Design & Fabrication of very important to evaluate energy

losses in the engine in order to

Exhaust Gas increase the engine performance. In

Calorimeter for IC engine, the main heat losses are

through cooling water so it is
Two Stroke Petrol important for IC engine to find out

Engine optimum mass flow rate of cooling

M. R. Todkar*, Akash Bhosale**,
Khushal Bisen, Shivanjali Jadhav,
Rekha Lohar
Department of Mechanical Engineering
water & to avoid overheating of the
engine & under cooling of the
engine. So with this minimum fuel
consumption take place by the IC

Tatyasaheb Kore Institute of Engineering engine. For achieving this concept, it

and Technology, Warananagar is very important to design/fabricate
*mrtmech@tkietwarana.org, proper exhaust gas calorimeter. The
**bhosaleakash143@gmail.com
result showed that the rate of heat
losses through the exhaust gas is
ABSTRACT increased with the increasing of
Exhaust Gas Calorimeter is used for engine speed. This is due to the fact
the checking the performance of a that when the engine speed increase,
two stroke petrol engine. In present the throttle opening will also
study, the experiments are conducted increase in order to allow more mass
with the purpose to test the of air entering the cylinder during
applicability of exhaust gas combustion. Consequently, the mass
calorimeter model in order to of fuel also will be increased and
quantify the heat loss through affect the exhaust gas temperature.
exhaust gas. The exhaust gas Investigation about the rate of heat
calorimeter is basically a heat losses through exhaust gas using
exchanger consists of pipe for water exhaust gas calorimeter also provides
in and out as a cold fluid and pipe the useful design and fabrication
connected from exhaust tail pipe to information to engineers.
the calorimeter for the hot fluid. It is
Key Words - Two stroke petrol engine,
heat losses, Exhaust gas calorimeter.
INTRODUCTION
At present, in petrol engines the method is to
obtain the temperature of the exhaust gas
based on assuming a specific heat, calculate
the weight from the volumetric efficiency,
and then calculate the heat lost. Recognizing
the need of more accurate information on
this phase of gas engine analysis, it is
decided to design and construct an
EXHAUST GAS CALORIMETER for High
Speed Automobile engines.
The heat to be measured is to be imparted to
a stream of water. The volume of water
flowing through the calorimeter, a known
volume of combustible fuel is consumed in
the engine and the resultant temperature of
the water, furnish the data necessary to
calculate the heat imparted to the water. The
temperature of the water entering and
leaving the calorimeter is measured by
means of inlet and outlet thermometers.
These observations are used to determine the
thermal performance of petrol engine by
parameters such as Exhaust gas temperature,
indicated and brake power, brake thermal
efficiency, Brake specific fuel consumption.
In an automobile the heat is produced on the
combustion of fuel. From this heat, some
amount of heat is utilized for work-done and
remaining amount of heat is distributed in
various ways such as cooling water,
lubrication oil, and radiation & through
exhaust gas etc. So we are going to design a
exhaust gas calorimeter which is heat
exchanger. This heat exchanger will give the
amount of heat carried away by exhaust gas.
LITERATURE REVIEW
1.Design of an Exhaust gas
calorimeter for Automobile Engines
The object of this thesis is to design,
construct and test an EXHAUST GAS
CALORIMETER for High Speed
Automobile engines. This thesis is divided
into three parts. In the first part is given a
complete description of the calorimeter,
including its design and method of
construction. The second part is devoted
exclusively to the description of the engine
and its accessory apparatus. The third part,
in addition to the results and method of
testing, contains a discussion of the results
obtained.
2.Performance Analysis of Exhaust
Gas Calorimeter for diesel Engine.
A four stroke diesel engine with water &
diesel coolant is used as a reference in this
study. The experiments are conducted with
the purpose to test the applicability of
exhaust gas calorimeter model in order to
quantify the heat losses through exhaust gas.
The model considered the calorimeter
system components such as pipe for water in
and out as a cold fluid and pipe connected
from exhaust tail pipe to the calorimeter for
the hot fluid. It is very important for I.C.
Engine to find out optimum mass flow rate
of cooling water & to avoid overheating of
the engine & under cooling of the engine. So
with this minimum fuel consumption take
place by the I.C. Engine so for achieving
this concept it is very important for
optimization of mass flow rate of cooling
water fabricate/design exhaust gas
calorimeter. It is important to evaluate
energy losses in the engine in order to
increase the engine performance. The result
showed that the rate of heat losses through
the exhaust gas is increased with the
increasing of engine speed. Consequently,
the mass of fuel also will be increased and
affect the exhaust gas temperature. The
present study will investigate about the rate
of heat losses from exhaust gas using
exhaust gas calorimeter.
3. A Review on performance of
Diesel Engine with Heat Exchanger.
In this paper, a study of experiments which
were conducted to study about recovery of
exhaust waste heat from a diesel engine
using heat exchanger (HE). Engine
performance parameters such as Exhaust gas
temperature brake thermal efficiency, Brake
specific fuel consumption were analyzed.
The performance of an available shell and
tube heat exchanger using water as the
working fluid was conducted. With the
available data, computer simulation was
carried out to improve the design of the heat
exchanger. The exhaust gas was first passed
through EGR valve then through the heat
exchanger.
4.Computational design &
fabrication of exhaust gas
calorimeter with c-programming
template.
In this Paper, author presented their work on
design and fabrication of Exhaust gas
Calorimeter. Computational design is
performed and Fabrication of Exhaust gas
Calorimeter is done then Experiment is
conducted on Automobile 4-Stroke Diesel
Engine. After getting the results we compare
the effectiveness of Exhaust gas Calorimeter
between the Theoretical and Practical
values.
ALL ABOUT CALORIMETER  There are several types of heat
exchanger suitably can be used for
What is a Calorimeter ? exhaust gas calorimeter:
 Tube in Tube type
A calorimeter is a mechanical device used to
Heat Exchanger.
measure the heat gained or lost by the
 Shell & Tube type
system. The science deals with the study of
Heat Exchanger.
calorimeters are termed as calorimetry.
 Plate fins type Heat
What is an Exhaust gas calorimeter ? Exchanger.
 Spiral Tube type Heat
 An exhaust gas calorimeter is a
Exchanger.
device used in testing of Internal
Combustion Engines for analysing How does the exhaust gas calorimeter
the performance of engines. work ?
 The power produced after the
 The heat to be measured is to be
combustion of charge sucked in
imparted to a stream of water.
suction stroke is termed as Indicated
 The weight of water flowing through
power. And the power at shaft is
the calorimeter during the time that a
termed as Brake power.
flowing volume of combustible is
 Brake power is always less than the
consumed in the engine and the
Indicated power, because of some
resultant temperature of the water,
mechanical losses i.e. frictional
furnish the data necessary to
losses, heat lost with exhaust, etc.
calculate the heat imparted to the
 To account the power losses with
water.
exhaust gases the Exhaust Gas
 The exhaust gas is passed through
Calorimeter came into existence.
one tube & water is passed through
 Exhaust Gas Calorimeter is nothing
another tube and during which heat
but a heat exchanger. Heat exchanger
is transferred from exhaust gas to the
is a device in which the heat from
water.
one fluid is exchanged with another
 The temperature of the water
fluid.
entering and leaving the calorimeter
 is measured by means of inlet and Cpw – Specific heat of water
outlet thermo-couples. Same the Tci – Inlet temperature of
temperature of exhaust gas at inlet & cold water
outlet is measured by thermocouples.

DESIGN OF TUBE IN TUBE

TYPE HEAT EXCHANGER.

The design of heat exchanger involves a bit

of trial in the selection of the inner and outer
diameter of pipes. If the heat transfer
coefficient are too low or pressure drop is
too high for set of assumed pipe diameters,
the calculations have to be repeated for
WORKING
another set of values of the pipe diameter.
1. The exhaust gas from engine is passing The design procedure of a tube and tube heat
through exhaust gas calorimeter. exchanger is involving trial and error
method. The more important tasks in the
2. Heat carried away by the exhaust gas is
design process of tube and tube heat
transferred to cooling water which is
exchanger are
circulated in the exhaust gas calorimeter.
1. To find out the Logarithmic
3. The amount of heat transferred from
Mean Temperature
exhaust gas to cooling water is calculated by
Difference ( LMDT )
the formula,
2. To determine the heat transfer
Q = mw Cpw (ΔT) area required for the given
heat duty.
Q = mw Cpw (Tco-Tci)
3. To specify the tube diameter,
Where, length.
4. To determine the heat
Q – Heat carried out by
transfer coefficient of inner &
exhaust gas
outer side.
mw– Mass of water
From the known terminal temperatures, the 2. Cold Fluid
LMTD can be calculated. But the quantities - Mass Flow Rate
Ud and heat transfer area A has considerable Kg/s
mutual dependence. This is because Ud - Inlet Temperature ᵒC
depends, beside other quantities, upon - Outlet Temperature ᵒC
Reynolds number Re and for a given liquid - Cold Fluid
flow rate, Re depends upon the size, density, - Properties Of Fluid
velocity of flow & viscosity. Therefore the ( ρ, Cp, μ, K )
heat transfer coefficient, in turn, depends
upon the diameter. The latter quantities give 3. Hot Fluid
the heat transfer area. The coefficient Ud is - Mass Flow Rate
also determine partly by outer tube side Kg/s
coefficient which depends upon the outer - Inlet Temperature ᵒC
tube side Reynolds number and which in - Outlet Temperature ᵒC
turn is a function of the tube number, - Hot Fluid
diameter. Therefore, the independence of Ud - Properties Of Fluid
and A is not fully explicit, and a trial and ( ρ, Cp, μ, K )
error method of calculation is adopted for
design. Due to this reason, design procedure 4. Data Of Tube
becomes complicate, requires large number - Material selection
of iterative calculation which is time o Inner tube
consuming. material= Copper
Tube (k= 385 W/m
A. Inputs for design of heat
K)
exchanger o Outer tube

1. Heat Transfer Rate Q in Watt material= Mild

Steel (k= 66 W/m
Q = m × Cp( Thi – Tho )
K)

5. Heat Transfer Rate Q in Watt

- For exhaust Gas

 - Diameter of inner pipe
Qg = mg × Cpg( Thi – Tho )
- Diameter of outer pipe
- For Water
A) Outer tube side
Qw = mw × Cpw( Tco – Tci )
1. Flow Area = inner diameter of -

Outer diameter of

DESIGN PROCEDURE Outer pipe inner pipe

𝜋 𝜋
1. Compute the Logarithmic Mean = Di - do2
4 4

Temperature Difference (LMTD)

from the inlet and outlet 2. Wetted Perimeter = Π ( Di + do )

temperature of hot and cold fluid

3. Hydraulic Diameter of the annular,
4×𝑓𝑙𝑜𝑤 𝐴𝑟𝑒𝑎
to heat exchanger. dH =
𝑊𝑒𝑡𝑡𝑒𝑑 𝑃𝑒𝑟𝑖𝑚𝑒𝑡𝑒𝑟

a. For counter fluid flow 𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟

4. Velocity = 𝐴𝑟𝑒𝑎
t  t   t ho  t ci 
LMTD  hi co For water,
 t  t 
ln  hi co  μ = 0.89 Cp
 t ho  t ci 
Where,
Cp = 4.187 KJ/Kg
K = 0.6 W/mK
b. For parallel fluid flow
5. Reynolds Number,
t  t   t ho  t co 
LMTD  hi ci
 t  t   Re =
𝜌×𝑣×dH
ln  hi ci  𝜇
 t ho  t co 
6. Prandtl Number,
𝜇×𝐶𝑝
Pr =
2. Select the Diameter of Inner & 𝐾

Outer Tube 7. Calculation of ho from the Dittus -

Boelter Equation
 Nu = 0.023( Re)0.8 × (Pr )0.3 On the outer area basis,

And
1 1 𝐴𝑜 ( 𝑟𝑜 − 𝑟𝑖 )
= +[ × ]
ℎ𝑜×dH 𝑈𝑜 ℎ𝑜 𝐴𝑚 𝐾𝑤
Nu = 𝐴𝑜 1
𝐾
+ [( ) × ( )]
𝐴𝑖 hi
B) Inner Tube Side

Cp= 1.063 KJ/kg

di = 15.75 mm
do = 19.05 mm Where,
μ = 0.165 × 10-3kg/m.s
8. Flow Area, Ao = Π × do × l
𝜋 Ai = Π × di × l
Af = × di2
4
𝐴𝑜−𝐴𝑖
Am = 𝐴𝑜
9. Flow Rate, ln
𝐴𝑖

Q = Af × ʋ D) Therefore the required area

from,
Therefore,
Q = Uo × Ao × ΔTm
Q
ʋ = 𝐴𝑓
Therefore,
10. Reynolds Number,
Ao = Π × do × L
𝜌×𝑣×di
Re = 𝜇
So that,
11. Prandtl Number, 𝑄
L= 𝑈𝑜 ×𝛥𝑇𝑚 ×𝛱𝑑𝑜
𝜇×𝐶𝑝
Pr = 𝑘

12. Dittus – Boelter Equation,

ℎ𝑖 ×𝑑𝑖
Nu = 𝑘

Where,
Nu = 0.023 × ( Re)0.8
× (Pr )0.4

C) Calculation for clean overall

heat transfer coefficient,
CONCLUSION Engine”, SVMIT, Bharuch-392001, Gujarat,
INDIA GEC, Bhuj-370001, Gujarat, INDIA
In case of IC engine it is important to find
© 2014 IJEDR | Volume 2, Issue 2 | ISSN:
heat balance sheet. How much heat goes to
2321-9939
brake power, how much heat goes to exhaust
2.“A review on performance of diesel
gas as a loss and heat loss in cooling water.
engine with heat exchanger”, Dept. of
Existing exhaust gas calorimeter is of shell
Mechanical Engg, Agnos Collage of
and tube type heat exchanger and of
Technology, RKDF University, Bhopal
oversize. It doesn’t gives the accurate
(M.P), India.
results, as amount of water flowing through
ISSN 2277-2685 IJESR/May 2015/ Vol-
this heat exchanger is more & it affects on
5/Issue-5/184-186
the temperature of water. While testing the
3.“Computational Design and Fabrication of
temperature of exhaust gas is decreasing but
Exhaust Gas Calorimeter with C-
temperature of water doesn’t increases. The
Programming Template”, International
problem is quantity of exhaust gas produced
Journal of Emerging Engineering Research
by two stroke petrol engine is less and
and Technology
amount of water in the annular space of heat
Volume 3, Issue 5, May 2015, PP 47-54
exchanger is more so the water temperature
ISSN 2349-4395 (Print) & ISSN 2349-
doesn’t increases. We analyzed the exact
4409.
problem and selected the appropriate heat
exchanger which is tube in tube type. The
4.Thesis “Design of an exhaust gas
design of tube & tube type heat exchanger is
calorimeter for automobile engines” by 1). J.
in according with the exhaust gas outlet pipe
L.Mayer 2). L. E. Hibbard
and is giving the accurate results.
Armor Institute of technology, 1915

REFERENCES Published in 1915.

Journals and research papers Handbooks

1.Mr. Hemant M Patel, Mr. Dipak C Gosai, 1. Perry’s Chemical Engineering
Mr.Ashish J Modi, “Performance Analysis Handbook
of Exhaust Gas Calorimeter for diesel 1. Handbook On Process Heat
Transfer by “ Sarit K. Das”
2. Handbook of Heat Transfer 3rd
edition by
1. Warren M. Rohsenow.
2. James P. Hartnett.