Final Year Project Report:

Title:
Energy Conservation of Exhaust Gases of SG-34 Gas Engine at Crescent Textile Mill
Faisalabad
1. INTRODUCTION
Crescent Group of industries have captured fame from all over Pakistan and around the
globe by its multifaceted and distinctive range of products that includes woven fabric,
polyester and cotton products that are valued and admired internationally. Crescent
Textiles Mill is located on Sargodha road in Faisalabad with a working boundary 0f
300 acres in the premier lounge of city stocking a clean environment and substantial
system. Due to diversity and vast range of products, Crescent holds contradistinctive
machineries and departments that work in collaboration to achieve the quality goals of
industry. Stepping forward, Crescent managed to install a 47 MW power plant in order
to perpetrate their power demand. This proved to be advantageous to the industry as it
leads in accordance towards more favourable circumstances for the industry to excel in
their field. With the chapter of success, Crescent power plant is famous due to its
pleasant and safe working arena with the machines that provides a responsive platform
to the workers and helps them to achieve reputation. Moreover, the Plant includes
modern and contemporary set of machines which are recognized worldwide and fulfil
all quality standards. The engines that they are using for power generation belongs to
Wartsila & Nohab manufacturers and our project revolves around Wartsila SG34
engine generating set. Discussing the technical data of the engine, it hold 18 cylinders
with cylinder bore of 340mm and piston stroke of 400mm categorized in the V type of
engines. Engine has brake mean effective pressure of 22 bar while mean piston speed
of 50 Hz. The engine has rated configuration, with water pumps that are tangible
towards high as well as low temperature cooling. The engine operates with Natural Gas
(Sui Gas) as a fuel and provides even load bearing for every cylinder. The combustion
chamber of the engine makes it more efficient as it provides a stable combustion due to
its pre heating and illusion chamber for pre combustion. The engine is set with a
turbocharger, a boiler and an economizer to settle and utilize exhaust gases from the
liberation till the process to stretch out heat at the end of economizer. The custom heat
is transformed and employed at every set for the different purposes to adequate with
the exhaust gases to avoid heat loss. We are working to improve the efficiency of the
economizer as it proceed from the turbocharger making it charged with the maximum
extent of heat delivery at the initial and very first point of heat liberation. The boilers
compensate the remaining heat cluster according to its potential for heat absorption. As
the heat passes through the supplementary heat evaluating sets it finally casters its final
approach in to the economizer. Our project is based on the working of economizer and
we are trying to improve the efficiency of the economizer to process heat as there is no
proceeding technique to engulf heat after the economizer. Calculating heats evaluation
at different points, we have come to a point that the heat processing at the final point
can be explored and obsessed with more heat usage allowing the process to supply more
heat that can be utilized somewhere. The heat recovery can be in account to the overall
efficiency of the plant to provide surplus generation in low charge. The industry has
shown interest towards our project as it is beneficial for the industry in every mean
while it is shaded under the thrown of technology. The industry is cooperating to meet
the challenges that will be faced while achieving the goals and we are hopeful to shutter
out useful results from this project.
2. SIGNIFICANCE
We are always concerned with the efficiency of every process we observe and
invariably, we require more output with less input. No doubt these are the primary goals
of every muddle we suggest and relating this theory to our project, we anticipate the
serviceable consequences from the innovations we are trying to put in the discussed
point. With the improved efficiency of the economizer, the overall process of exhaust
gases heat evaluation can be revolutionized as it will focus on the lost heat and will try
to manage it in the most favourable places. The heat reaching the economizer is
supposed to contain enough heat even after delivering its parts to the water pipes. Our
project is basically targeting that amount of heat to be further processed in order to
snatch out maximum amount of heat. The significance of this project can be felt from
the primary goals of the system that is set up to make the mislaying element in to use
and to avoid every type of loss in the process. By making innovations in the economizer
the heat can be processed more efficiently and the performance of economizer will also
be improved. The condensate will then be suppressed and heated at the economizer
more smoothly. The water for feed water tanks is accumulated towards this heat and in
this way it is preheated to raise the temperature of the fluid, that is why they are also
known as pre heaters. We can reduce environmental effects by processing this heat and
with that we can also run our primary purposes from that amount of heat. We are
working on the economizer to set it in such a way that it should work in such a way so
as to reduce all the chances for the water to flood at the boilers. The constraints that lie
with its use are of no logic and therefore it proves itself to be a most suitable process in
many aspects. It provides extra boost to the whole process and improves the overall
efficiency without putting extra cans to the process.
3. METHODOLOGY
1. Availability of Exhaust Heat in the Flue Gases:
The amount of waste heat contained in the flue gas depend on both temperature and the
mass flow rate of the exhaust gas:
𝑄 = ṁ𝐶𝑝∆𝑇
Where, Q is the heat contained in the exhaust gases (kJ/h), ṁ is flue gases mass flow rate
(kg/h), Cp is the specific heat of exhaust gas (kJ/kg°K) and ∆T is the temperature difference
in °K. The magnitude of the temperature gradient between the exhaust gases temperature
and ambient temperature is an important factor for exhaust heat utility. The flue gases and
sink temperature difference decides the rate at which heat is transferred per unit surface
area of the recovery system and the maximum theoretical efficiency of converting thermal
from the exhaust gases to another form of energy (i.e., mechanical or electrical). Lastly,
the temperature range of exhaust gases has important function for the selection of waste
heat recovery system designs.
2. Heat Loss through the Exhaust in Internal Combustion Engine:
 Density of gas fuel is 0.01602 kg/m³ at average engine inlet temperature of 41.5
⁰C and average 2.48 kPa pressure. It is measured by natural gas density
measuring calculator available online.
 Calorific value of Natural Gas is 34.09 MJ/m³ in Pakistan but delivered to
Industrial zone is 30.5 MJ/m³.
 Density of Air is calculated as follows:
Using PV = nRT (general gas equation)……………….. (2.1)
Rearranging we have,
Ƥ =MP/RT …………………………………………. (2.2)
Here,
Ƥ = density of air = 2.44 kg/m3
M = Molecular weight of air = 28.85 gm/mole
P = Average pressure of air at inlet of engine = 222kPa
R = Universal gas constant = 8.314 kJ/mole K
T = Average temperature of air in Kelvin at engine inlet = 315.66 ⁰K
 Specification of Engine:
Engine 18 Cylinder,4-Stroke,S-I Engine,34SG
WӒRTSILӒ
Bore 340 mm
Stroke 350 mm
Power (Average) 4.050 MW
RPM 750rpm
BHP@750rpm 4.050 MW
Cooling System Water Cooled
Specific fuel consumption 0.273 m³/kW hr
Compression Ratio 12
As
𝑇𝑜𝑡𝑎𝑙 𝑣𝑜𝑙𝑢𝑚𝑒
Compression Ratio = 𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 𝑣𝑜𝑙𝑢𝑚𝑒
𝑉𝑠+𝑉𝑐
ɣc = ………………………….(2.3)
𝑉𝑐

Here, VS = Swept Volume

VC = Clearance Volume
And,
𝜋
VS = 4 (𝐵𝑜𝑟𝑒)2(Stroke)
𝜋
VS = 4 (340)2(350)

VS = 0.0317 m3 (for one cylinder)

Then, using equation (2.3) we have,
VC = 2.88 × 10-3 m3 (for one cylinder)
 The combustion reaction of natural gas is given by stoichiometric combustion
chemistry is as follow:
(Natural gas) + 2 (O2 + 3.76 N2) high pressure
CO2 + 2 H2O + 2 (3.76 N2) ……
As clear from the above stoichiometric equation to burn one mole of natural gas, 2
mole of air is required for proper combustion. It can be written as follow:
Chemical Reactants: (Natural gas composition is 96.5% CH4, 1.8% ethane, 0.45%
propane).But the combustion products remain same.
Reactant (mole) Mole Fraction
Natural gas 1 9%
O2 2 19%
N2 7.52 72%

Combustion Products:
Product (mole) Mole Fraction
CO2 1 9%
H2O 2 19%
N2 7.52 72%
On average 1070 m3/hour natural gas is supplied to the confined SG34, WӒRTSILӒ
engine at Crescent textiles Faisalabad.
Reactant (mole) Mole Fraction Volume
Natural gas 1 9% 1,070 m3
O2 2 19% 2,140 m3
N2 7.52 72% 8,046.4 m3
But in actual combustion engine is operating at lean condition, therefor, 10% extra air
is added for lean combustion.
Actual combustion equation will be as follow:
high pressure
(Natural gas) + 2.2 (O2 + 3.76 N2 CO2 + 2 H2O + 2.2 (3.76 N2) +0.2O2
Therefore, the reactant quantities become:
Reactant (mole) Mole Fraction Volume
Natural gas 1 8.71% 1,070 m3
O2 2.2 19.17% 2,354 m3
N2 8.272 72.11% 8,851.04 m3

Total volume 12,275.04 m3

Hence, total volume (12,275.04) will produce equal volume of products after combustion and
send out as flue gases. The exhaust gas components quantities as follow:

Combustion Product (mole) Molar Fraction Volume

CO2 1 8.71% 1,069.16 m3
H2O 2 17.42% 2,138.31 m3
N2 8.272 72.11% 8,851.53 m3
O2 0.2 1.76% 216.04 m3
Densities of the above flue gases are as follow using density of gases calculator available
online.
Flue gas Density
component (kg/m3)
CO2 1.952
H2O 0.8
N2 1.23
O2 1.428
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑒𝑥ℎ𝑎𝑢𝑠𝑡 𝑔𝑎𝑠𝑒𝑠 = (0.087 × 1.952) + (0.174 × 0.8) +
(0.721 × 1.23) + (0.017 × 1.428)
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 = ƥ = 1.22 𝑘𝑔/m3
Specific heats of flue gases taken through literature given below:
Flue gas Specific heat
component (kJ/kg K)
CO2 1.126
H2O 1.882
N2 1.098
O2 1.043

𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 ℎ𝑒𝑎𝑡 𝑜𝑓 𝑓𝑙𝑢𝑒 𝑔𝑎𝑠𝑒𝑠 = (0.087 × 1.126) + (0.174 × 1.882) +

(0.721 × 1.098) + (0.017 × 1.043)
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 ℎ𝑒𝑎𝑡 𝑜𝑓 𝑓𝑙𝑢𝑒 𝑔𝑎𝑠𝑒𝑠 = 𝐶𝑝 = 1.189𝑘𝐽/𝑘𝑔 𝐾
So, the available heat in the exhaust at exhaust manifold is
𝐸𝑛𝑒𝑟𝑔𝑦 𝑖𝑛 𝑡ℎ𝑒 𝑓𝑙𝑢𝑒 𝑔𝑎𝑠𝑒𝑠 = 𝑄 = 𝑚𝐶𝑝∆𝑇 = Ṽƥ𝐶𝑝∆𝑇
Using the respective values of total volume, density and specific heat we get,
𝐸𝑛𝑒𝑟𝑔𝑦 𝑖𝑛 𝑡ℎ𝑒 𝑓𝑙𝑢𝑒 𝑔𝑎𝑠𝑒𝑠 = 𝑄 = 12,275.04 × 1.221 × 1.189 × 457
𝐸𝑛𝑒𝑟𝑔𝑦 𝑖𝑛 𝑡ℎ𝑒 𝑓𝑙𝑢𝑒 𝑔𝑎𝑠𝑒𝑠 = 𝑄 = 8,142𝑀𝐽/𝐻
These flue gases then enter 1spex type turbocharger and leave at a captive average temperature
of 4050C.Therefore, energy in the exhaust gases after turbocharger and entering to the waste
heat recovery steam generation system (WRSG) is calculated as follow:

𝐸𝑛𝑒𝑟𝑔𝑦 𝑖𝑛 𝑡ℎ𝑒 𝑓𝑙𝑢𝑒 𝑔𝑎𝑠𝑒𝑠 = 𝑄 = 12,275.04 × 1.221 × 1.189 × 375

𝐸𝑛𝑒𝑟𝑔𝑦 𝑖𝑛 𝑡ℎ𝑒 𝑓𝑙𝑢𝑒 𝑔𝑎𝑠𝑒𝑠 = 𝑄 = 6,682.7𝑀𝐽/𝐻