Upgradation of Two Cylinder NA Diesel Genset Engine into TCIC Configuration for Achieving Stricter Emission Norms for 19 kW to 75 kW Power Categories

摘要

Single cylinder and two cylinder diesel engines are widely used as a source of power generation, three wheelers, agricultural machines and in small house-hold applications in India as well as other Asian countries. Use of high end technologies in such engines are very expensive and also becoming complex. Therefore simple mechanically controlled components are used for these engines which make them simple in operation and maintenance. In order to meet stringent emission norms, there is a need for the development of these engines. In the present work, an existing two cylinder naturally aspirated DI diesel engine is upgraded with Turbocharged & Intercooled (TCIC) version to meet the revised stringent stage-II emission limits. The two cylinder diesel engine has been upgraded with optimum selection of turbocharger, intercooler and EGR valve to control the EGR mass flow rate. The up-gradation of a two cylinder diesel genset engine come with minimum hardware changes in the engine to make it cost effective. A very unique & special feature of this work is that the developed engine is with odd injection firing type which is a very simple in basic design. This type of engine requires painstaking and correct matching of turbocharger and combustion optimization. On the other hand, turbocharging of an even firing 2 cylinder engines is relatively simple & easier however, require complete balancing of the engine by using a required balancer shafts. Putting a balancer shaft will increase the engine weight complexity, serviceability & cost. The power of the upgraded turbocharged & intercooled engine is increased from 18.6 kW to 23 kW with the existing fuel injection pump and without any change in the basic engine design. NO_x+HC emission of the developed engine is reduced by around 34% from the base naturally aspirated engine keeping CO & PM emissions almost same. An attempt is made to bring out by comparison of the effectiveness & advantages of 2 cylinder TCIC version with a 3 cylinder naturally aspirated engine of similar power output.