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Performance and Emission Characteristics of an Automotive Diesel Engine Using Biodiesel Fuel with the Influence of Air Intake Va

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Performance and Emission Characteristics of an Automotive Diesel Engine Using Biodiesel Fuel with the Influence of Air Intake Va PERFORMANCE AND EMISSION CHARACTERISTICS OF AN AUTOMOTIVE DIESEL ENGINE USING BIODIESEL FUEL WITH THE INFLUENCE OF AIR INTAKE VARIABLES by RIZALMAN MAMAT A thesis submitted to The University of Birmingham for the degree of DOCTOR OF PHILOSOPHY School of Mechanical Engineering The University of Birmingham November 2009 0 University of Birmingham Research Archive e-theses repository This unpublished thesis/dissertation is copyright of the author and/or third parties. The intellectual property rights of the author or third parties in respect of this work are as defined by The Copyright Designs and Patents Act 1988 or as modified by any successor legislation. Any use made of information contained in this thesis/dissertation must be in accordance with that legislation and must be properly acknowledged. Further distribution or reproduction in any format is prohibited without the permission of the copyright holder. ABSTRACT The air induction system plays a major role by providing necessary air charge for combustion to take place in an engine cylinder. The pressure drop across the air intake manifold is known to have a significant effect on the indicated power of the internal combustion engine. Most car manufacturers locate the air grill at the front of a vehicle to enhance the volumetric efficiency. However due to wading performance, for a sport utility vehicle like a Land Rover Freelander the air grill is located at the side of the front tyre. The air speed at the grill side is high and creates negative pressure, thus reducing the volumetric efficiency. Therefore, a thorough study of the design of the air induction system (AIS) with negative pressure at the air grill is vital, in order to fully understand the flow behavior in this AIS. Moreover, when the engine is equipped with turbocharger, the performance of the air intake system is also affected by the exhaust parameter which depends on the combustions of fuel in the engine cylinder. The properties of biodiesel are slightly different in density, viscosity and cetane number. These parameters are potentially affecting the combustion in engine cylinder. Thus, the investigation of the effect of fuel on the air intake system is vital for the study of the diesel engine operating with biodiesel. The analysis of the combustion of biodiesel in a V6 diesel engine includes the ignition delay, rate of heat release, in-cylinder peak pressure as well as the exhaust emissions. The study consists of 3 parts; (1) three-dimensional CFD analysis on the performance of the Land Rover Freelander AIS, (2) one-dimensional analysis of a V6 diesel engine with the effect of the AIS, (3) experimental study of a V6 diesel engine operating with RME and ULSD; The three-dimensional analyses on the performance 1 of a Freelander AIS have been conducted to study the effect of negative pressure on pressure-drop in the intake manifold. The results show that the magnitude of negative pressure gives significant effect not just to pressure drop but also to the flow behavior in the intake manifold. The steady flow tests on the actual intake manifold of a Freelander model have been conducted to validate the simulation outcome. The results show good agreement between experiment and simulation. In order to improve understanding on the flow wave action on the intake manifold of a V6 diesel engine, one-dimensional engine simulations have been conducted using commercial Ricardo WAVE v7.2 software. The result shows good agreement between simulation and experiment. The simulation result shows a significant affect on the wave action as pressure drop increases from zero to 20% in the intake manifold. The research continued further to investigate the effect of air induction parameters in the V6 diesel engine such as pressure drop and flow temperature on the performance and emissions of the engine. The effect of intake flow parameter to the engine when operated with RME has been studied and the comparisons have been made when ULSD is used as base fuel. The experimental results show that in general, the engine operating with RME produces lower power and higher bsfc due to low energy content of RME as compared to ULSD. The emissions of NOx are slightly higher, but lower CO and HC are produced. The pressure drop along the AIS has significantly affected the performance as well as emissions of the engine. The performance of the diesel engine drops significantly as the pressure drop increases and exhaust emissions increase considerably. 2 ACKNOWLEDGEMENTS I would like to express my gratitude and sincere thanks to my supervisor Professor Hongming Xu for his guidance, support and encouragement throughout my study. I also would like to thank my associate supervisor Professor Miroslaw Lech Wyszynski for his passions toward the remarkable end of my study. I would also like to thank my sponsors: • The Malaysia Government for the provision of my Ph.D. scholarship • Jaguar Land Rover (JLR) for financial and technical support towards the research project, o Dr J. Qiao and Dr Steven Pierson (Jaguar Cars Limited) for their technical assistance o Dr Adrian Gaylard (Land Rover Gaydon) for the provision of the 3D geometry of the Land Rover air intake system • Shell Global Solutions UK through Dr R. F. Cracknell for the supply of ULSD and RME test fuels; I gratefully acknowledge Dr. Athanasios Tsolakis for his helpful discussion during this project. I would like to acknowledge Dr Mingshan Wei and Dr Xin Shi for long discussion and advice on developing the one-dimensional model. A special thank you goes to my colleagues Dr S. Chuepeng, Dr. A. F. Mahrous, Dr. K. Theinnoi, Mr Nik Rosli Abdullah, and friends in FPS group for their fruitful discussions, friendship and help. Rizalman Mamat November 2009 3 I wish to dedicate this thesis… To my parents To my beloved wife and lovely kids: Nur Dania, Nur Najah and Haziq To my brothers and sisters, And friends 4 TABLE OF CONTENTS CHAPTER 1 INTRODUCTION 1.1 Background 24 1.1.1 Diesel Engine Technology 25 1.1.2 Alternative Fuels for Diesel Engines 28 1.1.3 Combustion in Diesel Engines 29 1.2 Objectives and Approaches 31 1.3 Thesis Outline 33 CHAPTER 2 LITERATURE REVIEW 2.1 Air Intake System for Diesel Engines in a Vehicle 34 2.1.1 System Component and Development 37 2.1.2 Optimisation of AIS by Computational Fluid Dynamics 42 2.1.3 One-Dimensional Modelling of an Air Intake System 46 2.2 Biodiesel as an Alternative Fuel 2.2.1 Biodiesel Production, Policies and Standardisation 47 2.2.2 Performance and Emissions of Biodiesel as Fuel in ICE 50 2.3 Exhaust Emissions from the Combustion of Biodiesel 2.3.1 Oxides of Nitrogen 53 2.3.2 Carbon Monoxide 55 2.3.3 Unburned Hydrocarbons 56 2.3.4 Particulate Matter 57 2.4 Summary 58 5 CHAPTER 3 RESEARCH METHODOLOGY 3.1 Setup of CFD Models 59 3.1.1 Governing Equations 60 3.1.2 Turbulence Model 64 3.1.3 Modelling Approach 67 3.1.4 Grid Generation 68 3.2 Experimental System and Techniques 3.2.1 Steady Flow Test 72 3.2.1.1 Purpose of Steady Flow Testing 72 3.2.1.2 Design and Setup of Steady Flow Test Bench 73 3.2.2 The engine Performance Characteristic 80 3.2.3 Diesel Engine Test Setup 3.2.3.1 Engine Test Bench 83 3.2.3.2 Engine Fuel System 87 3.2.3.3 Engine Cooling System 88 3.2.3.4 Exhaust Emissions Measurement 90 3.2.3.5 Data Acquisition System 91 3.3 Summary 96 6 CHAPTER 4 CFD MODELLING OF AIR INTAKE SYSTEM AND VALIDATION 4.1 Introduction 97 4.2 Problem Definitions 97 4.3 Boundary Conditions 100 4.4 Result & Discussions 102 4.4.1 Simulation under Static Entry Flow 103 4.4.2 Tangential Velocity Magnitude 107 4.4.3 Grid Sensitivity Test 110 4.5 Summary 111 CHAPTER 5 ONE DIMENSIONAL MODELLING OF A V6 DIESEL ENGINE AND VALIDATION 5.1 Introduction 112 5.2 Engine Model Setup 112 5.2.1 General Parameter of Diesel Engine 114 5.2.2 Heat Transfer and Combustion Model 116 5.2.3 Engine Valves, Injection Timing and Turbocharger Set-up 122 5.3 Simulation Results and Data Validation 5.3.1 Simulation Result and Validation at Full Load Curve 124 5.3.2 Simulation Results with Variable Boost Pressure 128 5.4 Summary 135 7 CHAPTER 6 ENGINE PERFORMANCE AND EMISSIONS WITH BIODIESEL 6.1 Introduction 136 6.2 Engine Test Conditions 137 6.3 Engine Testing at Low Load and Part Load 138 6.4 Diesel Engine Operating with RME and ULSD 144 6.5 Effect of Fuel Temperatures 148 6.6 Effect of Multiple Injection 158 6.7 Summary 168 CHAPTER 7 EFFECT OF AIR INTAKE VARIABLES TO THE ENGINES PERFORMANCE AND EMISSIONS 7.1 Effect of Boost Pressure Drop 170 7.1.1 Engine Performance 173 7.1.2 Exhaust Gas Emissions 178 7.2 Effect of Charge Air Temperature 181 7.2.1 Engine performance 187 7.2.2 Exhaust Gas Emission 189 7.3 Summary 191 8 CHAPTER 8 CONCLUSION AND RECOMMENDATIONS 8.1 Conclusion Remarks 194 8.1.1 Influence of Negative Pressure on Induction Grill 194 8.1.2 One-Dimensional Analysis of Air Induction System 194 8.1.3 Engine Performance and Emissions of a Diesel Engine Operating with ULSD and RME 195 8.1.4 The Effect of Intake Charge Pressure Drop and Temperature on Engine Performance 196 8.2 Recommendation for Future Work 198 8.2.1 The Modifications of Current Design of a Freelander Air Intake System 198 8.2.2 The Effect of EGR Rate and Exhaust Gas Temperature to the Intake Charge 198 8.2.3 Transient Operation on Diesel Engine Operating with ULSD and RME 199 REFERENCE 200 APPENDIX 215 9 LIST OF ABBREVIATIONS AIS Air induction system BMEP Brake mean effective pressure [Bar] bsfc Brake specific fuel consumption [kg/kWh] BSN Bosch smoke number [BSN] BV Butterfly valve CAD Crank angle degree [degree] CFD Computational
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