The purpose of this project was to optimise a diesel engine converted to operate on natural gas, to suit the requirements for: low emissions, a high efficiency and sufficient power delivery within the constraints of cogeneration (combined heat and power) systems. Cogeneration Installations seek to improve the efficiency of power generation by utilising waste heat from the prime mover, as well as the production of electricity. Many small scale systems are based on open chamber gas engines, and, to reduce the payback time for the installation, the overall engine efficiency is of prime importance. Stationary engines can be subject to strict standards for emissions, the greatest challenge being presented by the control of NO emissions. The main difficulty is that the highest efficiency operating point of a spark ignition engine is also the point of maximum NO emissions. The extent of this problem was analysed by conducting tests across the entire operating map of the baseline engine at the required speed of 1500 rpm. The solution, in the form of a new high compression ratio combustion system was based on the following: An extensive literature review, the previous Brunel experience with gas engines, an evaluation of the baseline combustion and emissions performance, and the predictions of the Integrated Spark Ignition engine Simulation (ISIS) thermodynamic model. Tests were conducted on the new Fast Bum High Compression Ratio combustion system at compression ratios of 15:1 and 13:1, which demonstrated an extended lean burn capability such that an operating point was identified, that satisfied the conflicting requirements of: low emissions (less than 1g NOx/kWh or 360mg/m3), and a high brake efficiency (above 30%), as well as particular cogeneration criteria. The bmep was mostly above 6 bar. After further tuning and calibration with experimental data, the ISIS model was used to predict the engine power output, efficiency and emissions (NOx and CO) for the compression ratio of 15:1, across the entire operating map for both naturally aspirated and turbocharged configurations. The naturally aspirated results showed good agreement with the results of the experimental 15:1 FBHCR combustion system. The turbocharged engine was simulated with a bmep of 10 bar. The results identified much larger operating areas and all emissions limits were met above a brake efficiency of 36%. The conclusions are, that an open chamber fast bum high compression ratio combustion system can achieve very low emissions, particularly of NOx, and a high efficiency by having the capability of operating with lean enough mixtures. Further improvement in the efficiency is likely if other engine parameters (such as the valve timing) were to be optimised for 1500 rpm. The results from the turbocharged simulation show that turbocharging, whilst restoring the output can also achieve low emissions, and a higher efficiency than a naturally aspirated engine.

Thesis (M.Ing. (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2008.

Selecting a suitable power source, during the design process, for a stand-alone soya business unit is challenging and complex. Especially with the aim of optimizing electrical and thermal energy, as well as minimizing the life cycle cost. During the design and development of a soya business unit it was realized that a design tool is needed to assist with the decision making process when selecting a power source. Waste heat can be recovered from either or both the exhaust gas and cooling system of the power source and can be utilized in the soya process. Research of available literature revealed no design tool to assist with the decision making process of the stand-alone business unit and consequently lead to this study. This dissertation presents different possible power sources that could be utilized in supplying energy to the business unit, as well as design tools available. Advantages and disadvantages of the different power sources are discussed. The shortfalls of a number of the available design tools are also discussed. A diesel generator set was selected as the preferred power source for the business unit. Criteria for this selection included the price per kWhe generated, the ease of maintenance, the availability of the diesel generators in rural areas and the availability of diesel as a fuel. The diesel engine was characterized through experimental work for a more in depth understanding of the energy profile of the engine at part load conditions. These results were used as guidelines in the development of the design tool. The design tool was developed with the aim of being user friendly and versatile. The time intervals of the required load of the business unit are flexible. Different types of power sources and fuels can be used within the design tool. User defined heat exchangers are utilized to calculate the possible heat recovery from the power source. The design tool matches the available energy of different power sources at part load conditions with the required load profile of the soya business unit. It then eliminates power sources that would not be able to deliver the minimum required energy. The running cost is calculated for each of the remaining power sources and the power source with the minimum annualized cost, which includes capital cost, maintenance cost and fuel cost, is suggested. The design tool was verified against a base load condition of the soya business unit and the suggested power source showed a saving of 31,4% in electrical energy, an increased overall efficiency of 24,9% and a saving in annualized cost of 27,3%. The design tool can be used to optimize specific components and design options within a combined heat and power system. Sensitivity analysis can be performed with the design tool to determine various influences on the designed system. / Thesis (M.Ing. (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2008.

Selecting a suitable power source, during the design process, for a stand-alone soya business unit is challenging and complex. Especially with the aim of optimizing electrical and thermal energy, as well as minimizing the life cycle cost. During the design and development of a soya business unit it was realized that a design tool is needed to assist with the decision making process when selecting a power source. Waste heat can be recovered from either or both the exhaust gas and cooling system of the power source and can be utilized in the soya process. Research of available literature revealed no design tool to assist with the decision making process of the stand-alone business unit and consequently lead to this study. This dissertation presents different possible power sources that could be utilized in supplying energy to the business unit, as well as design tools available. Advantages and disadvantages of the different power sources are discussed. The shortfalls of a number of the available design tools are also discussed. A diesel generator set was selected as the preferred power source for the business unit. Criteria for this selection included the price per kWhe generated, the ease of maintenance, the availability of the diesel generators in rural areas and the availability of diesel as a fuel. The diesel engine was characterized through experimental work for a more in depth understanding of the energy profile of the engine at part load conditions. These results were used as guidelines in the development of the design tool. The design tool was developed with the aim of being user friendly and versatile. The time intervals of the required load of the business unit are flexible. Different types of power sources and fuels can be used within the design tool. User defined heat exchangers are utilized to calculate the possible heat recovery from the power source. The design tool matches the available energy of different power sources at part load conditions with the required load profile of the soya business unit. It then eliminates power sources that would not be able to deliver the minimum required energy. The running cost is calculated for each of the remaining power sources and the power source with the minimum annualized cost, which includes capital cost, maintenance cost and fuel cost, is suggested. The design tool was verified against a base load condition of the soya business unit and the suggested power source showed a saving of 31,4% in electrical energy, an increased overall efficiency of 24,9% and a saving in annualized cost of 27,3%. The design tool can be used to optimize specific components and design options within a combined heat and power system. Sensitivity analysis can be performed with the design tool to determine various influences on the designed system. / Thesis (M.Ing. (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2008.