KATHMANDU UNIVERSITY

SCHOOL OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING

MID TERM PROJECT REPORT

USE OF COMPRESSION RATIO OF DIESEL ENGINE FOR GAS FUELLING

In Partial Fulfillment of the Requirements for the
Bachelor’s Degree

By
Anil Kumar Pachhain (03)
Ishan Kafle (16)
Lokesh Paudel (23)
Sajesh Bhochhibhoya (45)

Date, 4th May 2014

 CERTIFICATION

USE OF COMPRESSION RATIO OF DIESEL ENGINE FOR GAS FUELLING

Project Members:
Anil Kumar Pachhain (03)
Ishan Kafle (16)
Lokesh Paudel (23)
Sajesh Bhochhibhoya (45)

This is to certify that we have examined the above Project and have found that it is complete and
satisfactory in all respects, and that any and all revisions required by the project examination
committee have been made.

_________________________________________
Assoc Prof. Bivek Baral, PhD
Department of Mechanical Engineering
Project Supervisor

_________________________________________
Mr. Anup K.C.
Department of Mechanical Engineering
Project Coordinator

Date, 4th May 2014

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ACKNOWLEDGEMENT
We would like to express our deep gratitude to the Department of Mechanical Engineering,
Kathmandu University for providing us an opportunity to carry out this project. We wish to
acknowledge our deep appreciate gratitude to our project supervisor Dr. Bivek Baral for his
supportive nature and guidance throughout this project. Also, we are very thankful to our project
co-coordinator Mr. Anup K.C., who provided assistance and motivated during our project
period. We acknowledge our appreciation to Mr. Pravin Shrama for his indispensible support
throughout the project. We are equally indebted to the authors of many references and book
which we used as a reference.

Last but not the least; we are very thankful to those who were always there for us to give
different ideas in making this project a unique and a success.

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ABSTRACT
We, the students of mechanical engineering are trying to develop a producer gas driven engine
from diesel engine. Here we are adding a suitable ignition system and proper spark plug to
convert it to producer gas engine. Otto cycle is the basics of the project since producer gas is a
spark ignited fuel. Mainly we will be focusing on ignition which will be designed according to
the spark voltage required for the ignition of producer gas. Although this seems like assembling
and developing of system, this project helps us to conceptualize the thermo-dynamical approach
in an engineering way.

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Table of Contents
ABSTRACT ............................................................................................................................. iii

1. INTRODUCTION ...............................................................................................................1

1.1. Problem statement .........................................................................................................1

1.2. Scope of study...............................................................................................................1
1.3. Objectives .....................................................................................................................1
2. DISCUSSION .....................................................................................................................2

2.1. Methodology.................................................................................................................3
2.1.1. Literature review ....................................................................................................4

2.1.2. Spark plug installation ...........................................................................................5

2.1.3. Ignition system installation ....................................................................................6

2.1.4. Carburetion of the fuel and air ................................................................................6

2.2. Work done ....................................................................................................................6

2.2.1. Accessibility of Producer gas for the project ..........................................................6

2.2.2. Installation of Spark plug .......................................................................................6

2.2.3. Installation of Magneto System ..............................................................................7

2.2.4. Installation of CDI circuit ......................................................................................8

2.2.5. Arrangements for carburetion .................................................................................9

2.2.6. Survey for better ignition system ............................................................................9

2.2.7. Installation of Battery ignition system ....................................................................9

2.3. Work Remaining ...........................................................................................................9

2.4. Progress chart ............................................................................................................. 10
3. CONCLUSION ................................................................................................................. 11

Works Cited .............................................................................................................................. 12

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 1. INTRODUCTION

1.1. Problem statement

The rising oil prices and shortage of fuel oils together with exploding population have resulted in
serious energy crisis. [1] There is thus a need to develop technology for utilizing the renewable
energy sources that can make significant contribution to the economy and the well being of the
rural people. Hydro electricity, solar power, wind energy etc are few such renewable sources.
But one with a great potential is the use of a producer gas instead of fuel oils.

1.2. Scope of study

The project is focused on using the product of gasification i.e. “Producer gas” to drive the diesel
engine. The project is about studying combustion characteristics of a producer gas and using it in
spark ignition mode. Selection of suitable spark ignition system for the conversion of the engine
would be conducted along with further testing of producer gas under pressurized condition in the
combustion chamber.

1.3. Objectives
The main objectives of our project are:

 To study the chemical characteristics of the producer gas

 To convert the existing diesel engine into producer gas engine.
 To install a suitable spark ignition system
 To find out the emissions produced by producer gas and compare the results with
gasoline engine
 To study the combustion characteristics of producer gas under pressurized condition in
the combustion chamber
 To compare efficiency and power generation of tested engine with the gasoline engine

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 2. DISCUSSION
For the project a diesel generator is used as a test engine which is available in the gasifier lab at
the university. The table 2.1 contains the technical detail of the engine used in the project.

Type KIRLOSKAR, 4-stroke cycle diesel engine

No. of cycle 1
Cubic Capacity (cc) 661
Bore (mm) 87.5
Stroke (mm) 110
Specific fuel consumption (g/BHP/h) 180
Crankshaft speed, rated (r/min) 1500
Power (Kw) 5.7
Cooling system Water cooled
Lubrication Oil Concentration(g/h) 19
Table 2.1: Specification of diesel engine under test

Producer gas is generated from solid carbonaceous fuels by gasification process. It is the
working fuel which drives the modified diesel-cum-producer gas engine. The carbonaceous fuels
for this project are seeds of Lapsi (a fruit only found in Nepal). These seeds are at first separated
from the fruit and dried for few days. Then they are gasified with air, consists of some 40 per
cent combustible gases, mainly carbon monoxide, hydrogen and some methane. The gas also
contains condensable tar, acids and dust. These impurities may lead to operational problems and
abnormal engine wear, are removed in the passive filter area of the gasifier. At last a purified
producer gas is ready for fuelling. [2]

When converting a diesel engine to run on producer gas, the engine has to be slightly altered.
First, the diesel injection nozzles are replaced by spark plug. The plugs are coupled to an ignition
system, which controls the ignition timing and generates electricity to produce the spark. Second,
a gas train will cut of the gas supply in case of an engine stop. Third, air and fuel must be mixed
before entering the engine. This is normally done by a carburetor, which assures a homogeneous
mixture and makes it possible to regulate the air fuel ratio. [3]

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2.1. Methodology

Analysis of
Diesel Engine

Literature
Review

Selection of a
component

Assembly

Select similar
component
Prototype
Testing

Selection of
next component

Final Testing

Result Analysis

Producer cum
Diesel engine
`

Fig. 2.1.1: Methodology Flowchart

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The project started with the analysis of a diesel engine present in Gasifeir lab in Kathmandu
University. The engine was KIRLOSKAR, 4-stroke cycle diesel engine. After brief study of the
engine, literature review on producer gas, conversion of diesel engine into producer gas engine,
ignition system, heating value, distributer etc. were conducted. Different components were
selected according to requirement. Components such as Spark plug, Distributer system, Ignition
coil, ignition switch etc. were selected sequentially. These components were assembled and then
followed by a small prototype test. Many components have been selected and tested e.g. Mico-
super spark plug, Battery ignition system, ignition coil etc. and still few components are left to
be confirmed. After all the components are selected and assembled there will be a final testing
and analysis. Then the final product i.e. Producer-cum-diesel engine will be ready.

2.1.1. Literature review

Information on producer gas mainly its history, current use, chemical composition, calorific
value, use as a gas fuel and so on were collected. Method of converting a diesel engine into a
spark ignited producer gas engine, different parts that are to be changed e.g. spark plug instead of
injector, type of different parts e.g. Magneto ignition system, Battery ignition system etc were
reviewed.

Basically literature reviews on following topics were conducted:

 History and background of a spark ignited producer gas engine

 Producer gas
 Heating value of different mixtures
 Conversion of a diesel engine to a spark ignited producer gas engine
 Ignition system
o Magneto Ignition System
o Battery Ignition System
 Ignition system distributor
 Ignition system coil
 Switches

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 2.1.2. Spark plug installation
We used a hot type spark plug in the test engine. Name of our spark plug is “Mica Super”. It is
manufactured by the Bosche Company. It was taken from a Hero Honda Splendor.

For the installation of spark plug the injector slot of the diesel engine was tapped into (10X1.25)
mm thread hole. Gap between the external and central electrode was 1.2mm.

Several other factors like torque had to be included while installing a spark plug. Since the
dynamic forces acting on the threaded hole couldn’t be calculated, we searched the net and
directly inserted our required diameter and depth for the plug hole. So empirical data provided by
certain sites were our source for diameter and hole depth.

Maximum temperature reached in the combustion chamber can be calculated as follows

P1=1 atm

T1=25 ￮C=298K

The system works on Otto cycle so the compression is done adiabatically

Since compression ratio of the engine is 18:1

Or, P2 = P1 * 18

Or, P2 = 18 atm

Similarly,

(P2 / P1)^ (1- γ) = (T1 / T2) ^ γ [4]

Or, T2 = 407 ￮C

Since, maximum temperature reached in the combustion chamber is 407 C so spark plug should
be selected such that it would withstand this temperature. So Mica Super spark plug which could
withstand up to 550 C was selected.

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 2.1.3. Ignition system installation
At first we decided to install a magneto ignition system to drive the CDI system. We used the
CDI of CT-100 bike. This phase included following procedure:

 Welding of the shaft into the gearing system

 Installing a magneto system in the rotating shaft
 Installing casings and holder for ignition coil and CDI circuit

2.1.4. Carburetion of the fuel and air

Carburetion was done by the following procedure:

 Air was passed through a pipe such that it would superimpose the pipe containing
producer gas before entering the intake valve.
 Flow rate was controlled by using a gate valve in both pipes so that the air to fuel ratio
was 1.1:1

2.2. Work done

2.2.1. Accessibility of Producer gas for the project

Producer gas is the fuel necessary for the project. A source of it is necessary for the continuity of
the project. Different prototype as well as final test cannot be performed without it. So a small
survey on availability and accessibility of producer gas was conducted. The conclusion of this
survey is that: Producer gas is produced in gasification lab present Kathmandu University by
using dry seeds of “Lapsi” as source through the gasification process and it can be accessed for
conducting research/Projects.

2.2.2. Installation of Spark plug

Since the test engine is diesel engine we had to replace the injector present in the engine with a
spark plug. We first removed the injector from injector hole. The hole was then threaded with
(10X1.25) mm tap. Then a spark plug of Hero Honda Splendor (Mico-Super) was fitted into the
hole. The spark plug used in the engine was hot type.

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 Fig 2.2.2.2: Mico-super sparkplug

Fig 2.2.2.1: Installation of Mico-super sparkplug in engine.

2.2.3. Installation of Magneto System

A shaft was welded into the smallest among three gears of the engine for rotating the magnet
around the pickup coil. The coil was kept in the Aluminum plate attached in the engine case. The
large gear was provided with a crank. When the large gear was rotated it would increase the rpm
of the smallest gear which was attached with the magnet. In turn the magnet would rotate along
with shaft around the coil which would produce input voltage of around 12V.

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 Magneto Ignition System

Fig 2.2.3.1: Magneto Ignition System (after installation)

2.2.4. Installation of CDI circuit

The installed CDI circuit was of CT-100 motorbike. Necessary casings and holders were made in
the engine casing for the circuit. The output terminal of the magneto was attached with the input
terminal of the CDI.

Fig 2.2.4.1: CDI circuit

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 2.2.5. Arrangements for carburetion
Intake of the engine was connected with the fuel source i.e. gasifier. Flow of the fuel was
controlled by gate valve present in the pipeline. The pipeline of the fuel was bifurcated and was
attached with an air source (blower). Arrangements were made such that the air and fuel would
superimpose in the junction. Mixing will occur in the junction and would enter into the cylinder
through inlet valve. Required mixture of air and fuel was controlled by gate valve present on
each pipeline. Necessary stoichiometric air-fuel ratio is maintained at 1.1:1.

2.2.6. Survey for better ignition system

The Magneto ignition system installed previously was unable to produce the required amount of
voltage for spark generation. The main reason for this was that the shaft welded in the gear was
little eccentric due to which the magnet attached to it could not rotate properly around the pickup
coil. So the required constant 12volts emf was not induced in the pickup coil as a result the
ignition coil could not produce the required voltage of 20000volts or above.

2.2.7. Installation of Battery ignition system

So to avoid the above problem a Battery Ignition System is to be used. Thus the various
components of the battery ignition system like distributer, ignition switch were surveyed in the
market. It was a hectic task and the required distributer for one cylinder engine could not be
found. Only the distributer for four cylinder engines was available. So, we grinded the cam of the
distributer in such a way that the contact breaks in the circuit only one time in a cycle. The
distributer cap was also removed which facilitated in the smooth operation of the distributer.
Thus the parts of the ignition system are now ready to be installed.

2.3. Work Remaining

 Complete the installation of the ignition system
 Experiment combustion characteristics of producer gas under pressurized condition in
the combustion chamber
 Compare efficiency and power generation of tested engine with the gasoline engine.

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 2.4. Progress chart

April May June July

Literature review

Survey of better ignition system

Installation of Battery Ignition system

Mid-term report submission

Mid-term presentation

Management of Gasifier for test run

Test Run of the engine

Experiment combustion characteristics of producer gas

Compare efficiency with gasoline engine

Final report submission

Final presentation

Table 2.4.1: Progress chart

Work Completed

Work Remaining

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 3. CONCLUSION
Thus we now have completed the market survey of the battery ignition system. All the
components are in place and the final installation is remaining. We are debugging the errors
which were prevalent during early stages of circuit installation. Since spark requirement is main
hurdle for us during installation we are working further to calculate optimum amount of spark.

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Works Cited

[1] [Online]. Available: http://4.bp.blogspot.com/-

cth6T48OuvQ/Tv6WQ9ILzPI/AAAAAAAAAkY/oHnOnDg4WA4/s1600/CDI+Ignition+Circuit+
Diagram.jpg.

[2] J. S. L. U. H. a. J. B. C. Hindsgaul, "Physical and chemical characterization of particles in

producer gas from wood chips," in Bio Resource Technology, 2000, pp. 147-155.

[3] S. M. D.K.Das, "Performance Study of a Diesel Engine by using producer gas from
Selected," World renewable energy congress, Linkoping, 2011.

[4] B. Cengel, Thermodynamics An Engineering Approach, McGraw hill company, 2008.

[5] "Producer gas," 12 11 2013. [Online]. Available: http://www.wikipedia.com/producer_gas.

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