Investigations on the utilization of ethanol and bio-diesel in a single cylinder compression ignition engine

INVESTIGATIONS ON THE UTILIZATION OF ETHANOL AND BIO-DIESEL IN A SINGLE CYLINDER COMPRESSION

IGNITION ENGINE

by

CHANDAN KUMAR

Centre for Energy Studies

Submitted

in fulfilment of the requirements of the degree of Doctor of Philosophy

to the

INDIAN INSTITUTE OF TECHNOLOGY, DELHI

AUGUST 2006

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CERTIFICATE

The thesis entitled “INVESTIGATIONS ON THE UTILIZATION OF ETHANOL AND BIO-DIESEL IN A SINGLE CYLINDER COMPRESSION IGNITION ENGINE" being submitted by Mr. Chandan Kumar to the Indian Institute o f Technology, Delhi, for the award o f the degree o f Doctor o f Philosophy, is a record o f bona fid e research work carried out by him. He has worked under my supervision, and has fulfilled the requirements for the submission o f this thesis, which has attained the standard required for a Ph.D. degree o f the Institute. The results presented in this thesis have not been submitted elsewhere for the award o f any degree or diploma.

Date: \\ 0% G>£>

Prof. M.K.G.Babu

Head, Centre for Energy Studies Indian Institute o f Technology, Delhi New Delhi - 110 016

Prof. L.M. Das

Centre for Energy Studies

Indian Institute o f Technology, Delhi New Delhi - 110 016

i

ACKNOWLEDGEMENTS

The present research on “Investigations on the Utilization o f Ethanol and Bio- Diesel in a Single Cylinder Compression Ignition Engine” was carried out under the venerable patronage o f my guides Prof. M K G Babu, Head, Centre for Energy Studies and Prof. L M Das, Centre for Energy Studies. It is my great privilege to express deep sense o f gratitude to them for their panegyric efforts, ever helping attitude, critical and valuable comments and constant inspiration with a keen interest in the progress o f present research. Their words o f solace and encouragement especially during difficult times ever remembered. To them, I am forever, indebted.

Thanks are also due to my student research committee members Prof. T. S.

Bhatti, Prof. J.P. Subrahmanyam and Dr. M. G. Dastidar. Sincere regards are due to Prof. A. Chandra, Dr. K. Gadgil and Dr. S .N. Naik for their valuable suggestions to carry out the study.

With sense o f gratitude and great pleasure, the author acknowledges the whole hearted cooperation extended by Prof. N. K. Bansal, Vice-Chancellor, SMVDU, Jammu, during my working tenure.

I would like to thank all the staff at the Engines & Unconventional Fuels Lab.

Special word o f thanks to Mr. G. P. Singh and Mr. Attar Singh for providing technical support during the experimentation work. I also thank Mr. Rakesh Kumar and Mr.

Virendra Singh for their support during the experiments.

There are also some friends and colleagues who have helped me along the way for the successful completion of this project and had given a good company during my stay at IIT, Delhi. I take this opportunity to thank Mr. Yogesh Vishnu Aghav, Dr,

Ranjan Swain, Dr. Rajeev Srivastava, Milton Polly, Vishal, Ram Chandra, Surya, Prashant, Kavita, Manoj, Vishal (AVL), Bhupendra, Malay, Mohit, Gajanan, Mehar, Pradeepta and Sanjeev Srivastava for their support and encouragement.

Due to the preoccupation with the priorities for the researches project my parents, brother and sister, who were deprived o f the privileges and prerogatives which God has bestowed on them. Their patience and kind understanding and constant encouragement have always been a moral booster for me.

Finally, I am unable to express my gratitude in words for the affection, encouragement, moral support and sacrifices given to me by my friend, Veenita during my entire study period

Lastly I would like to apologize to all those names, which do not figure here, but have helped me during the tenure o f my research.

New Delhi

August 2006 (CHANDAN KUMAR)

ABSTRACT

Rapid escalation o f fuel prices and depleting hydrocarbon resources o f the world have forced us to look for alternative fuels, which can satisfy the ever- increasing demands o f energy as w ell as protect the environment by repressing the levels o f noxious pollutants. By now , it has been conclusively realized that internal combustion engines form an indispensable part o f modem life style. They play a' vital role in the transport and modem mechanized sector. There are more than 6.5 million diesel engines being used in the Indian agricultural sector. For various activities it is impossible to do away with these existing systems and hence alternative fuels m ust be expeditiously sought. Ethanol and biodiesel can serve as a perfect alternative against fossil fuels like petrol and diesel. Ethanol and biodiesel, which are based on agricultural products are clean, renewable and are readily available. They can be used to run Compression Ignition (Cl) engines used in commercial sector, agricultural sector and domestic purposes.

The present study was done to visualize the potential o f ethanol and biodiesel as an alternative fuel in diesel engines (Direct ignition, naturally aspirated and air cooled). The salient features of the investigation include: (1) Comparative study of basic fuel properties o f ethanol, biodiesel and different blends o f these with diesel. (²) To evaluate the potential of using biodiesel, ethanol and their blends with diesel for Cl engine. (3) To design and develop a liquid multi fuel blending and supply system.

(4) Analytic study on the engine performance, combustion and exhaust emission characteristics at various fuel injection pressures and fuel injection timings operating on the selected fuel blends.

Different fuel blends were prepared from biodiesel and ethanol with diesel. On the basis of basic fuel properties, fuel blends were selected for engine testing. To prevent phase separation of diesel-ethanol fuel blends, ethyl acetate was used as emulsifying agent. Experimental setup was developed to carry out engine performance, emission and combustion characteristic studies on selected fuel blends at different load conditions. On the basis of the results obtained through exhaustive engine testing, optimization of various engine operating parameters like various start of fuel injection tim ing start up and fuel injection pressures were done for various fuel blends.

v

The present work has resulted in giving a good insight into the performance, em ission and combustion characteristics of the Compression Ignition engine using biodiesel, ethanol and its blend w ith diesel fuel. As biodiesel proportion w ith diesel is increased, at higher fuel injection pressure, the performance, emission and com bustion characteristics im prove. However, in case o f ethanol (maximum 40 percent blend), as fuel injection timing is retarded overall engine performance, em issions and combustion o f fuel blends improved. Variation in biodiesel and/or ethanol with diesel has m arginal effect on engine performance, emission and com bustion characteristics at different fuel injection timings and fuel injection pressures respectively.

CONTENTS

Page No.

Certificate

Acknowledgments Abstract

Contents List o f Figures List o f Plates List o f Tables Nomenclature

1 iii v vii xi xvii xix xxi

Chapter: 1 INTRODUCTION 1-24

1.1 Current Energy Scenario j

1.2 Need for Alternative Fuels ⁴

1.2.1 Depletion o f Fossil Fuel 5

1.2.2 Environmental Issues g

1.3 Compression Ignition Engines and Alternative Fuels g

1.3.1 Biodiesel as a Potential Diesel Engine Fuel g

1.3.1.1 Economics o f Biodiesel 1.3.1.2 Production of Biodiesel

1.3.1.3 Derivatives o f Triglycerides (vegetable oils) as Diesel Fuels

1.3.2 Ethanol as a Potential Diesel Engine Fuel 2 2

1.3.2.1 Ethanol Diesel Blends (e-Diesel) 1 4

1.4 Combustion Characteristics of C.I. Engine j⁵

1.4.1. Heat Release Rate Analysis 27

1.5 Diesel Engine Emissions 1.5.1. Unbumt Hydrocarbon

1.5.2. NOx Emissions ^{2 1}

1.6 Emissions Reduction with Biodiesel and Ethanol 2 2

1.7 Objectives o f Present W ork 2 2

10

10 10

19 20

Page No.

2.3 Sum m ary of Literature Survey 2.4 Statem ent of the Problem

25 28

Chapter: 2 LITERATURE REVIEW 25-56

2.1 Introduction

2 .1 . 1 Transport Scenario in India

2.1 . 2 Rationale o f Biofuels for Transport in India 2 9

2.2 Biofuels as Alternative to Diesel Fuel 3 0

2.2 . 1 Vegetable Oil as Diesel Substitute

2.2.1. 1 Vegetable Oil-diesel Blends as Diesel Substitute 3 2

2.2.1 . 2 History o f Transesterification ^

2.2.2 Biodiesel as Diesel Substitute

37 2.2.2.1 Biodiesel Production and Development around the 37

World

2.2.2.2 Performance, Em ission and Combustion

Characteristics using Biodiesel as Diesel Substitute ^9

2.2.3. Ethanol as Diesel Substitute ^

2.2.3.1 Performance Emission and Combustion

Characteristics using Ethanol Blended Diesel Fuel 47 2.2.4 Ethanol-diesel-biodiesel (EB-diesel) Blends as Diesel Substitute

53 54 56

Chapter-3 TEST RIG DEVELOPMENT & EXPERIMENTAL

METHODOLOGY 5798

3.1 Introduction ^ 7

3-2 Fuel Development and Characterization 5 7

3.2.1 Fuel Blends Preparation ^ 2

3.2.2 Fuel Blends Stability Test ^ 2

3.2.3 D ensity ^

3.2.4 Viscosity ^

3.2.5 Flash and Fire Point 3.2.6 Cloud and Pour Point 3.2.7 Calorific Value

3.3.8 Development of Online Fuel M ixing System gp

66 66 68

viii

3.3

3.3.1

3.3.2

3.3.3 3.4

Chapter-4

4.1 4.2

4.2.1 4.2.2

4.3 4.4

4.4.1 4.4.2

Engine Selection & Instrumentation 7 j

Development of Experimental Test Rig 7 2

3.3.1.1 Installation o f the Instrument Control Panel 7 4

Page No.

3.3.1.2 Parameters Selection 76

M easurement Methods and Selection o f Instruments 79

3.3.2.1 Brake Power 79

3.3.2.2 Engine Speed 79

3.3.2.3 Crank Angle 79

3.3.2.4 Air Consumption 82

3.3.2.5 Fuel Consumption 83

3.3.2. 6 Cylinder Gas Pressure 85

33.2.1 Computer Interfacing 8 8

3.3.2^{. 8} Rate of H eat Release and Combustion Characteristics 89

3.3.2.9 Temperature M easurement 92

3.3.2.10 Exhaust Emission Analysis 92

Variation o f Injection Pressure and Injection Timings ^{9 4}

Experimental Approach ^ 5

RESULTS AND DISCUSSIONS 99 m

Introduction ^

Fuel Development and Characterization gg

Transesterification jqj

Fuel B lends Preparation jq^

4.2.2.1 Diesel -ethanol Fuel B lends 4.2.2^{. 2} Diesel-biodiesel Fuel B lends

103 103

4.2.2.3 Biodiesel-ethanol Fuel B lends j j q

Selection o f Different Fuel Blends fo r Engine Testing j J3

Engine Performance Characteristics ^ 6

Brake Specific Energy Consumption j ^

Brake Therm al Efficiency j ^

ix

Page No.

4.4.3 Exhaust Gas Tem perature

125 4.5 Exhaust Emission Characteristics

128 4.5.1 NOx Emissions

128 4.5.2 Unbum t H ydrocarbon Emission

133 4.5.3 Carbon M onoxide Emission

136 4.5.4 Smoke Opacity

140 4.6 Effects o f D ifferent Injection Pressures on Engine Performance

for Different D iesel- biodiesel F uel Blends 144

4.7 4.8

Effects o f D ifferent Injection Pressures on Engine Emissions for Diesel-biodiesel F uel Blends at F u ll Load and 60 Percent Load Effects o f V ariation of start o f injection angle on engine performance and emission for D ifferent Fuel Blends

149 152 4.9 Combustion Characteristics of Diesel-biodiesel Fuel Blends

162 4.10 Combustion Characteristics of Diesel-ethanol Fuel Blends

168 4.11 Combustion Characteristics of Biodiesel-ethanol fuel Blends

173

Chapter 5 CONCLUSIONS

5.1 Conclusions

177 5.2 Scope for Future W ork

182

References

Appendices

Appendix-I: Engine specification

Appendix-II: Specification of Pressure Transducer

Appendix-III: specification of C harge Amplifier

Appendix-IV: T echnical specification of AVL-437 Smoke m eter

Appendix-V: T echnical Specification O f AVL Di-Gas A nalyzer

x