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Generators are widely used across the world as portable power units in case of power outages, used for emergency services and are also used in rural areas without access to electricity. The majority of commercially available generators use internal combustion engines designed as automobile engines with little or no optimization for use in generators. With operating conditions vastly different than that of automobile engines, they can be re-designed to operate much more efficiently as generator engines. The development objective here was to design a low cost, 1.6L, lean burn, internal combustion engine which minimizes heat losses, time losses and frictional losses to improve thermal efficiency. Various high swirl, high squish, easily CNC’d combustion chambers were created in the re-design process. A computer model was used to provide insight into the trade-off between time losses and heat losses. A maximum brake thermal efficiency of 37.2% was achieved.

The extraction-condensing cogeneration system is a popular technology for heat and power integration which can be used by petrochemical process. To compare with back pressure system, extraction-condensing system has better flexibility for process control. However, the thermal efficiency of extraction- condensing system could be affected by the amount of effective heat to process. If the effective heat to process and the plant power demand were not well designed, the cogeneration system may violate government regulation of ¡§qualified cogeneration system¡¨ by MOEA, or the system economics can not meet investor¡¦s requirement. From another point of view, if the cogeneration system bias original design operating condition or it has to run under low loading, the energy efficiency will move away from the target. A 94.9 MW extraction-condensing system of a petrochemical plant was selected as an example. For the purpose of data requisition, the author established a model to predict main steam flow, extraction steam flow, and power generation load. Moreover, a set of equations for the calculation of heat rate of turbine plant was developed. Besides, a Microsoft Excel calculation sheet was programmed to compute real time plant thermal efficiency. The actual operation data was compared with computer simulation. Results show (1) To meet the regulation, the process steam shall exceed 100 t/h with rated power generation. (2) For the minimum generator load (about 20 MW), the effective heat to process must exceed 78% in order to ensure a 52% overall thermal efficiency. (3) Low load means low thermal efficiency of this system. Some energy conservation ideas of this cogeneration system were assessed. Four ideas were presented, including (1) Increase boiler feed water temperature during low evaporation load. (2) Recovering of flash steam vented from blow down tank for the heating of boiler combustion air. (3) Control of cooling tower fans speed by using frequency inverter. (4) Utilization of hydraulic coupled forced draft fan. The total benefit of these energy conservation ideas is 2,546.44 kilo-liter fuel oil equivalent.

In most previous studies that have been conducted on converting waste heat energy from exhaust gases into useful energy, the engine waste heat recovery system has been placed along the exhaust flow pipe where the temperature differs from the temperature just behind the exhaust valves. This means that an important fraction of the energy from the exhaust gases is still lost to the environment. The present work investigates the potential thermodynamic analysis of an integrated exhaust waste heat recovery (EWHR) system based on a Rankine cycle on an engine's exhaust manifold. The amount of lost energy contained in the exhaust gases at the exhaust manifold level, at average temperatures of 500 °C and 350 °C (for petrol and diesel), and the thermodynamic composition of these gases were determined. For heat to occur, a temperature difference (between the exhaust gas and the working fluid) at the pinch point of 20°C was considered. A thermodynamic analysis was performed on different configurations of EWHR thermal efficiencies and the selected suitable working fluids. The environmental and economic aspects of the integrated EWHR system just behind the exhaust valves of an internal combustion engine (ICE) were analysed. Among all working fluids that were used when the thermodynamic analysis was performed, water was selected as the best working fluid due to its higher thermal efficiency, availability, low cost and environmentally friendly characteristics. Using the typical engine data, results showed that almost 29.54% of exhaust waste heat can be converted. This results in better engine efficiency and fuel consumption on a global scale by gaining an average of 1 114.98 Mb and 1 126.63 Mb of petrol and diesel respectively from 2020 to 2040. It can combat global warming by recovering 56.78 1 011 MJ and 64.65 1 011 MJ of heat rejected from petrol and diesel engines, respectively. A case study of a Volkswagen Citi Golf 1.3i is considered, as it is a popular vehicle in South Africa. This idea can be applied to new-design hybrid vehicles that can use the waste heat to charge the batteries when the engine operates on fossil fuel. / Dissertation (MSc)--University of Pretoria, 2016. / Mechanical and Aeronautical Engineering / MSc / Unrestricted

In the realm of class 8 trucking, fuel economy and emissions compliance are becoming the driving force for development of new heavy-duty direct injected (HDDI) diesel engine technologies. Current production engines in this class convert around 40% of the fuels energy into usable work while the unused potential transfers to the environment as excess heat energy. Current OEMs are working toward decreasing this heat loss and improve engine efficiency and emissions. Quantifying the energy lost by component and system highlights the areas that demand the most attention. By studying test cell data of heat rejection on a production Cummins ISX engine and using the data to calibrate an engine model for the simulation software GT-Suite, heat rejection values and the components which transfer the energy are exposed. The simulation software provides energy transfer by both system and component type. The results reveal that 10% of engine total heat rejection (THR) is transferred through the cylinder wall to the engine coolant system. When the heat imparted on the cylinder wall is broken up by component, the piston rings contribute nearly as much heat into the liner as the combustion gas.

Submitted by Eunice Novais (enovais@uepg.br) on 2018-05-18T19:33:14Z No. of bitstreams: 2 license_rdf: 811 bytes, checksum: e39d27027a6cc9cb039ad269a5db8e34 (MD5) Bruna Martins Bomfati.pdf: 1871828 bytes, checksum: 025d7196b1adc075dc67eda4558cee36 (MD5) / Made available in DSpace on 2018-05-18T19:33:14Z (GMT). No. of bitstreams: 2 license_rdf: 811 bytes, checksum: e39d27027a6cc9cb039ad269a5db8e34 (MD5) Bruna Martins Bomfati.pdf: 1871828 bytes, checksum: 025d7196b1adc075dc67eda4558cee36 (MD5) Previous issue date: 2018-02-27 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / Os problemas ambientais decorrentes do uso de combustíveis fósseis têm incentivado o desenvolvimento de fontes renováveis de energia. Neste cenário, em relação à busca por possíveis substitutos ao petrodiesel, os óleos vegetais e seus derivados vêm se revelando a melhor alternativa. Porém, para os óleos vegetais serem utilizados de forma pura como combustível, adaptações devem ser feitas para reduzir sua viscosidade e minimizar a ocorrência de possíveis problemas de desempenho e de danos ao motor. Neste trabalho, foi realizado ensaio de longa duração em motor ciclo Diesel, monocilíndrico e com injeção indireta, utilizando óleo de crambe pré-aquecido a 100 °C como combustível, com o objetivo de avaliar o desempenho do motor alimentado com este óleo vegetal, em comparação ao petrodiesel, assim como observar possíveis contaminações no óleo lubrificante decorrentes da utilização do óleo de crambe. O ensaio teve duração total de 100 horas. Em intervalos de tempo predeterminados, mensurou-se o consumo e a perda de potência relativa para os combustíveis crambe e petrodiesel, e realizou-se retirada de amostra de lubrificante para análise laboratorial, sendo as primeiras avaliações no tempo zero e as subsequentes a cada 15 horas de operação do motor. Também foi calculada a eficiência térmica do conjunto motor-gerador nos dois tratamentos. O consumo de óleo de crambe foi, em média, superior ao de petrodiesel nos quatro regimes de operação do motor, sendo mais evidente a diferença entre os combustíveis nos regimes com carga. A perda de potência relativa do combustível crambe foi superior à do petrodiesel nas avaliações em que se aplicou a carga de 51% da potência nominal do motor sobre a condição de 1.800 rpm de velocidade livre de carga e para a aplicação de carga adicional de 15% sobre a condição de 51% de demanda da potência nominal do motor; porém, para a aplicação de 66% de demanda da potência nominal do motor sobre a condição de 1.800 rpm livre de carga, o combustível crambe apresentou menor perda de potência relativa. Não houve diferença na eficiência térmica do conjunto motor-gerador com os dois combustíveis, comprovando que o maior consumo de óleo de crambe compensa seu menor poder calorífico em relação ao petrodiesel. Nas análises realizadas nas amostras de lubrificante não foram observados indícios de contaminação pelo combustível e nem alterações de suas propriedades, indicando combustão adequada do óleo de crambe, entretanto, observou-se aumento acentuado da concentração de ferro. Em geral, apesar do desempenho inferior, obteve-se bons resultados com o óleo de crambe pré-aquecido como combustível, porém mais estudos são necessários para avaliar a viabilidade técnica e econômica de seu uso. / The environmental problems arising from the use of fossil fuels have encouraged the development of renewable energy sources. In this scenario, in relation to the search for possible substitutes for petrodiesel, fuels made from vegetable oils are considered an interesting alternative. However, to use pure vegetable oils as fuel, adaptations must be made to reduce the oil viscosity and minimize the occurrence of performance issues and engine damage. In this study, a long-term test was performed in a single-cylinder, indirect injection diesel engine fueled with crambe oil preheated at 100 °C, with the aim of evaluating the performance of the engine with the use of this vegetable oil as fuel, in comparison to petrodiesel, and also possible contaminations in the lubricant due to the use of crambe oil. The essay had a duration of 100 hours. At specific time intervals, consumption and relative power loss for crambe oil and petrodiesel were measured, and lubricant samples were taken for laboratory analysis. The initial evaluations were at time zero and the subsequent at each 15 hours of engine operation. Also, the thermal efficiency was calculated for both fuels. The consumption of crambe oil was, on average, higher than that of petrodiesel for the four engine operating regimes, and the difference between the fuels consumptions was more evident at load conditions. The relative power loss of crambe fuel was higher than that of petrodiesel in the evaluations in which the load of 51% of rated engine power was applied over the condition of 1,800 rpm load-free and for the application of additional load of 15% over the demand of 51% of rated engine power; however, for the application of load of 66% of rated engine power over the condition of 1,800 rpm load-free, crambe oil presented less relative power loss. There was no difference between the fuels in the thermal efficiency of the engine-generator set, proving that the higher consumption of crambe oil compensates its lower heating value in relation to petrodiesel. In the lubricant analyses, there was no evidence of contamination by the fuel and no changes in its properties, indicating adequate combustion of the crambe oil, but it was observed a marked increase in iron concentration. In general, despite the inferior performance, good results were obtained with preheated crambe oil as fuel. However, more studies are necessary to evaluate the technical and economic feasibility of its use.

The global growth in electricity consumption and the shortcomings of renewable electricity generation technologies are some of the reasons why it is still relevant to evaluate the performance of power conversion technologies that are used in fossil fuel power stations. The power conversion technology that is widely used in fossil fuel power stations is the Rankine cycle. The goal of this study was to determine if the efficiency of a typical Rankine cycle can be improved by adding a heat pump as a bottoming cycle. Three simulation models were developed to perform this evaluation. The first is a simulation model of a Rankine cycle. A quite detailed Rankine cycle configuration was evaluated. The simulation model was used to determine the heating requirements of the heat pump cycle as well as its operating temperature ranges. The efficiency of this Rankine cycle was calculated as 43.05 %. A basic vapour compression cycle configuration was selected as the heat pump of the combined cycle. A simulation model of the vapour compression cycle and the interfaces with the Rankine cycle was developed as the second simulation model. Working fluids that are typically used in vapour compression cycles cannot be used for this application, due to temperature limitations. The vapour compression cycle’s simulation model was therefore also used to calculate the coefficient of performance (COP) for various working fluids in order to select a suitable working fluid. The best cycle COP (3.015 heating) was obtained with ethanol as working fluid. These simulation models were combined to form the simulation model of the Rankine-heat pump combined cycle. This model was used to evaluate the performance of the combined cycle for two different compressor power sources. This study showed that the concept of using steam turbine or electrical power to drive a compressor driven vapour compression cycle in the configuration proposed here does not improve the overall efficiency of the cycle. The reasons for this were discovered and warrant future investigation. / Thesis (MIng (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2013.