Industrial Diesel Engines Research Articles

Reliability analysis of marine diesel engines vs. industrial diesel engines: a comparative approach

Reliability analysis of marine diesel engines vs. industrial diesel engines: a comparative approach

Full load optimization of a hydrogen fuelled industrial engine

There are a large number of applications in which hydrogen internal combustion engines represent a sensible alternative to battery electric propulsion systems and to fuel cell electric propulsion systems. The main advantages of combustion engines are their high degree of robustness and low manufacturing costs. No critical raw materials are required for production and there are highly developed production plants worldwide. A CO2-free operation is possible when using hydrogen as a fuel. The formation of nitrogen oxides during hydrogen combustion in the engine can be effectively mitigated by a lean-burn combustion process. However, achieving low NOx raw emissions conflicts with achieving high power yields. In this work, a series industrial diesel engine was converted for hydrogen operation and comprehensive engine tests were carried out. Various measures to improve the trade-off between NOx emissions and performance were investigated and evaluated. The rated power output and the maximum torque of the series diesel engine could be exceeded while maintaining an indicated specific NOx emission of 1 g/kWh along the entire full load curve. In the low-end-torque range, however, the gap to the full load curve of the series diesel engine could not be fully closed with the hardware used.

Testing the Inclination of an Industrial Diesel Engine Under Static Conditions According to the International Convention for the Safety of Life at Sea (SOLAS) Regulations

many industrial diesel engines are used as the main engine of the ship. Apart from being relatively cheaper, the availability of industrial engine is also very abundant, and the repair process is also not too complicated. However, when viewed from the SOLAS regulations related to the main requirements for a ship propulsion engine, it must also be considered, because it operates at sea, so that ship engines must be tougher than industrial engines, especially related to engine performance when experiencing rolling and trim. The purpose of this research is to test the feasibility of industrial diesel engines being operated on ships. By using a water-cooled single-cylinder diesel engine which is commonly used in small ships. The experimental method was used in this research to obtain optimal results according to the conditions in the field, the engine was made in three variations, namely the normal condition (without inclination angle), the rolling condition of 15 0 , and the trim condition of 5 0 which complies with SOLAS regulations related to the inclination angle. The results of the research obtained torque, Specific Fuel Consumption (SFC), and engine thermal efficiency in various engine variations. The highest torque is in the condition of the 15 0 rolling engine, which is 13.87 N.m. The lowest SFC is in the condition of the 15 0 rolling engine, which is 194 gr/kW.h. and the highest thermal efficiency was also obtained at the condition of the 15 0 rolling engine, namely 44.9%. The higher the engine speed, the higher the engine performance value in rolling 15 0 conditions, and the 5 0 trim conditions experience an increasing trend, but in low rotation conditions (750 Rpm) the performance decreases. Seeing the results obtained, a water-cooled single-cylinder diesel engine can be used as a small boat propulsion engine.

A frame work for comparative wear based failure analysis of CNG and diesel operated engines

Application of alternative fuels in engines is essential and encouraged for their non-polluting nature as well as shifting from fossil fuel use. But engine life span should be investigated for better efficiency and economy. In this study, industrial diesel and CNG engines have been investigated periodically for the surface degradation through wear. Ferrographic techniques have been applied on the used lubricating oils for checking the engine wear conditions. Different wear parameters have been obtained by quantitative ferrographic technique. Bath-tub curves have been plotted for the cases based on their severity index. Qualitative ferrographic technique enables to obtain images of the wear particles. Fractal dimensions of the wear particles have been compared for both the cases. The results indicate that CNG engine requires early maintenance and the diesel engine can run more time considering severity index. Some failure parts are physically observed at the end of experimented running hours. The results reveal that the failure of CNG engine happens early and consequently economy loss is more for CNG engine compared to that of diesel engine. Implementation of circular economy concept is suggested for regaining economy from the damaged parts of engine. This comparative analysis is beneficial for better industrial resource utilization.

Effects of six sigma implementation on occupational health and safety in industrial diesel engine production and maintenance processes

This study researched the results of implementing the Six Sigma approach to occupational health and safety in the Diesel engine industry in Europe. Six Sigma is a robust philosophy used in manufacturing industries to improve production processes, reduce risks, and enhance quality. It also aims to prevent work accidents and create a safer working environment by eliminating process faults. Employers must prioritize employee protection and a healthy working environment, and the Six Sigma methodology offers opportunities to achieve this. The study focused on the accident and injury types and amounts of one of the industrial Diesel engine production and maintenance companies operating worldwide. Occupational accident statistics were used between 2019-2022 as data. The path taken in occupational health and safety with Six Sigma in these three years was examined. In order to be able to decide on changes in health and safety conditions, the company's analysis of air-flows and heat transfer using the exhaust gas temperature in a project aimed at optimizing workplace temperature control is exemplified.

Computational Investigation on the Performance Increase of a Small Industrial Diesel Engine Regarding the Effects of Compression Ratio, Piston Bowl Shape and Injection Strategy

This paper describes the simulative approach to calibrate an already extremely highly turbocharged industrial diesel engine for higher low-speed torque. The engine, which is already operating at its cylinder-pressure maximum, is to achieve close to 30 bar effective mean pressure through suitable calibration between the compression ratio, piston-bowl shape and injection strategy. The basic idea of the study is to lower the compression ratio for even higher injection masses and boost pressures, with the resulting disadvantages in the area of emissions and fuel consumption being partially compensated for by optimizations in the areas of piston shape and injection strategy. The simulations primarily involve the use of the 3D CFD software Converge CFD for in-cylinder calibration and a fully predictive 1D full-engine model in GT Suite. The simulations are based on a two-stage turbocharged 1950 cc four-cylinder industrial diesel engine, which is used for validation of the initial simulation. With the maximum increase in fuel mass and boost pressure, the effective mean pressure could be increased up to 28 bar, while specific consumption increased only slightly. Depending on the geometry, NOx or CO and UHC emissions could be reduced.

Effects of Propanol on the Performance and Emissions of a Dual-Fuel Industrial Diesel Engine

The search for alternative fuels that can limit the use of traditional fossil fuels to power internal combustion engines is one of the main tasks faced by both the modern automotive industry and the modern energy industry. This paper presents experimental tests of a compression ignition engine, in which the conventional fuel, i.e., diesel, was partially replaced with propyl alcohol, i.e., a renewable biofuel. Studies on the co-combustion of diesel fuel with propanol were carried out, in which the energy share of alcohol varied from 0 to 65%. The research showed that an increase in the proportion of propanol, up to 30%, resulted in a significant increase in the rate of heat release and the rate of pressure increase in the cylinder of a compression-ignition engine. Increasing the alcohol content to 65% resulted in an increase in the ignition delay time and significantly shortened the duration of combustion. During the combustion of diesel fuel with a 50% propanol share, the engine was characterized by maximum efficiency, higher than diesel fuel combustion by 5.5%. The addition of propanol caused a slight deterioration of the combustion stability determined by the coefficient of variation for IMEP. The study of engine exhaust emissions has shown that the combustion of diesel fuel with a small proportion of propanol, up to 30%, causes an increase in nitrogen oxide emissions, while up to 50% contributes to a decrease in HC emissions. The increased share of alcohol contributed to a significant decrease in the emissions of both carbon monoxide and carbon dioxide, and caused a significant reduction in the concentration of soot in the exhaust of the compression-ignition engine.

Power enhancement of a turbo-charged industrial diesel engine by using of a waste heat recovery system based on inverted Brayton and organic Rankine cycles

In this study, energy assessment is performed for an industrial turbocharged diesel engine integrated with a novel waste heat recovery (WHR) system. The exhaust energy is used in inverted Brayton cycle (IBC) for waste heat recovery purpose. Also, the heat energy from IBC heat exchanger is used as the heat source for the organic Rankine cycle (ORC) to produce extra power. The case study engine is modelled in AVL BOOST software and the model is validated against real engine performance data. For studying the performance of the proposed waste energy recovery system, IBC is added to the engine model in AVL BOOST software and the thermodynamic model of the ORC is developed in MATLAB and it is linked to AVL BOOST. Then, the model is solved, and the main engine output parameters are studied at 1800 RPM and various engine loads. The results show that employment of the proposed WHR system leads to enhancement of the system power by about 18%. However, the backpressure produced by installing the WHR system can result in increase of the BSFC up to 3% and reduction of the total thermal efficiency by almost 1% at engine full load condition. The results of this work contribute to determine the interactions between the proposed novel waste heat recovery system (IBC-ORC) and the engine. The proposed bottoming cycle based on IBC-ORC can be installed on existing industrial stationary engines for enhancement of power generation without imposing a new source of power generation.

Effect of Exhaust Gas Flow and Back Pressure on Urea Dosing Unit and Pipe of SCR in Industrial Diesel Engine

Effect of Exhaust Gas Flow and Back Pressure on Urea Dosing Unit and Pipe of SCR in Industrial Diesel Engine

Experimental Studies and Theoretical Modelling of Diesel Engine Running on Biodiesels from South African Sunflower and Canola Oils

Abstract The attributes of cost-effectiveness, reliability, consistency and better understanding, have made researchers prefer studying engine characteristics of IC engines fuelled with alternative fuels/diesel blends with computer simulation compared to conventional experimental study. For the first time, the study attempted to simulate combustion, performance, and emission characteristics of biodiesels from Canola and Sunflower oil domiciled in South Africa. The properties of biodiesel vary from one region to another depending on the local properties of the feedstock used for its production. In this study, a computer model-based C++ was used to evaluate the performance characteristics of biodiesel fuels produced from local South African sunflower and canola oil feedstocks. The developed model was validated using experimental results. The performance characteristics of biodiesel and biodiesel-diesel blends from these oils were tested in a Mercedes Benz OM 364A turbocharged four-stroke, four-cylinder direct ignition industrial diesel engine. Results show similar combustion characteristics for all the tested samples. Diesel shows a higher brake power and higher exhaust gas temperature than all the tested fuel samples. The brake thermal efficiency increases with the amount of biodiesel in the biodiesel-diesel blends. Biodiesel and its diesel blends show higher specific fuel consumption than diesel. In terms of emissions, nitrogen oxide emission was higher for biodiesel and its blends with diesel compared with diesel while smoke emission from biodiesel and its diesel blends was lower compared with diesel.

Modeling the Operating Behavior of an Industrial Diesel Engine used as an Electrical Power Generator

Modeling the Operating Behavior of an Industrial Diesel Engine used as an Electrical Power Generator

Experimental Investigation on the Performance and Emission Characteristics of a Compression Ignition Engine Using Waste-Based Tire Pyrolysis Fuel and Diesel Fuel Blends

Due to the world’s growing population, the size of areas intended for food production in many countries of the world can only be achieved through severe environmental damage and deforestation, which has many other detrimental consequences in addition to accelerating global warming. By replacing the bio-content of fuels with other alternative fuels, land that is used for energy crops can also be used to grow food, thus mitigating the damaging effects of deforestation. Waste-based tire pyrolysis oil (TPO) can be a promising solution to replace the bio-proportion of diesel fuel. Since it is made from waste tires, it is also an optimal solution for recycling waste. This research shows the effect of different low-volume-percent tire pyrolyzed oil blended with diesel on the performance, fuel consumption, and emissions on a Mitsubishi S4S-DT industrial diesel engine. Four different premixed ratios of TPO were investigated (2.5%, 5%, 7.5% and 10%) as well as pyrolysis oil and 100% diesel oil; however, the following studies will only include the data from the pure diesel and the 10% TPO measurements. The experimental investigations were in an AVL electric dynamometer, the soot measurements were in an AVL (Anstalt für Verbrennungskraftmaschinen List) Micro soot sensor (MSS), and the emission measurements were in a AVL Furier-transform infrared spectroscopy (FTIR) taken. The scope of research was to investigate the effect of low volume percentage TPO on performance and emissions on a light-duty diesel engine.

Prognostic Assessment of the Performance Parameters for the Industrial Diesel Engines Operated with Microalgae Oil

A study conducted on the high-speed diesel engine (bore/stroke: 79.5/95.5 mm; 66 kW) running with microalgae oil (MAO100) and diesel fuel (D100) showed that, based on Wibe parameters (m and φz), the difference in numerical values of combustion characteristics was ~10% and, in turn, resulted in close energy efficiency indicators (ηi) for both fuels and the possibility to enhance the NOx-smoke opacity trade-off. A comparative analysis by mathematical modeling of energy and traction characteristics for the universal multi-purpose diesel engine CAT 3512B HB-SC (1200 kW, 1800 min−1) confirmed the earlier assumption: at the regimes of external speed characteristics, the difference in Pme and ηi for MAO100 and D100 did not exceeded 0.7–2.0% and 2–4%, respectively. With the refinement and development of the interim concept, the model led to the prognostic evaluation of the suitability of MAO100 as fuel for the FPT Industrial Cursor 13 engine (353 kW, 6-cylinders, common-rail) family. For the selected value of the indicated efficiency ηi = 0.48–0.49, two different combinations of φz and m parameters (φz = 60–70 degCA, m = 0.5 and φz = 60 degCA, m = 1) may be practically realized to achieve the desirable level of maximum combustion pressure Pmax = 130–150 bar (at α~2.0). When switching from diesel to MAO100, it is expected that the ηi will drop by 2–3%, however, an existing reserve in Pmax that comprises 5–7% will open up room for further optimization of energy efficiency and emission indicators.

산업용 디젤엔진의 후처리장치 단열에 따른 질소산화물 저감특성에 관한 실험적 연구

산업용 디젤엔진의 후처리장치 단열에 따른 질소산화물 저감특성에 관한 실험적 연구

Effect of Oxygen Enrichment in Propane Laminar Diffusion Flames under Microgravity and Earth Gravity Conditions

Diffusion flames are the most common type of flame which we see in our daily life such as candle flame and match-stick flame. Also, they are the most used flames in practical combustion system such as industrial burner (coal fired, gas fired or oil fired), diesel engines, gas turbines, and solid fuel rockets. In the present study, steady-state global chemistry calculations for 24 different flames were performed using an axisymmetric computational fluid dynamics code (UNICORN). Computation involved simulations of inverse and normal diffusion flames of propane in earth and microgravity condition with varying oxidizer compositions (21, 30, 50, 100 % O2, by mole, in N2). 2 cases were compared with the experimental result for validating the computational model. These flames were stabilized on a 5.5 mm diameter burner with 10 mm of burner length. The effect of oxygen enrichment and variation in gravity (earth gravity and microgravity) on shape and size of diffusion flames, flame temperature, flame velocity have been studied from the computational result obtained. Oxygen enrichment resulted in significant increase in flame temperature for both types of diffusion flames. Also, oxygen enrichment and gravity variation have significant effect on the flame configuration of normal diffusion flames in comparison with inverse diffusion flames. Microgravity normal diffusion flames are spherical in shape and much wider in comparison to earth gravity normal diffusion flames. In inverse diffusion flames, microgravity flames were wider than earth gravity flames. However, microgravity inverse flames were not spherical in shape.

A comprehensive methodology for computational fluid dynamics combustion modeling of industrial diesel engines

Combustion control and optimization is of great importance to meet future emission standards in diesel engines: increase in break mean effective pressure at high loads and extension of the operatin...

Software-supported Thermal Management Design for a Small Industrial Diesel Engine

Software-supported Thermal Management Design for a Small Industrial Diesel Engine

High-Pressure Electronic Fuel Injection for Small-Displacement Single-Cylinder Diesel Engines

Small-displacement single-cylinder diesel engines employ mechanically actuated fuel injection systems. These mechanically governed systems, while robust and low cost, lack the ability to fully vary injection parameters, such as timing, pulse duration, and injection pressure. The ability of a particular injection system to vary these injection parameters impacts engine efficiency, power, noise, and emissions. Modern, multicylinder automotive engines employ some form of electronically controlled injection to take advantage of the benefits of fully variable injection, including advanced strategies such as multipulse injections and rate shaping. Modern diesel electronic fuel injection (EFI) systems also operate at considerably higher injection pressures than mechanical fuel systems used in small-bore industrial engines. As the cost of electronic fuel systems continues to decrease and the demand for high-efficiency engines increases, EFI becomes a more viable option for incorporation into small industrial diesel engines. In particular, this technology may be well-suited for demanding and critical applications, such as military power generation. In this study, a small-bore single-cylinder diesel was retrofit with a custom high-pressure EFI system. Compared to the mechanical injector, the electronic, common-rail injector had a 50% smaller orifice diameter and was designed for a fourfold higher injection pressure. The mechanical governor was also replaced with an electronic speed controller. The baseline and modified engines were installed on a dynamometer, and measurements of exhaust emissions, fuel consumption, brake torque, and in-cylinder pressure were made. The electronic injector leads to lower smoke opacity and NOx emissions, while CO and hydrocarbon emissions were observed to increase slightly, likely due to some wall wetting of fuel with the initial prototype injector. Testing with low ignition quality fuels was also performed, and the electronic fuel system enabled the engine to operate with fuel having a cetane number as low as 30.

Development of the knocking and the defective cylinder decision system of industrial CRDI diesel engine through the CKP sensor signal analysis

As an abnormal combustion caused by the compression and spontaneous ignition of unburned mixture during the latter process of combustion, if knocking occurs, it will result in loss of engine power as well as severe damage to the engine. Therefore, it is very significant to monitor knocking. Generally, a practical method of monitoring knocking is to use a knocking sensor. However, by this method it is not possible to distinguish between the engine's own vibrations and knocking if the vibrations match up with the range of the knocking sensor signal for the use of detection of knocking. Therefore, in this study, knocking was diagnosed by way of using the signals of crankshaft position (CKP) sensor which is basically installed in the engine, instead of using such a problematic knocking sensor.

Development of the knocking and the defective cylinder decision system of industrial CRDI diesel engine through the CKP sensor signal analysis

Development of the knocking and the defective cylinder decision system of industrial CRDI diesel engine through the CKP sensor signal analysis