Fabrication of Water Fuel Engine With Power Generation
Fabrication of Water Fuel Engine With Power Generation
Fabrication of Water Fuel Engine With Power Generation
POWER GENERATION
Submitted in a partial fulfillment of the requirement to award the
degree of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted by
CH.Sravani 15JR1A0303
A.Prudhvi 15JR1A0309
A.V.Bharath Raj 15JR1A0311
M.Pavan Kalyan 15JR1A0353
i
BONAFIDE CERTIFICATE
This is to certify the work report titled “FABRICATION OF WATER FUEL
EXTERNAL EXAMINER
ii
ACKNOWLEDGEMENT
BY
CH.Sravani 15JR1A0303
A.Prudhvi 15JR1A0309
A.V.Bharath Raj 15JR1A0311
M.Pavan Kalyan 15JR1A0353
iii
DECLARATION
CH.Sravani 15JR1A0303
A.Prudhvi 15JR1A0309
A.V.Bharath Raj 15JR1A0311
M.Pavan Kalyan 15JR1A0353
iv
KKR & KSR INSTITUTE OF TECHNOLOGY &
SCIENCES
Institute Vision: To produce eminent and ethical Engineers and Managers for
society through imparting quality professional education with emphasis on human
values and holistic excellence.
Institute Mission:
Department Vision:
Department Mission:
1. Meeting the needs of students in the area of their interest and to make
them good engineers.
2. Promoting creativity and innovative thinking among students.
3. Inculcating integrity, honesty and ethical values through curricular, cocurricular
and extra-curricular activities
v
Program Educational Objectives (PEO’S):
vi
PO8 : Ethics
PO9 : Individual and Team Work
PO10 : Communication
PO11 : Project Management and Finance0
P012 : Long Life Learning
Title of the PO PO PO PO PO PO PO PO PO P0 PO PO
project 1 2 3 4 5 6 7 8 9 10 11 12
WATER
FUEL
WITH 2 2 3 -- 2 2 2 1 3 3 1 1
POWER
GENERATI
ON.
vii
CONTENTS PAGE NO
ABSTRACT
LIST OF FIGURES
LIST OF TABLES
1. INTRODUCTION 1
2. LITERATURE SURVEY 2
3. I.C ENGINE 5
3.2 WORKING 5
4.1 INTRODUCTION 14
6. HYDROGEN PRODUCTION 29
viii
7. BATTERY 34
7.1 INTRODUCTION 34
8. MANUFACTURING PROCESS 37
8.3 WELDING 39
8.4 DRILLING 41
9. WORKING PRINCIPLE 42
12.1 ADVANTAGES 65
12.2 DISADVANTAGES 65
12.3 APPLICATIONS 65
13. CONCLUSION 68
ix
ABSTRACT
injection, is spraying water into the cylinder or incoming fuel-air mixture to cool the
combustion chambers of the engine, allowing for greater compression ratios and
reduces the air intake temperature in the combustion chamber, meaning that
the air intake temperature allows for a more aggressive ignition timing to be
employed, which increases the power output of the engine. Depending on the engine,
improvements in power and fuel efficiency can also be obtained solely by injecting
water. Water injection may also be used to reduce NOx or carbon monoxide
emissions. Finally the load test is carried out in order to find the efficiency of the
engine and they are compared with that of the conventional engines.
x
LIST OF FIGURES
x
LIST OF TABLES
Table 10.1 55
Table 11.1 64
x
CHAPTER 1
INTRODUCTION
Many companies are working to develop technologies that might efficiently exploit
the potential of hydrogen energy for mobile uses. The attraction of using hydrogen as
an energy currency is that, if hydrogen is prepared without using fossil fuel inputs,
vehicle propulsion would not contribute to carbon dioxide emissions.
The drawbacks of hydrogen use are low energy content per unit volume, high
tank age weights, the storage, transportation and filling of gaseous or liquid hydrogen
in vehicles, the large investment in infrastructure that would be required to fuel
vehicles, and the inefficiency of production processes.
Buses, trains, PHB bicycles, canal boats, cargo bikes, golfcarts, motorcycles,
wheelchairs,ships,airplanes,submarines, and rockets can already run on hydrogen, in
various forms. NASA uses hydrogen to launch Space Shuttles into space. There is
even a working toy model car that runs on solar power, using a regenerative fuel cell
to store energy in the form of hydrogen and oxygen gas. It can then convert the fuel
back into water to release the solar energy.
The current land speed record for a hydrogen-powered vehicle is 286.476 mph
(461.038 km/h) set by Ohio State University's Buckeye Bullet 2, which achieved a
"flying-mile" speed of 280.007 mph (450.628 km/h) at the Bonneville Salt Flats in
August 2008. For production-style vehicles, the current record for a hydrogen-
powered vehicle is 333.38 km/h (207.2 mph) set by aprototype Ford Fusion Hydrogen
999 Fuel Cell Race Car at Bonneville Salt Flats in Wend over, Utah in August 2007.
It was accompanied by a large compressed oxygen tank to increase power. Honda has
also created a concept called the FC Sport, which may be able to beat that record if
put into production.
1
CHAPTER-2
LITERATURE SURVEY
2
Choongsik Bae and Jaeheun Kim in the journal Alternative fuels for internal
combustion engines in the year 2017 wrote that the representative alternative
fuels for SI engines include compressed natural gas (CNG), hydrogen
(H2) liquefied petroleum gas (LPG), and alcohol fuels (methanol and ethanol);
while for CI engines, they include biodiesel, di-methyl ether (DME), and jet
propellent-8 (JP-8). Naphtha is introduced as an alternative fuel for advanced
combustion in premixed charge compression ignition. The contents of engine
combustion basically consist of the combustion process from spray
development, air–fuel mixing characteristics, to the final combustion
product formation process, which is analyzed for each alternative fuel.
P.Balashanmugam and G.Balasubramanian in the journal Global journal of
advanced research in the year 2015 ha explained that hydrogen vehicle is an
alternative fuel vehicle that uses hydrogen as its onboard fuel for motive
power. The term may refer to a personal transportation vehicle, such as an
automobile, or any other vehicle that uses hydrogen in a similar fashion, such
as an aircraft. The power plants of such vehicles convert the chemical energy
of hydrogen to mechanical energy either by burning hydrogen in an internal
combustion engine, or by reacting hydrogen with oxygen in a fuel cell to run
electric motors. The widespread use of hydrogen for fueling transportation is a
key element of a proposed economy. Hydrogen fuel does not occur naturally
on Earth, and thus is not an energy source, but is an energy carrier. Currently it
is most frequently made from methane or other fossil fuels. However, it can be
produced from a wide range of sources (such as wind, solar, or nuclear) that
are intermittent, too diffuse or too cumbersome to directly propel vehicles.
Integrated wind-to-hydrogen plants, using electrolysis of water, are exploring
technologies to deliver cost low enough, and quantities great enough, to
compete with traditional energy sources.
3
Akhileshpati tiwari, Manoj kumar yadav, Surender kumar ,Ramnaresh yadav
in the journal International Journal of Engineering Trends and Technology
(IJETT) in the year 2017 has explained that Hydrogen is an environmentally
friendly alternative to fossil fuels, and they can be used to power just about
any machine needing energy. The fuel cell, which is the energy conversion
device that can capture and use the power of hydrogen effectively, is the key
to making this happen. Compared to diesel or gas, hydrogen is much more fuel
efficient as it can produce more energy per pound of fuel. This means that if a
car is fueled by hydrogen, it can go farther than a vehicle loaded with the same
amount of fuel but using a more traditional source of energy. Hydrogen-
powered fuel cells have two or three times the efficiency of traditional
combustion technologies.
4
CHAPTER-3
I.C ENGINE
Internal combustion engines are those heat engines that burn their fuel inside
the engine cylinder. In internal combustion engine the chemical energy stored in
expansion of gases against the piston attached to the crankshaft that can rotate.
The engine which gives power to propel the automobile vehicle is a petrol
burning internal combustion engine. Petrol is a liquid fuel and is called by the name
gasoline in America. The ability of petrol to furnish power rests on the two basic
principles;
When a gas is heated, it expands. If the volume remains constant, the pressure
3.2 WORKING
There are only two strokes involved namely the compression stroke and the
power stroke; they are usually called as upward stroke and downward stroke
respectively.
5
UPWARD STROKE
During this stroke, the piston moves from bottom dead center to top
dead center, compressing the charge-air petrol mixture in combustion chamber of the
cylinder, at the time the inlet port is uncovered and the exhaust, transfer ports are
DOWNWARD STROKE
The charge is ignited the hot gases compress the piston moves
downwards, during this stroke the inlet port is covered by the piston and the new
uncovers first exhaust port and then transfer port and hence the exhaust starts through
the exhaust port. As soon as the transfer port open the charge through it is forced in to
1.CYLINDER
reciprocating motion.
6
2.PISTON
3.COMBUSTION CHAMBER
It is the space exposed in the upper part of the cylinder where the
4. CONNECTING ROD
It inter connects the piston and the crankshaft and transmits the
5. CRACKSHAFT
6. CAM SHAFT
7
7. CAM
These are made as internal part of the camshaft and are designed in such a way to
8. PISTON RINGS
It provides a tight seal between the piston and cylinder wall and preventing
9. GUDGEON PIN
It forms a link between the small end of the connecting rod and the piston
10. INLET
The pipe which connects the intake system to the inlet valve of the engine end
The pipe which connects the exhaust system to the exhaust valve of the
They are provided on either on the cylinder head or on the side of the cylinder
and regulating the charge coming in to the cylinder and for discharging the product of
8
13. FLYWHEEL
It is a heavy steel wheel attached to the rear end of the crank shaft. It absorbs
energy when the engine speed is high and gives back when the engine speed is low.
14. NOMENCLATURE
This refers to the position of the crank shaft when the piston is in it
slowest position.
BORE(d)
STROKE(s)
The volume of cylinder above the piston when it is in the TDC position.
Vd = V s N
Where,
9
Vs ------- Swept Volume
It is the ratio of the total cylinder volume when the piston is at BDC to
ENGINE SPECIFICATION
Arrangement : Vertical
10
3.4 Spark Ignition Engine
A spark ignition (SI) engine runs on an Otto cycle—most gasoline engines run on a
modified Otto cycle. This cycle uses a homogeneous air-fuel mixture which is
chamber, the mixture is compressed, and then ignited using a spark plug (spark
ignition). The SI engine is controlled by limiting the amount of air allowed into the
engine. This is accomplished through the use of a throttling valve placed on the air
Advantages
A century of development and refinement - For the last century the SI engine
has been developed and used widely in automobiles. Continual development of this
technology has produced an engine that easily meets emissions and fuel economy
standards. With current computer controls and reformulated gasoline, today's engines
are much more efficient and less polluting than those built 20 years ago.
11
Disadvantages
The SI engine has a few weaknesses that have not been significant problems in
reasonable cost - Technology has progressed and will enable the SI engine to meet
current standards, but as requirements become tougher to meet, the associated engine
Throttling loss lowers the efficiency - To control an SI engine, the air allowed
into the engine is restricted using a throttling plate. The engine is constantly fighting
mixed with the air during compression, it will auto-ignite (undesirable in a gasoline
engine) if the compression ratio is too high. The compression ratio of the engine is
HEVs can reduce this contribution significantly through increased fuel economy, use
of alternative fuels, and improved power unit and after treatment technology. A well-
tuned spark ignition engine produces relatively low emissions. Significant emissions
occur when the vehicle is started and warming up. During this time the engine must
be choked to run properly. This creates excess unburned fuel in the exhaust, which
12
emissions are relatively low because the air-to-fuel mixture is precisely controlled,
The diesel engine emissions are primarily nitrogen oxides (NOx) and particulate
matter (PM). NOx is produced because the engine is operated with a lean air-to-fuel
combustion cylinder. This lean mixture and high temperature cause the higher level of
NOx production. At high engine loads, where more fuel is injected, some of the fuel
burns incompletely leading to the black smoke (PM) characteristic of a diesel engine.
Other types of fuel cells have reformers that convert methane to hydrogen, then use
the hydrogen.
13
CHAPTER-4
The bearings are pressed smoothly to fit into the shafts because if hammered
the bearing may develop cracks. Bearing is made upon steel material and bearing cap
is mild steel.
4.1 INTRODUCTION
Ball and roller bearings are used widely in instruments and machines in order
to minimize friction and power loss. While the concept of the ball bearing dates back
at least to Leonardo daVinci, their design and manufacture has become remarkably
only after a long period of research and development. The benefits of such
of the proper size and type. However, such bearings cannot be used indiscriminately
without a careful study of the loads and operating conditions. In addition, the bearing
must be provided with adequate mounting, lubrication and sealing. Design engineers
have usually two possible sources for obtaining information which they can use to
14
4.2 Construction and Types of Ball Bearings
A ball bearing usually consists of four parts: an inner ring, an outer ring, the
To increase the contact area and permit larger loads to be carried, the balls run
in curvilinear grooves in the rings. The radius of the groove is slightly larger than the
radius of the ball, and a very slight amount of radial play must be provided. The
between the assembled shaft and mounting. The separator keeps the balls evenly
spaced and prevents them from touching each other on the sides where their relative
velocities are the greatest. Ball bearings are made in a wide variety of types and sizes.
Single-row radial bearings are made in four series, extra light, light, medium, and
heavy, for each bore, as illustrated in Fig. 1-3(a), (b), and (c).
100 Series 200 Series 300 Series Axial Thrust Angular Contact
The heavy series of bearings is designated by 400. Most, but not all,
manufacturers use a numbering system so devised that if the last two digits are
15
The digit in the third place from the right indicates the series number. Thus,
bearing 307 signifies a medium-series bearing of 35-mm bore. For additional digits,
details.
Some makers list deep groove bearings and bearings with two rows of balls.
For bearing designations of Quality Bearings & Components (QBC), see special
pages devoted to this purpose. The radial bearing is able to carry a considerable
amount of axial thrust. However, when the load is directed entirely along the axis, the
thrust type of bearing should be used. The angular contact bearing will take care of
both radial and axial loads. The self-aligning ball bearing will take care of large
Radial bearings are divided into two general classes, depending on the method of
assembly. These are the Conrad, or non filling-notch type, and the maximum or
filling-notch type. In the Conrad bearing, the balls are placed between the rings as
shown in Fig. 1-4(a). Then they are evenly spaced and the separator is riveted in
place. In the maximum-type bearing, the balls are a (a) (b) (c) (d) (e) (f) 100
Series Extra Light 200 Series Light 300 Series Medium Axial Thrust Bearing Angular
16
CHAPTER-5
This is a cycle chain sprocket. The chain sprocket is coupled with another
generator shaft. The chain converts rotational power to pulling power, or pulling
The sprocket looks like a gear but differs in three important ways:
1. Sprockets have many engaging teeth; gears usually have only one or two.
2. The teeth of a gear touch and slip against each other; there is basically no slippage
in a sprocket.
17
5.1 Engagement with Sprockets:
Although chains are sometimes pushed and pulled at either end by cylinders,
chains are usually driven by wrapping them on sprockets. In the following section, we
explain the relation between sprockets and chains when power is transmitted by
sprockets.
1. Back tension
First, let us explain the relationship between flat belts and pulleys. Figure 2.5
shows a rendition of a flat belt drive. The circle at the top is a pulley, and the belt
hangs down from each side. When the pulley is fixed and the left side of the belt is
loaded with tension (T0), the force needed to pull the belt down to the right side will
be:
T1 = T0 3 eµu
For example, T0 = 100 N: the coefficient of friction between the belt and
T1 = T0 3 2.566 = 256.6 N
In brief, when you use a flat belt in this situation, you can get 256.6 N of drive
For elements without teeth such as flat belts or ropes, the way to get more drive power
or oil, which decreases the coefficient of friction, gets onto the contact surface, the
configuration is square, as in Figure 2.6, the direction of the tooth's reactive force is
opposite the chain's tension, and only one tooth will receive all the chain's tension.
19
Fig 5.4 The Balance of Forces Around the Roller
But actually, sprocket teeth need some inclination so that the teeth can engage
and slip off of the roller. The balances of forces that exist around the roller are shown
For example, assume a coefficient of friction µ = 0, and you can calculate the
back tension (Tk) that is needed at sprocket tooth number k with this formula:
T0 = chain tension
N= number of teeth
k= the number of engaged teeth (angle of wrap 3 N/360); round down to the
20
By this formula, if the chain is wrapped halfway around the sprocket, the back
tension at sprocket tooth number six is only 0.96 N. This is 1 percent of the amount of
a flat belt. Using chains and sprockets, the required back tension is much lower than a
flat belt. Now let's compare chains and sprockets with a toothed-belt back tension.
Although in toothed belts the allowable tension can differ with the number of pulley
teeth and the revolutions per minute (rpm), the general recommendation is to use
1/3.5 of the allowable tension as the back tension (F). This is shown in below
Figure 2.8. Therefore, our 257 N force will require 257/3.5 = 73 N of back
tension.
Both toothed belts and chains engage by means of teeth, but chain's back
The key factor causing chain to jump sprocket teeth is chain wear elongation (see
Basics Section 2.2.4). Because of wear elongation, the chain creeps up on the sprocket
teeth until it starts jumping sprocket teeth and can no longer engage with the sprocket.
21
Figure 2.9 shows sprocket tooth shape and positions of engagement. Figure
In Figure 2.9 there are three sections on the sprocket tooth face:
b: Working curve, where the roller and the sprocket are working together;
c: Where the tooth can guide the roller but can't transmit tension. If the roller, which
should transmit tension, only engages with C, it causes jumped sprocket teeth.
The chain's wear elongation limit varies according to the number of sprocket
teeth and their shape, as shown in Figure 2.11. Upon calculation, we see that
sprockets with large numbers of teeth are very limited in stretch percentage. Smaller
sprockets are limited by other harmful effects, such as high vibration and decreasing
strength; therefore, in the case of less than 60 teeth, the stretch limit ratio is limited to
22
Fig 5.7 The Engagement Between a Sprocket and
an Elongated Chain
than transmission chains, the stretch ratio is limited to 2 percent. Large pitch conveyor
chains use a straight line in place of curve B in the sprocket tooth face.
23
A chain is a reliable machine component, which transmits power by means of
tensile forces, and is used primarily for power transmission and conveyance systems.
The function and uses of chain are similar to a belt. There are many kinds of chain. It
construction.
Forged chain.
Steel chain.
Plastic chain.
Demand for the first three chain types is now decreasing; they are only used in
some special situations. For example, cast iron chain is part of water-treatment
In this book, we are going to focus on the latter two: "steel chain," especially
the type called "roller chain," which makes up the largest share of chains being
produced, and "plastic chain." For the most part, we will refer to "roller chain" simply
as "chain."
NOTE: Roller chain is a chain that has an inner plate, outer plate, pin, bushing, and
roller.
In the following section of this book, we will sort chains according to their
24
1. Power transmission chain.
4. Top chain.
The first one is used for power transmission; the other five are used for
conveyance. In the Applications section of this book, we will describe the uses and
transmission chain, small pitch chain, and large pitch conveyor chain. Because there
are special features in the composition of precision conveyor chain, top chain, and
free flow chain, checks the appropriate pages in the Applications section about these
features.
25
5.3 Basic Structure of Power Transmission Chain
Connecting Link
This is the ordinary type of connecting link. The pin and link plate are slip fit
in the connecting link for ease of assembly. This type of connecting link is 20 percent
lower in fatigue strength than the chain itself. There are also some special connecting
links which have the same strength as the chain itself. (See Figure 1.2)
In this link, the pin and the tap fit connecting link plate are press fit. It has
fatigue strength almost equal to that of the chain itself. (See Figure 1.2)
26
Fig 5.10 Standard Connecting Link (top)
27
Offset Link
percent lower in fatigue strength than the chain itself. The pin and two plates are slip
fit. There is also a two-pitch offset link available that has fatigue strength as great as
28
CHAPTER-6
HYDROGEN PRODUCTION
chilled to -253C and compressed, it makes the perfect fuel. Hydrogen’s greatest
oxygen. The resulting chemical reaction generates electric power, and the only by-
product it produces is clean water. At a time when there is real concern about global
warming due to carbon emissions, this makes hydrogen fuel a desirable technology
Many scientists and researches are working towards a vision of the hydrogen
economy. Hydrogen based fuel could potentially be used to run our cars or even drive
larger scale power plants, generating the electricity we need to light our buildings, run
our kettles and fridges, and power our computers. But hydrogen does not occur
naturally and it has to be processed. The big challenge is the large scale production
required to generate the hydrogen fuel. Electrolysis uses electricity to break water into
hydrogen and oxygen, with the two gases forming at opposite electrodes. Electricity is
also required to power the compression of the hydrogen and the refrigeration to chill it
through
Wind power, biomass, tidal, hydro power or nuclear. Hydrogen can also be
generated by extracting it from natural gas, but this process generates carbon dioxide
and negates the main motivation for moving to hydrogen fuel-cell vehicles: ending
panels.
30
6.2 HYDROGEN GAS FROM WATER MIXED WITH KOH:-
hydrogen gas. The beauty of this system, is that it uses a common inexpensive
chemical which is not consumed in the reaction, so it can be used again and again
chemical formula is KOH, and its used to manufacture soaps, dyes, alkaline batteries,
adhesives, fertilizers, drain pipe cleaners, asphalt emulsions, and purifying industrial
gases.
The chemical reaction we are interested in occurs with water in the following
equation.
Notice the free Hydrogen gas 2H2 which is stripped from the water added to
the KOH. Making this reaction more than a one-time event is the key to cheap
hydrogen production, which means controlling the reverse reaction to recover the
KOH without giving back the hydrogen. There is an easy way to do this however.
Stripping the Hydrogen from the water removed stored energy from the first
reaction, and it must be replaced to drive the reaction in the opposite direction,
31
butinstead of giving back the hydrogen gas we can give back the energy in another
32
Thus, heating the KOOH in a solar cooker will produce the following reaction:
KOOH + HEAT --> KOH + O. The balanced reaction is 2KOOH + HEAT --> 2KOH
The combined result of our double reaction cycle is the splitting of H20 into 2
free gases, and our initial Potassium Hydroxide is ready to be used again.
Furthermore, not only have we created a fuel supply, but also an oxygen
supply. Designing a continuous fuel supply system from this reaction cycle would
require 2 potassium hydroxide tanks. One for each reaction They would have to be
Hydrogen production can be regulated with a flow control value from the H2O
storage tank. O2 production is regulated by heat input. Matching gas production with
consumption would reduce the size of tanks needed for surplus gas storage. I haven’t
done the exact calculations on how much potassium hydroxide is needed to supply the
average gas requirements per capita consumed in the US, but I am guessing that it
wouldn’t require very many pounds of KOH, so the system size could be pretty small.
The solar collector for the oxygen reaction would probably be the biggest component,
and I suggest a focusing solar collector be used for higher heat input.
There you have it, a non-polluting source of free hydrogen and oxygen from
33
CHAPTER-7
BATTERY
7.1 INTRODUCTION:
In isolated systems away from the grid, batteries are used for storage of excess solar
energy converted into electrical energy. The only exceptions are isolated sunshine
load such as irrigation pumps or drinking water supplies for storage. In fact for small
Batteries seem to be the only technically and economically available storage means.
Since both the photo-voltaic system and batteries are high in capital costs. It is
necessary that the overall system be optimized with respect to available energy and
We use lead acid battery for storing the electrical energy from the solar panel
34
CURRENT RATINGS:
currents they can supply for a specified period of time; the output voltage must be
maintained above a minimum level, which is 1.5 to 1.8V per cell. A common rating
is ampere-hours (A.h.) based on a specific discharge time, which is often 8h. Typical
As an example, a 200 A.h battery can supply a load current of 200/8 or 25A,
used on 8h discharge. The battery can supply less current for a longer time or more
current for a shorter time. Automobile batteries may be rated for “cold cranking
power”, which is related to the job of starting the engine. A typical rating is 450A for
Note that the ampere-hour unit specifies coulombs of charge. For instance,
coulombs. One ampere-second is equal to one coulomb. Then the charge equals
720,000 or 7.2*10^5ºC. To put this much charge back into the battery would require
The ratings for lead-acid batteries are given for a temperature range of 77 to
80ºF. Higher temperature increase the chemical reaction, but operation above 110ºF
Low temperatures reduce the current capacity and voltage output. The
below normal temperature rating. At 0ºF the available output is only 60 % of the
35
automobile battery unto full charge. In addition, the electrolyte freezes more easily
necessary to produce current in one direction. Also, the charging voltage must be
driver by a belt from the engine. When you start the car, the battery supplies the
cranking power. Once the engine is running, the alternator charges the battery.
36
CHAPTER-8
MANUFACTURING PROCESS
These are secondary manufacturing processes where the starting raw materials
are produced by any one of the previous manufacturing processes desired. Its
assembly involve joining pieces either temporary or permanent. So that they would be
perform the necessary function. The joining can be achieved by either or both of heat
and pressure joining materials. Many of the steel structure construction, we see are
· Gas welding
· Thermo welding
· Brazing welding
· Soldering welding
· Cold welding
37
8.2 Material removal processes:
additional unwanted material is removed in the form of chips from the blank material
Because more energy is consumed and also a lot of waste material is generated in this
process. Still this process is widely used because it deliver very good dimensional
accuracy and good surface finished. Material removal process are also called
Turning
Drilling
Milling
Grinding
Broaching
Sawing
Trimming
38
8.3 WELDING:
Welding is the least expensive process and widely used now a days in fabrication.
Welding joints different metals with the help of a number of processes in which heat
are used in the manufacturing of Auto mobiles bodies, structural work, tanks, and
general machine repair work. In the industries, welding is used in refineries and pipe
There are about 35 different welding and brazing process and several
soldering methods, in use by the industry today. There are various ways of classifying
the welding for example, they may be classified on the basis of source of heat (flames,
arc etc.)
1: Gas Welding
2: Arc Welding
3: Resistance Welding:
39
(a): Spot welding
Welding Joints:
40
Fig 8.2 welding positions
8.4 DRILLING:
Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-
section in solid materials. The drill bit is usually a rotary cutting tool, often
multipoint. The bit is pressed against the workpiece and rotated at rates from
hundreds to thousands of revolutions per minute. This forces the cutting edge
against the workpiece, cutting off chips (swarf) from the hole as it is drilled.
In rock drilling, the hole is usually not made through a circular cutting motion,
though the bit is usually rotated. Instead, the hole is usually made by hammering a
drill bit into the hole with quickly repeated short movements. The hammering
action can be performed from outside of the hole (top-hammer drill) or within the
hole (down-the-hole drill, DTH). Drills used for horizontal drilling are called
drifter drills.
41
CHAPTER-9
WORKING PRINCIPLE
The hydrogen gas is produced by mixing the KOH and water with the
help of cathode and anode terminals. The 12 volt battery supply is given to these
electrodes, so that the hydrogen is comes out from the negative terminal tank. This
output gas is dipped to the water tank so that hydrogen is produced. This will
hydrogen gas. The beauty of this system is that it uses a common inexpensive
chemical which is not consumed in the reaction, so it can be used again and again
chemical formula is KOH, and its used to manufacture soaps, dyes, alkaline batteries,
adhesives, fertilizers, drain pipe cleaners, asphalt emulsions, and purifying industrial
gases.
The chemical reaction we are interested in occurs with water in the following
equation.
42
Notice the free Hydrogen gas 2H2 which is stripped from the water added to
the KOH. Making this reaction more than a one-time event is the key to cheap
hydrogen production, which means controlling the reverse reaction to recover the
KOH without giving back the hydrogen. There is an easy way to do this however.
43
CHAPTER-10
housing
= (35 + 15) / 2
dm = 25 mm
44
fig 10.1 bearing
45
10.2ENGINE DESIGN CALCULATIONS:-
ELEMENT METHOD:
Bore/Stroke : 50 x 50 mm
CALCULATION:
Volume
Here,
46
Vc = 19.64
Assumption:
1. The component gases and the mixture behave like ideal gases.
P₁ = (M₁RT)/V
Here,
Weight)
K.
T₁ = 303 ºK
V₁ = V = 253.28 x 10¯⁶ m³
Here,
47
∴P₁ = {[(m₁/(1.165 x 22.4)] x 8.314 x 303}/253.28 x 10¯⁶
P₁ = 381134.1 m₁
P₂ = (N₂ R T)/V
10¯⁶
P₂ = 555.02 m₂
PT = P₁ + P₂
48
Calculation of air fuel ratio:
Carbon = 86%
Hydrogen = 14%
We know that,
Therefore,
= [ (8/3c) + (3H₂) + S] Kg
Little of oxygen may already present in the fuel, then the total oxygen required
As air contains 23% by weight of Oxygen for obtain of oxygen amount of air
required = 100/23 Kg
0.14) ] }
49
= 14.84 Kg of air
= 14.84
Therefore,
By Delong’s formula,
50
Lower Calorific Value = HCV – (9H₂ x 2442)
= 46151.08 KJ/Kg
We know that,
= 2.8291 x 10¯⁴ Kg
= 2.0405 x 10¯⁴ Kg
= 72.125 %
51
(1) Percentage of oxygen present in 1 Kg of air is 23%
= 21.54 %
= 5.444%
= 0.886 %
Cp = 1.1138 KJ/Kg.K
Cv = ∑msi Cvi
= 0.8 KJ/Kg.K
52
(All Cvi, Cpi values of corresponding components are taken from clerks table)
= 1.11/0.8
n = 1.38
= 1.01325 bar
T₁ = 30ºC = 303 K
P₂/P₁ = (r)ⁿ¯¹
Where,
P₁ = 1.01325 bar
r = 6.6
n = 1.38
T₂ = (r)ⁿ¯¹ x T₁
Where,
T₁ = 303 K
∴T₂ = 620.68 K
53
Where,
T₁ = 303 K
∴T₂ = 620.68 K
P 4
Q = MCv
Q = 0.8265 KJ/Cycle
T₃ = 4272.45 K
Where,
54
V₂ = V₃
Where,
P₃ = 94.27 bar
P₄ = P₃ / (r)ⁿ
T₄ = T₃ / (r)ⁿ¯¹
= 2086.15 K
POSITION
Table 10.1
55
10.4 DESIGN OF ENGINE PISTON:
Thickness of piston:
Where,
t = D (3/16 x P/f)½
Here,
100 bar
N/mm²
= 12 mm
Here,
56
We adopt 3 compression rings and 1 oil rings
= 50/32
= 1.5625 mm
= 2.5 mm
The distance of the first ring from top of the piston equals
= 0.1 x D
= 5 mm
Length of the piston skirt =Total length – Distance of first ring from top of
57
Width of ring)
= 65 mm
Other parameter:
= 65 mm
= 33.5 mm
= 6 mm
= 3250 mm²
58
Figure 10.3 engine spraket
59
fig 10.5 frame
60
fig 10.6 block diagram
61
2D DRAWING
Fig10.7 2d modelling
62
fig10.8 2d drawing of model
63
CHAPTER-11
LIST OF MATERIALS
v. Engine 1 75 Cc
x Wheel Arrangement 1 -
Xi Electrode 2 Steel
Xii KOH - -
Table 11.1
64
CHAPTER-12
12.1 ADVANTAGES
Checking and cleaning are easy, because of the main parts are screwed.
Repairing is easy.
12.2 DISADVANTAGES
12.3 APPLICATIONS
Hydrogen cars are beneficial for the environment in a number of ways. For
example, they do not emit greenhouse gases that are harmful for the welfare of
the ecosystem. These cars are much more fuel efficient than gasoline vehicles,
and let out less pollution overall. However, there are many drawbacks to using
65
hydrogen-powered vehicles, though scientists are working to eliminate these
downsides.
GOING GREEN
The main objective of using hydrogen cars is to save the environment from the
hydrogen fuel is better because it does not release carbon dioxide into the air.
vehicles; for example, a car using hydrogen fuel can go up to twice the
ENGINE DURABILITY
Many other types of engines cannot work properly in high temperatures, and
counterparts.
COST
would cost billions of dollars to replace all of the current gas stations with
66
HYDROGEN AVAILABILITY
hydrogen to use as a fuel. Hydrogen is not readily gotten from air, so it must
be obtained from water molecules. There are several ways for hydrogen to be
extracted from water, but none are efficient and all are very expensive.
HYDROGEN STORAGE
development of efficient hydrogen fuel cells which will carry more hydrogen
fuel in a vehicle.
67
CHAPTER-13
CONCLUSION
The project adventured by us is the one that can be used for both Petrol and
water , we have entered to this project. We have done the project to simple in
This is one of the advantageous project conserving the cost and low fuel cost.
This project work has provided us an excellent opportunity and experience, to use our
purchasing, assembling and machining while doing this project work. We feel that
the project work is a good solution to bridge the gates between institution and
industries.
We are proud that we are able to increase efficiency and complete the work
maintaining the tolerances and also quality. We have done to our ability and skill
work, let us add a few more lines about our impression project work. Thus we have
helps to know how to achieve low fuel cost to run the vehicle.
68
PHOTOGRAPHY OF THE MODEL
69
REFERENCES
Dempsey, J. "Module 9: Acts, Codes, Regulations and Guidelines." Energy
Technology Training Center College of the Desert, 2001.
Greenhalgh, D.A.; Haq, M.Z.; Lockett, R.D.; Sheppard, C.G.W.; Wooley, R.
"Wrinkling and Curvature of Laminar and Turbulent Premixed Flames." Combustion
and Flame. 2002, pp. 131, 1-15.
Heywood, John B. Internal Combustion Engine Fundamentals. McGraw Hill,1988.
[4]. Eickhoff, H. "Analysis of Turbulent Burning Velocity." Combustion and Flame,
2002, pp. 128, 347-350. [5].
Keller, J.; Lutz, A. Hydrogen Fueled Engines in Hybrid Vehicles. SAE,2001
[6]. Buchner, H.; Kulsheimer, J. "Combustion Dynamics of Turbulent Swirling
Flames." Combustion and Flame. 2002, pp. 131, 70-84.
[7]. Heffel, J.; Kabat, D.; Natkin, R.; Stockhausen, W.; Tang, X. Ford P2000
Hydrogen Engine Dynamometer Development. SAE, 2002.
[8]. Hiruma, M.; Nakajima, Y.; Shudo, T.; Takagi, Y.; Yamane, K. Research and
Development of a Hydrogen-Fueled Engine for Hybrid Electric Vehicles.SAE, 2001.
[9]. Cheng, R.K.; Shepard, I.G. "The Burning Rate of Premixed Flames in Moderate
and Intense Turbulence." Combustion and Flame, 2001, pp. 127, 2066 - 2075.
[10]. Drake, M.C.; Fansler, T.D.; Roberts, W.L.; Xiong, Y. "Investigation of Pre-
Mixed Flame-Kernel/Vortex Interactions via High-Speed Imaging." Combustion and
Flame, 2001, pp. 126, 1827-1844.
[11]. Armfield, J.S.; Domingo, N.; Green, J.B.; Storey, J.M.E.; Wagner, R.M.
Experimental Evaluation of SI Engine Operation Supplemented by Hydrogen Rich
Gas From a Compact Plasma Boosted Reformer. SAE, 2000.
[12]. Kababt, Daniel M.; Natkin, Robert J.; Stockhausen, William F. Ford P2000
Hydrogen Engine Design and Vehicle Development Program. SAE, 2002.
[13]. Thaller, M.; Council. "Air and Space Propulsion." California Hydrogen
Business Council, 2003, p. 7.
[14]. Woolsey, J. "Hydrogen and National Security." California Hydrogen Business
Council, 2003, p. 8.
[15]. Heffel, J. "Latest Advances in Hydrogen: How Terrorism Has Accelerated Fuel
Cells and Renewable Energy." California Hydrogen Business Council, 2003.
[16]. Gorman, J. "Creating Hydrogen." California Hydrogen Business Council, 2003.
[17]. Failey, P. "Hydrogen Storage." California Hydrogen Business Council, 2003, p.
3.
70
[18]. Shmidt, D. "Hydrogen Vehicles." California Hydrogen Business Council,
2003,p. 4.
[19]. Matheson Gas Products, Pamphlet: How to Use Your Lecture Bottle, 100M7/72
[20]. Matheson Gas Products, Pamphlet: How to Open and Close Cylinders of
Corrosive Gases, 1974
[21]. Matheson Gas Products, Pamphlet: Safe Handling of Compressed Gases in the
Laboratory, 1961
[22]. Compressed Gas Association, Inc., Pamphlet C-6: Standards for Visual
Inspection of Compressed Gas Cylinders, 1984
[23]. Compressed Gas Association, Inc., Pamphlet P-1: Safe Handling of Compressed
Gases, 1991
[24]. Compressed Gas Association, Inc., Pamphlet C-7: Precautionary Labeling and
Marking of Compressed Gas Cylinders, 1992
[25]. Compressed Gas Association, Inc., Pamphlet S-1.1: Pressure Relief Device
Standards Part 1 -Cylinders for Compressed Gases, 1989
[26]. Compressed Gas Association, Inc., Pamphlet V-9: Standard for Compressed
Gas Cylinder Valves, 1991
[27]. Compressed Gas Association, Inc., Pamphlet G-1: Acetylene, 1990
71