DESIGN AND FABRICATION OF AQUA SILENCER FOR I.C ENGINES

International Journal of Recent Innovation in Engineering and Research Scientific Journal Impact Factor - 3.605 by SJIF e- ISSN: 2456 2084 DESIGN AND FABRICATION OF AQUA SILENCER FOR I.C ENGINES Ajay Kumar Dhiman 1, Prakash Joshi 2, Deepak Basantani 3, Ganesh Jadhav 4 and Vinayak W. Bembrekar 5 1,2,3,4 BE in Mechanical D. Y. Patil College Of Engineering, Akurdi, Pune, Maharashtra, India. 5 Asst. Professor Mechanical Engineering, D. Y. Patil College Of Engineering, Akurdi, Pune, Maharashtra, India. Abstract - An Aqua Silencer is a concept which is designed to replace conventional single unit engine silencers on board structure. It is made to deal with the control of overall emissions and undesirable sound at the engine exhaust of the vehicle. An aqua silencer is fitted to the exhaust pipe of the engine. The activated charcoal filters the harmful sulphur and nitrous content produced from the engine. Sound produced under water is less hearable than it produced in atmosphere. Automobiles are not only the source of air pollution, other sources such as electric power generating stations, industrial and domestic fuel consumption, refuce burning, industrial processing etc. also contribute heavily to contamination of our environment so it is imperative that serious attempts should be made to conserve of our environment from degradation. An aqua silencer is an attempt in this direction; it is mainly dealing with emissions and sound produced in engine of automobile. Keywords -Aqua Silencer, Conventional, Degradation, Exhaust emissions, Pollution. I. INTRODUCTION An aqua silencer System is designed to replace conventional single unit engine silencers on board structures. With it s light weight and slender design, it offers a minimal 'footprint' while optimizing the entire exhaust system for low noise and reduced backpressure. It is used to control the noise and emission in IC engines. The reason why we go for aqua silencer is, in today life the air pollution causes physical ill effects to the human beings and also the environment. The main contribution of the air pollution is Automobile releasing the gases like carbondioxide and unburnt Hydrocarbon. In order to avoid this type of gases by introducing this aqua silencer. It is fitted to the exhaust pipe of the engine, Sound produced under water is less hearable than it produced in atmosphere. This mainly because of small sprockets in water molecules, which lowers its amplitude thus, lowers the sound level. The emission can be controlled by using the activated charcoal layer and it is highly porous and posse extra free valences so it has high absorption capacity. So absorb the gases from the engine and release much less position to the environment. The noise and smoke level is considerable less than the conventional silencer, no need of catalytic converter and easy to install. In this silencer, the Charcoal and Water so it is called hybrid aqua silencer, and it is useful in automobile, industry, DG sets & DG machines, Marin and Boats also so, It is known as hybrid universal aqua silencer. II.COMPONENTS AND EXPLANATION 2.1 Perforated Tube : The perforated tube consists of number of holes of different diameters. It is used to convert high mass bubbles to low mass bubbles. The charcoal layer is pasted over the perforated tube. 2.2 Charcoal Layer: The charcoal layer has more absorbing capacity because it has more surface area. This charcoal is called as ACTIVATED CHARCOAL. It is produced by heating the charcoal above 1500 c for several hours in a burner. Its surface area gets increased. @IJRIER-All rights Reserved -2017 Page 71

2.3 Outer Shell : The whole setup was kept inside the outer shell. It is made up of iron or steel. The water inlet, outlet and exhaust tube was provided in the shell itself. 2.4 U-Bend : The U Bend is provided instead of a non-return valve which is a mechanical device, which normally allows fluid (liquid or gas) to flow through it in only one direction. The Aqua silencer was filled with water and it is directly connected to the exhaust pipe of the engine. There is a chance for the water to get enter into the engine cylinder. To avoid this, U bend is used. 2.5 Flange : A flange joint is a connection of pipes, where the connecting pieces have flanges by which the parts are bolted together. Here flange is used to connect the silencer to the engine. III. CONSTRUCTION Basically an aqua silencer consists of a perforated tube which is installed at the end of the exhaust pipe. The perforated tube may have holes of different diameters. The very purpose of providing different diameter hole is to break up gas mass to form smaller gas bubbles the perforated tube of different diameters. Generally 4 sets of holes are drilled on the perforated tube. The other end of the perforated tube is closed by plug. Perforated tube contains lime water inside it which chemically reacts with exhaust gas from the engine. Around the circumference of the perforated tube a layer of activated charcoal is provided and further a metallic mesh covers it. The whole unit is then placed in a water container. A small opening is provided at the Top of the container to remove the exhaust gases. A U bend is provided at the end of perforated tube which functions as a non-return valve which prevents the back flow of exhaust gas and lime water back to the engine. IV. WORKING Fig-1: Working Layout As the exhaust gases enter in to the aqua silencer, the perforated tube converts high mass bubbles in to low mass bubbles after that they come in to contact with lime water they chemically react with it and pass through the pass through charcoal layer which again purify the gases. It is highly porous and posse extra free valences so it has high absorption capacity. Since the charcoal layer is covered with outer shell which is filled with water. Sound produced under water is less hearable than it produced in atmosphere. This is mainly because of small sprockets in water molecules, which lowers its amplitude thus, lowers the sound level hence aqua silencer reduces noise and pollution. Available Online at : www.ijrier.com Page 72

V. CAD MODEL OF AQUA SILENCER Fig-2: Isometric view of Aqua Silencer Fig-3: Front view of Aqua Silencer Fig-3: Top view of Aqua Silencer Available Online at : www.ijrier.com Page 73

VI. EXPERIMENTAL SETUP AND CALCULATIONS STEP 1: BENCHMARKING As per design methodology we benchmarked same kind of engine models to set the target of transmission loss of muffler. Engine data: Hero Honda Splendor Bore (D) = 50 mm Stroke (L) = 49.5 mm No. Cylinders (n) = 1 Engine power (P) = 6.15kw (8.36ps) @ 8000rpm Max. RPM (N) = 8500 rpm Allowable back pressure for muffler = Not available (in H2O) Transmission Loss Noise target (muffler) = 30 db. STEP 2: TARGET FREQUENCIES To find fundamental frequency Cylinder Firing Rate (CFR): CFR = RPM/120 for 4-cycle engines CFR = 8000/120 CFR = 66.66Hz Engine firing rate (EFR): EFR = No. of cyl. x Cylinder firing rate EFR = 1 X 66.66 EFR = 66.66Hz STEP 3: MUFFLER VOLUME CALCULATION Swept volume (Vs): (π x d 2 x L)/4 = (3.14x50 2 x49.5)/4 = 97193.022 x 10-6 Lit. Volume to be consider for calculation Volume = (No. of cylinders) x Vs = (1) x 0.09714375 Lit = 0.0971930 As no. of cylinder = 1 for hero splendor. Silencer Volume =Factor of Safety X Consider Volume = 25 x 0.0971930 liters. = 2.42982556 Lit Assumed Factor =25 Silencer Volume: Volume of silencer must be factor of at least 12 to 25 times the volume considered. Volume can be adjusted depending on the space constraint. STEP 4: INTERNAL CONFIGURATION OF MUFFLER AND CONCEPT DESIGN Diameter of muffler calculated as: V m = (π/4) x D 2 x L 2429825.5568 mm 3 = (3.14/4) x D 2 x 0.350 D=94.01mm OR D=94 mm (Diameter of muffler) Here, we take L= 350 mm after studying various muffler lengths of similar engine mufflers and overall space available on a motorcycle for mounting of a muffler and hence we select the same length. Step 5: TAIL PIPE DESIGN: Generally Tail Pipe Diameter and shape is taken the same as selected by OEM or manufacturer for lesser flow resistance and optimum flow characteristics. Hence, Tail Pipe Diameter: 23.48mm (From Hero Honda splendor as seen below). Available Online at : www.ijrier.com Page 74

Fig-4: Experimental Testing STEP 6: Selection of other parameters 1. Charcoal Meshed around perforated tube to capture Pollutants. 2. The perforated tube remains completely immersed in water to maximize pollutants capture. 3. Inlet and Outlet extension to be kept in configuration as shown in CAD model below. 4. L a = Length at which Perforation starts on pipe = 5mm 5. L b = Length at which perforation ends = 180mm 6. Diameter of perforation: variable from 6mm to 11mm (referring to research paper), for breaking of gas bubbles in different sizes. 7. A drain plug and refill cap is provided for replacement of water and maintenance. 8. A non-return valve is provided before perforated pipe to prevent water entering engine 9. Material : SS (Any grade depending upon its availability in market and its cost). VII. EFFECT OF DISSOLVED GASES ON WATER The water is a good absorbing medium. In aqua silencer the gases are made to be dissolved in water. When these gases dissolved in water they form acids, carbonates, bicarbonates etc. (1) Action of dissolved SO 2 When SOx is mixed in water, it form SO 2, SO 3, SO 4, H 2 SO 4, H 2 SO, i.e. Sulfuric Acid (H 2 SO 3,), it forms Hydrogen Sulphide which causes foul rotten egg smell, acidify and corrosion of metals. (2 ) Action of dissolved CO 2 The dissolved carbon dioxide forms bicarbonate at lower PH and Carbonates at higher PH. This levels 40-400 mg/liter. This form a scale in pipes and boilers. The carbon dioxide mixes with water to form Carbonic acid. It is corrosive to metals and causes green house effect. Available Online at : www.ijrier.com Page 75

(3) Effect of dissolved NOx The Nitrogen in water under goes Oxidation to form ammonia, Nitrate, Nitrite, Nitric acid. This synthesis of protein and amino acids is affected by Nitrogen. Nitrate usually occurs in trace quantities in surface water. VIII. EXPERIMENTAL TESTING AND RESULTS Fig-5: PUC of Conventional Silencer Fig-6: PUC of Aqua Silencer without water Fig-6: PUC of Aqua Silencer with Water Fig-7: Test set up of Aqua Silencer Available Online at : www.ijrier.com Page 76

Parameter Table-1: Comparison of Results Conventional Aqua Silencer Silencer without Water Aqua Silencer with Water Carbon Monoxide (CO) 1.561 % 0.367 % 0.089 % Non-Methane Hydrocarbons (HC) 998 ppm 422 ppm 175 ppm Vibrometer Readings 119 db 115 db 99 db IX. CONCLUSION The aqua silencer is more effective in the reduction of emission gases from the engine exhaust using perforated tube, lime water and charcoal by using perforated tube the back pressure will remain constant and the sound level is reduced. By using perforated tube the fuel consumption remains same as conventional system by using water as a medium the sound can be lowered and also by using activated charcoal in water we can control the exhaust emission to a greater level. The water contamination is found to be negligible in aqua silencer. It is smokeless and pollution free emission equivalent to the conventional to the silencer. X. ACKNOWLEDGEMENTS We wish to express my sincere thanks and deep sense of gratitude to respected guides Asst Prof. Vinayak W. Bembrekar in Department of Mechanical Engineering of D. Y. Patil College of Engineering, Akurdi, Pune, Maharashtra, India for the technical advice, encouragement and constructive criticism, which motivated us to strive harder for excellence. REFERENCES [1] Miers S.A. and R.D. Chalgren, Noise and Emission Reduction, SAE Technical Paper Series 2000-01-2573. [2] Rohit R. Thakare and Ajit J. Khushwah. (2015) Design and Fabrication of Aqua Silencer for Automobiles, International Journal of Mechanical and Production Engineering Research and Development, Vol. 5, Issue 6, ISSN: 2249-6890. [3] Keval I. Patel, Mr. Swastik R. Gajjar (2014) Design and Development of Aqua Silencer for Two Stroke Petrol Engine, International Journal for Innovative Research in Science & Technology, Vol: 1, Issue: 1, ISSN: 2349-6010 [4] P. Balashanmugam and G. Balasubramanian. (2015) Developments of Emission and Noise Control Device (Aqua Silencer),International Journal of Modern Trends in Engineering and Research, Vol: 2 Issue: 1. ISSN: 2349-9745 [5] Rohit R. Thakare and Ajit J. Khushwah. (2015) Design and Fabrication of Aqua Silencer for Automobiles, International Journal of Mechanical and Production Engineering Research and Development, Vol. 5, Issue 6, ISSN: 2249-6890. Available Online at : www.ijrier.com Page 77