Report Performance Testing and Comparison of Portable Genset of 3KW {Compression ratio 11} on enriched Bio-Gas, Petrol and

Standard LPG Submitted by: Bhabani Shankar Pati

Under guidance of

Mr. Pankaj Kumar Sharma Assistant Professor (Selection Grade) pankjpme@ddn.upes.ac.in Phone: 9997103332 Department of Mechanical Engineering College of Engineering Studies

Department of Electrical, Electronics & Instrumentation Engineering

University of Petroleum & Energy Studies

Energy Acres, P.O. Bidholi, Via- Prem Nagar, Dehradun-248006 Tel: 0135-2102690/91, 0135-2694257/58, 0135-2694200 Fax: 0135-2694204

Abstract
Tight requirements posed by the increasingly stringent legislation complicate the design procedure for exhaust after treatment devices and systems. Since design optimization relies heavily on experiments and tests, emissions test data acquisition should comply with strict quality standards. Time-varying exhaust emission measurements incorporate a wealth of information stemming from the engine type, its fuel injection and ignition management and valve timing and the exhaust gas treatment devices present. The objective of this paper is on performance testing and comparison of portable Genset of 3KW on enriched Bio-gas and LPG with its base fuel as petrol. Testing of Genset to obtain their performance and generator efficiency on individual fuels and compare it with the other sets of fuels. Emission levels like Hydrocarbons, CO2, NOx, CO in ppm of the Gensets are also done to see the operation in agreement with the standard norms.

Objective: Performance Testing and Comparison of Portable Genset of 3KW {Compression ratio 11} on enriched Bio-Gas, Petrol and Standard LPG Scope of work:
As we know with the rapid Industrialization, explosive growth all around for last more than 100 years and burning of billions of tons of fossil fuels (Coal/Petroleum) every year for supporting our energy needs, are the major contributors to the problem of Global Warming. The solution now surely will come through development of cutting edge technology, that must be sustainable, affordable, limitless, practical, user-friendly & off course ecofriendly. The sooner & earlier we get the better & cost effective alternative technology for our energy needs, the world community as whole must ban immediately mining of coal & further sucking of petroleum from planet earth. In this project the performance of the newly developed Genset will be done by load variation method. The modern day Genset used in our home as backup are either petrol or diesel operated which is easily available but for rural electrification the source of fuel is the easily available biowaste. The Genset can be operated on LPG and enriched Bio-gas. These fuels directly help in reducing global warming as they yield lesser or no amount of harmful oxides of nitrogen, sulphur and hydrocarbons. The project aims at having electricity for all through these cost effective Gensets. With increasing prices of gasoline the new alternative for fuel is Biogas and kerosene which will propel the working of the Genset economically.

Literature Review:
An engine-generator is the combination of an electrical generator and an engine (prime mover) mounted together to form a single piece of equipment known as Genset.[1] The usage of Generators has widely increased in the recent past due to the increasing chances of power-cuts. Generators are a great back-up unit that is highly beneficial in emergency situations. They produce electrical energy through the principal of mutual-induction. Nowadays, you can find an extensive range of generators which include Natural Gas Generators, Diesel Generating Sets, and Power Generators.[2] Portable Genset as you can get a fair idea from the name are those generators that are compact and portable and offer better mobility. They are hence used in

homes, during erratic power situations. As they can be moved from one place to other even without using additional hands, they are also ideal when you hold parties or other events in your backyard. They offer the much needed power back up and access to power in place where electric connectivity is a constrain.[3] An electric generator is a device that converts mechanical energy into electric energy. The AC power generators for home use utilize small engines to produce the mechanical energy. The spinning shaft of the engine is used to create an alternating magnetic field through a coil. This induces electromotive force according to Faraday's law. Since such a system includes an engine and an alternator mounted together, a technical term for this appliance is an engine-generator set or Genset.
[4]

ISO 8528 (BS7698) part 6 is the standard for

test methods of engine-driven generating sets. It sets out general test requirements and defines a functional test and an acceptance test. Functional tests must always be done and usually occur at the manufacturer's factory. Acceptance tests are optional, may be done on site and are often witnessed by the customer or his representative. In all cases tests must be done with reference to the agreed specification of the generating set. Prior to operational tests, environmental data must be recorded and a preliminary inspection is specified. This includes safety checks, earth connections and guarding, insulation tests, fluid levels checks etc. On initial start-up emergency stop system must first be checked, followed by frequency, voltage and phase rotation checks, and an inspection for leaks and vibration.[5] Emissions of many air pollutants have been shown to have variety of negative effects on public health and the natural environment. Emissions that are principal pollutants of concern include:  Hydrocarbons: These are a class of burned or partially burned fuel, hydrocarbons are toxins. Hydrocarbons are a major contributor to smog, which can be a major problem in urban areas. Prolonged exposure to hydrocarbons contributes to asthma, liver disease, lung disease, and cancer. Regulations governing hydrocarbons vary according to type of engine and jurisdiction; in some cases, "non-methane hydrocarbons" are regulated, while in other cases, "total hydrocarbons" are regulated. Technology for one application (to meet a non-methane hydrocarbon standard) may not be suitable for use in an application that has to meet a total hydrocarbon standard. Methane is not directly toxic, but is more difficult to break down in a catalytic converter, so in effect a "non-

methane hydrocarbon" regulation can be considered easier to meet. Since methane is a greenhouse gas, interest is rising in how to eliminate emissions of it.  Carbon monoxide (CO): Product of incomplete combustion, carbon monoxide reduces the blood's ability to carry oxygen. Overexposure can be fatal. Carbon Monoxide poisoning is a major killer.  Nitrogen oxides (NOx): These generated when nitrogen in the air reacts with oxygen at the high temperature and pressure inside the engine. NOx is a precursor to smog and acid rain. NOx is a mixture of NO, N2O, and NO2. NO2 is extremely reactive. It destroys resistance to respiratory infection. NOx production is increased when an engine runs at its most efficient part of the cycle.  Particulate matter: Soot or smoke made up of particles in the micrometer size range: Particulate matter causes negative health effects, including but not limited to respiratory disease and cancer.  Sulfur oxide (SOx): A general term for oxides of sulfur, which are emitted from motor vehicles burning fuel containing sulfur. Reducing the level of fuel sulfur reduces the level of Sulfur oxide emitted from the tailpipe. Refineries generally fight requirements to do this because of the increased costs to them, ignoring the increased costs to society as a whole.  Volatile organic compounds (VOCs): Organic compounds which typically have a boiling point less than or equal to 250 C; for example chlorofluorocarbons (CFCs) and formaldehyde. Volatile are a subsection of Hydrocarbons that are mentioned separately because of their dangers to public health.

Methodology:
y The Genset is fixed to a test rig to avoid vibrations and disturbance to small parts attached to it during testing. y The load board is prepared for testing of the Genset at varying loads. The load board is to be connected to a proper wiring system for operating the output of generator at uniform loads. y The enrichment of the biogas is to be done to remove harmful gases like CO2, H2S and moisture. y y y The performance testing of the engine is to be done on base fuel in petrol/diesel. The test board is to be prepared to calculate specific fuel consumption. The emission testing is to be carried out by preparing an exhaust cylinder where the hot air will be cooled to obtain the percentage of harmful gases present in it that is getting exhausted to the atmosphere. y The Genset is then to be tested similarly on LPG and Bio-gas to obtain the results as it was tested on base fuel. y The performance of the Genset on various fuels will then be compared to see variations.

Enrichment of Biogas:
Regeneration (desorption) After saturation has been reached, one can restore the original adsorption properties by desorption. Usually the adsorbed molecules (adsorbate) are desorbed by addition of heat by a hot inert gas between 160 and 220C at reduced partial pressure. If only the partial pressure is reduced, the adsorbate concentration on the solid phase will be higher than that predicted by the adsorption isotherm. This phenomenon is called hysteresis. The most common configuration consists of two adsorbers, one operating in the adsorption mode while the other operates in the regeneration mode. Molecular sieves Molecular sieves are zeolite-based adsorbents consisting of crystalline aluminosilicates (zeolites) and clay. The zeolite represents the active phase. Zeolites occur only as small crystals (1 - 6 m)

which are too small for use in dynamic adsorption systems. A small amount of clay is therefore employed as a binder enabling fabrication of shaped products to adjust the mechanical properties of the adsorbent. The special characteristics of molecular sieves include reversible adsorption of various gaseous compounds and a network of cavities and narrow pores giving very high internal surface area. Type A zeolite with sodium cations has a pore width of 4 , and is called MS4A. Replacement of sodium by calcium cations leads to 5 pores, and is called MS5A. In the same way replacement of sodium by potassium leads to molecular sieve MS3A. Zeolite of type X gives pores of 10 and the calcium type corresponds to MS13X.

Adsorption The zeolite is responsible for the physical adsorption of the molecule to the surface. It is therefore necessary to develop the largest possible internal surface as is obtained by the presence of well-defined pores and cavities. Adsorption increases with the partial pressure of the adsorbate. Contrary to other adsorbents like activated alumina and silica, zeolites have a high adsorption capacity at low partial pressures. Adsorption capacity decreases with increasing temperatures, but zeolites keep their efficiency for drying up to 100C, whereas alumina has its more favorable adsorption characteristics below 50C. When the mass transfer zone (MTZ), which preceeds the adsorbate saturating the adsorbent in the equilibrium zone (EZ) reaches the bottom of the reactor (breakthrough condition), the adsorbers reactor is switched to the regeneration mode.

Regeneration Molecular sieves can be regenerated by changing the isotherm (thermal swing) by heating the adsorbent with a hot gas or by changing the partial pressure (pressure swing). Regeneration gas flows counter currently to the process gas at temperatures between 200 and 280C. If a fast regeneration is required, temperatures up to 320C could be considered.

Normally adsorbers units are used with one adsorber in adsorption mode and the other in regeneration mode. Depending upon volumes being treated a multi-adsorber system can be implemented. Regeneration is generally performed counter currently to the drying direction. This prevents the adsorbate from coming into contact with the bottom part of the adsorbent. This reduces hydrothermal aging (see next part) and enhances the number of cycles. When a dry gas (like nitrogen) is used, lower regeneration temperatures can be employed reducing aging. Wet gas is less costly, but requires higher regeneration temperatures (> 250C), causing faster aging. Subsequent cooling with dry cold gas is necessary. If dry gas is not available, it is recommended to perform the cooling step in the same direction (co-current) as the adsorption. Care must be taken to avoid the pick-up of water from the condenser or from unpurged parts of the unit. If there is a limitation in regeneration temperature we advise using a combination of activated alumina and molecular sieves, taking advantage of the lower temperature needed to regenerate activated alumina. For some applications however molecular sieves are preferred over activated alumina because of possible co-adsorption effects (see next part), such as the use of MS 3A SC molecular sieves for cracked gas drying.

Calculations For column Design

Column design for CO2 Calculation of column cross section Total bio-gas production = = = Let maximum flow in the chamber Area of section = = = = 6m3/day 0.25m3/hr 69.4 cm3/sec 0.5 cm/sec 69.4/.5 138.8 cm2 0.0138 m2

Radius of chamber for circular cross section,

R=

(.0138/ ) = .066277 m = 6.63

Calculation of height of the column

Biogas production

6m3/day

Total Volume of CO2 per day

= = =

60.35 2.11.8

(for 35% CO2) (density=1.8)

3.73 kg/day 3.733 11.19kg of CO2/operating day

Total kg of CO2

= =

1 kg absorbent can absorb 0.18 kg of CO2

Total mass of absorbent

= =

11.19/0.18 62.16 kg of Absorbent / operating day

Bulk density of absorbent Volume of absorbent

= = = =

0.64kg/l 62.16/0.64 97.125 lit/operating day 97.12510-3 m3/operating day 25% (0.2597.125) 24.2810-3 m3 121.4010-3 m3

Addition dead volume

= = =

Total volume of chamber

Height of the coloumn

= = = ~

volume/area 121.4010-3/.0138 8.797 m 9m

We have three coloumns connected in series Height of each coloumn Height of absorbent sectional area) = = = = Distance between trays = = 9/3 = 3m ((height of absorbent))/(total cross 0.097125/.0138 7m 7/12 60 cm

Column design for H2S Calculation of chamber cross section

Total biogas production

= =

6 m3/day 0.25 m3/hr = 69.4 cm3/sec. 0.5 cm/sec 69.4/.5 R =(.0138/ ) = 138.8 cm ~139cm =6.65cm

The maximum flow in the chamber Area of section Radius of chamber for circular cross section,

= =

Calculation of height of the chamber Total H2S per day Regeneration time Total H2S produced = = = = 1 kg of absorbent can absorb 150 gm of sulphur 18 g/day 60 days 18*60 1080 g/operating day (estimated)

Total mass of absorbent

= =

1080/150 7.2 kg absorbent/operating day 0.8 kg/l

Bulk density of absorbent

Gas Purification Setup

Volume of absorbent

= =

7.2/0.8 9 lit/operating day

Addition dead volume

= = =

25% (0.250.009) 2.2510-3 m3 11.2510-3 m3 volume/area 11.2510-3/.0138 0.815 m ~ 82 cm

Total volume of chamber Height of the chamber

= = = =

According to above calculation one chamber having diameter 13.3 cm and height 82cm for H2S and four chamber having diameter 13.3 cm and height 60 cm for CO2 has been fabricated. These chambers were arranged in such a way that H2S removed first and passed to another chamber through pipes for CO2 removal. The chamber used for H2S removal was filled with Activated Alumina and the chambers used for CO2 removal were filled with Molecular Sieves. Two pressure gauges, one at beginning and other at the end of the chamber setup are attached to measure the pressure drop and flow.

Reference:
1. http://en.wikipedia.org/wiki/Engine-generator
2. http://www.free-press-release.com/news-advantages-of-generators-1253183044.html, 17 September, 2009,Free press release

3. http://en.wikipedia.org/wiki/Vehicle_emissions_control