 401 435 502 Elliptical Ellipsoid NOx ppm Vol 358 391 432 475 NOx ppm Vol 330 374 416 450 Double concave NOx ppm Vol 374 412 448 512 Table 5.20 Emission of NOx for all engines with 15% EGR Load kg 0 5 10 15 Hemisphere NOx ppm Vol 374 409 448 507 Elliptical Ellipsoid NOx ppm Vol 368 400 442 492 NOx ppm Vol 339 380 427 455 Double concave NOx ppm Vol 386 422 461 524 Table 5.21 Emission of NOx for all engines with 20% EGR Load kg 0 5 10 15 Hemisphere NOx ppm Vol 394 431 469 529 Elliptical Ellipsoid NOx ppm Vol 388 422 463 521 NOx ppm Vol 357 399 448 475 Double concave NOx ppm Vol 407 444 482 546