GUJARAT TECHNOLOGICAL

UNIVERSITY

G. H. PATEL COLLEGE OF ENGINEERING

AND TECHNOLOGY
(Affiliated with GTU)

A Project Report on

ACETYLENE POWERED 4 STROKE SI ENGINE

(Project Type: UDP)

B.E., SEMESTER 7
Academic year: 2019-2020
MECHANIAL ENGINEERING
Project – 1 (2170001)

Submitted by:

Abhishekh Dubey (Enrollment No. 160110119023)

Jaykumar Makwana (Enrollment No. 160110119045)
Vrutant Patel (Enrollment No. 160110119078)
Ashishkumar Vadhavani (Enrollment No. 160110119116)

Guided by Head of Department

Dr. Manan Desai Dr. Darshak Desai

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 CERTIFICATE

G. H. PATEL COLLEGE OF ENGINEERING

AND TECHNOLOGY

Mechanical Engineering

Date :
This is to certify that the Project Report
“ACETYLENE POWERED 4 STROKE SI ENGINE”
has been carried out by Ashishkumar Vadhavani (160110119116),
Abhishekh Dubey (160110119023), Jay Makwana(160110119045) &
Vrutant Patel (160110119078) under my guidance in fulfillment of the
degree of Bachelor of Engineering in Computer Engineering (7th
Semester) at G. H. PATEL COLLEGE OF ENGINEERING AND
TECHNOLOGY, VV Nagar, Anand during the academic year 2019-20.
Dr. Manan Desai (Faculty Guide)

Dr. Darshak Desai

(HOD – Mechanical Engineering Dept.)

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 INDEX

No. Pg.no

1 LITERATURE REVIEW 4

2 ABSTRACT 5

3 INTRODUCTION 7

3.1 CONSTRUCTION 9

3.2 SPECIFICATION OF SYSTEM 12

3.3 WORKING 15

3.4 ADVANAGES AND LIMITATIONS 16

3.5 APPLICATIONS OF SYSTEM 16

4 ASSEMBLY DRAWING 18

10 COMPONENT COSTING 22

11 SPECIFICATION OF COMPONENTS 24

12 CANVAS EXERCISE 25

13 REFERENCES 31

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LITERATURE REVIEW:

Acetylene is the colorless gas with garlic smell produced from the calcium carbide CaC2,
which is obtained from calcium carbonate CaCo3. Further the calcium carbonate is heated in
lime kiln at about 8250c which forms calcium oxides (lime) liberating carbon dioxide gas.
Calcium oxide is then heated in electric furnace with coke to produce calcium carbide finally
calcium carbide is hydrolyzed producing acetylene

As acetylene is a colorless gas and is highly combustible with high flame speed and fast
energy release, it can be used as alternative fuel in IC engines. It has a very wide
flammability range and minimum ignition energy required for ignition. Furthermore
comparing with various other fuel properties, acetylene proved good to be used in internal
combustion engines.

• Reaction 1 : 2H2O(l) + CaC2 (s) C2H2 (g) + Ca(OH)2 (s) (inside tank)

• Reaction 2 : 2C2H2 + 5O2 4CO2 + 2H2O (inside engine)

How acetylene is produced from carbide powder?

Step 1: The first step involves the production of acetylene gas through the Calcium Carbide
reacting with water in the reaction tank.

The reaction tank constitutes two chambers:

• In first (upper) chamber the water is kept.

• In second (lower) chamber the calcium carbide is kept.

The water from the first chamber is released in such a way to proceed the reaction
spontaneously. The water is passed through the control valve. In the second chamber the
calcium carbide is kept in desirable amount to react with water. Through second chamber a
valve is connected to the storage tank where the gas produced during reaction is stored.

Step 2: In this step acetylene gas is stored in the storage tank and the pressure is measured by
the pressure gauge.

In this step the produced gas is stored and is passed through the pipes. Here the gas is stored
to avoid moisture and the gas stored in storage tank is provided pressure through pressure
gauge so the gas is of high concentration.

Step 3:The gas is passed in the pipes sophisticated manner and then pipe is joined in the
carburetor fitted with the filter, this then filters the air and then combines with petrol as
secondary fuel which is added in very few amount ( in about 10 to 15%) to prevent knocking
for smooth operation of an engine. Then the mixture is passed in the engine. We can illustrate
that introduction of secondary fuel is an essential part of this project as introducing alcohol
helps to reduce adiabatic flame temperature in the combustion process which leads to avoid
the auto ignition and and knocking.

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Abstract

In the present trend where fossil fuels are in the verge of exhaust, the search for an
alternative fuel is one of the needs for sustainable development, energy
conservation, efficiency, management and environmental preservation. Therefore,
any attempt to reduce the consumption of petrol and diesel possible alternative fuels
is mostly preferable, and we have many choices like LPG, CNG with their
drawbacks. Due to which it is complicated to use them among various options
acetylene gas is a very good fuel for automobiles. This study about the idea of using
acetylene gas in the internal combustion engine such that it reduces the demand of
the petroleum products that is going to be extinct in near future. It includes about the
emissions of harmful gases that can be reduced by the use of acetylene instead of
petroleum products. Various fuels have been tested on IC engines for their suitability
as alternate fuels.

Expect few alcohols, CNG and LPG, not many fuels have been found to be matched
with IC Engines requirements. As acetylene is colorless gas and is highly
combustible with high flame speed and fast energy release, it can be used as
alternative fuel in IC engines. It has a very wide flammability range and minimum
ignition energy required for ignition.

Furthermore comparing with various other fuel properties, acetylene proved good to
be used in internal combustion engines. The main objective of the study is to
manufacture the cylinder with all the measures, so that it can be used for chemical
reaction of calcium carbide with water and produce the acetylene gas, store the gas
and to supply to the engine. And also modify the petrol engine to work on acetylene
gas efficiently. The spark timing is changed, so that the spark ignition is little earlier
by changing breaker time distance, the timing valve adjustment. Introducing of
ethanol in fuel inlet for ignition and reduce adiabatic temperature and acetylene from
air inlet along air hose to carburetor. Thus this study is an attempt for the use of an
alternative resource such that it can prove to be useful for the peoples in future.

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 CHAPTER:1

INTRODUCTION

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 A. INTRODUCTION

Depleting petroleum reserves and increasing cost of the petroleum products necessitates an
intensive search for alternative fuels which can wholly or partially replace petroleum fuels.
Biofuels are tested from times and they prove to be very good substitutes for the existing
petroleum fuels. They require a little engine modification to be used in IC engines. Nowadays
gases like LPG (liquefied petroleum gas), LNG (liquefied natural gas), etc. are being used as
substitute of diesel and gasoline in IC engines. These are inducted into the engine along with
the air coming into the engine. Generally, biofuels are obtained from the living plant sources.
These oils may be obtained from resin and plant seeds. They are renewable and have low
Sulphur content. There widespread use as an IC engine fuel is restrained because they are
more costly than fossil fuels. Vegetable oil is in use as a diesel engine fuel before all other
alternative fuels were tried. But the problems associated with vegetable oil are the high
viscosity and low volatility. These properties affect the fuel injection system very badly.
Turpentine was used in early engines without any modification.
The abundant availability of fossil fuels had stopped the usage of turpentine in I.C. engines.
But the increasing cost of petroleum is prevailing today reopens the utility of turpentine in
I.C. engine.
Spark Ignition Engine: A spark-ignition engine is an internal combustion engine, generally a
petrol engine, where the combustion process of the air-fuel mixture is ignited by a spark from
a spark plug. This is in contrast to compression ignition engines, typically diesel engines,
where the heat generated from compression together with the injection of fuel is enough to
initiate the combustion process, without needing any external spark. Spark-ignition engines
are commonly referred to as "gasoline engines" or "petrol engines. However, these terms are
not preferred, since spark-ignition engines can (and increasingly are)run on fuels other than
petrol/gasoline, such as auto gas (LPG), methanol, ethanol, bio ethanol, compressed natural
gas (CNG), hydrogen, and(in drag racing) nitro methane.
Alternate Fuels: There are three types of fuels viz. solid, liquid and gaseous fuels. Mainly
liquid fuels are used in IC engines. Nowadays gaseous fuels such as LPG and CNG are also
in use as automobile fuels. In early periods even solid fuels like charcoal, coal and slurry
were also tried. Solid fuels: They are not used nowadays, but when Rudolf was designing the
engine he used coal dust mixed with water. He used very fine coal particles thoroughly mixed
with water and injected in the engine. As coal is abundantly available it becomes an attractive
fuel, but there are problems in using it. Major problems are abrasiveness due to solid particles
which leads to wear of injectors and the piston rings. Liquid fuels: Liquid fuels are preferred
due to their high calorific value and they can be easily stored. Moreover the problem of wear
is also overcome by using liquid fuels. The most common liquid alternative is alcohol. And
Gaseous fuels: Since physical delay is almost zero for gaseous fuels, they are suited for use in
IC engines. Since the gas displaces the equal amount of air, the volumetric efficiency of the
engine decreases.
Acetylene: Pure acetylene is a colorless, highly flammable gas with an ether-like odor, but
the odor of the commercial purity grade is garlic-like. Acetylene can be safely stored and

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used in cylinders filled with a porous material and containing acetone into which the
acetylene has been dissolved. Acetylene, when not dissolved in a solvent can begin to
decompose at pressures above 15 pounds per square inch gauge (psig). The products of
dissociation are carbon, in the form of lampblack and hydrogen. Considerable amounts of
heat are generated by dissociation, which may produce explosions of great violence. Steel
and wrought iron are recommended for use in acetylene piping. Rolled, forged, or cast steel,
or malleable iron fittings may be used. Cast iron is not permissible for fittings. Unalloyed
copper, silver, or mercury should never be used in direct contact with acetylene since there is
the possibility of forming explosive Acetylides. Wet acetylene will produce explosive
acetylides on copper, 70-30 brass, and aluminum-bronze. Weight (not pressure) is used to
determine the amount of acetylene in a cylinder. The tare weight is subtracted from the actual
weight, and the difference is multiplied by 14.7 to determine the amount of gas in standard
cubic feet. The molecular symbol for acetylene is C2H2.

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B. CONSTRUCTION

The system consists of following components arranged as shown in the figure:

 4 stroke spark ignition engine: A Bajaj CT100 4 stroke engine is locally available
from an automobile garage which is ideal for this project due to simpler construction
and electronics. Engine is in complete working condition along with accessories like
mounting frame.

 Water and carbide tank: This is one of the major component in this system. Here,
water is fed into the tank in a certain quantity where it mixes with calcium carbide to
form acetylene. The inner layer of this cylinder is bounded by foam dipped in acetone.
This keeps acetylene stable.

 Pressure gauge: A pressure gauge is mounted on top of water and carbide tank which
will measure pressure with respect to atmospheric value.

 Hoses: Hoses are pipes used to carry acetylene from tank to vaporizer and from
vaporizer to carburetor throat.

 FRL unit:
Acetylene leaving from reaction chamber which contains contaminants, and calcium
hydroxides particles which might cause improper combustion and affect the engine

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 and other components to avoid these problems, the gas is filtered and regulated its
pressure when the output pressure is high and removes the moisture in gas so that it
avoids the effect of rust on engine and other parts.

 Flash trap : At the carbide storage tank valve, pressure gauge is mounted where a
flash trap is also attached to stop flame from back fire.
 Electronic Tachometer :
An electric tachometer shows exact value of engine rpm by connecting it to ignition
coil of IC engine. It is a must requirement for measuring brake power and torque.

 Vaporiser : Vaporizer it is device which is use to transfer the gas from the gas
cylinder to engine with proper amount of air it consist of four knob
1. Vacuum inlet knob
2. Vacuum outlet knob
3. Gas inlet knob
4. Gas outlet knob

VAPORISER

HOSE PIPES

FLASH TRAP

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 4 STROKE IC ENGINE

ACETYLENE CYLINDER

PRESSURE GAUGE

FRL UNIT

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 ELECTRIC TACHOMETER

C. SPECIFICATION OF SYSTEM

A spark-ignition engine is an internal combustion engine, generally a petrol

engine, where the combustion process of the air-fuel mixture is ignited by a spark
from a spark plug. This is in contrast to compression-ignition engines, typically diesel
engines, where the heat generated from compression together with the injection of
fuel is enough to initiate the combustion process, without needing any external
spark.

Modification done in engine system: fuel injection with carburetor connected to

vaporizer and FLR unit. Spark timing advancement, generally spark is produced
within .03 to 0.5 seconds before the BDC after compression stroke with crank angle
about 10o to 15o, but this is advanced by modifying the CDI.

Reaction tank: Reaction tank is made up of mild steel with 6mm thickness, 16cm in
diameter, 36cm in length, with the volume of 7238.23mm3. The top flange is
removable can fasten with nut and bolt of 8mm for removing the bi product (calcium
hydroxide) after reaction, and it consists of three ports: For pressure gauge, Gas
outlet with valve and Emergency release for gas with valve.

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Figure 1: IC engine with setup

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Figure 2 : Acetylene producing cylinder

Figure 3 : Assembly of vaporizer unit

D. OPERATING PRINCIPLE OF ACETYLENE POWERED 4 STROKE SI

ENGINE
The engine used in our project will be a 4-stroke Single cylinder spark ignition engine which
will run on stoichiometric mixture of air and acetylene.
Acetylene ( Ethyne ) is a flammable gas with a higher calorific value of 56000 kJ/m3 which
is higher than that of petrol.
For running SI engine using water it is necessary to make acetylene using water.
For this a chemical compound known as Calcium Carbide is added to water, which creates an
exothermic reaction.
The products formed in this reaction are Acetylene in gaseous form and calcium hydroxide in
form of precipitates. This whole reaction takes place inside a cylinder made up of metal.
Reaction 1 : 2H2O(l) + CaC2 (s) C2H2 (g) + Ca(OH)2 (s) (inside tank)
Reaction 2 : 2C2H2 + 5O2 4CO2 + 2H2O (inside engine)

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Figure 3: Operating principle of Acetylene powered SI engine

E. WORKING
In the present work, water and calcium carbide are added in the ratio of 2:1 to the reaction
tank and, due to reaction the acetylene gas is generated, and it stored. The stored
acetylene gas enters the FLR UNIT to filter the gas and regulated and then is vaporized in
vaporizer. Tank pressure is reduced to approximately 1.5 psi. As negative pressure is
transmitted from the carburetor to the vaporizer, the regulator in vaporizer releases
acetylene vapor and acetylene gas was aspirated in the intake manifold. The SI engine
will start with petrol or ethanol being the ignition source also use of ethanol will reduce
adiabatic temperature, after that the performance and emission characteristics are
compared with baseline acetylene gas

Calculation: Calculation procedure for performance testing:

Braking Torque (N-.m): Braking Torque = (W – S) × Rb:

Where, W = Dead weight in Newton (N); S = spring balance Reading (N); Rb = Radius
of brake drum (D/2).

Brake power (w): BP = (W- S) ×Rb×2πN/60.

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Indicated power (w): IP = (IMEP LAnK / 60;
Where, IP = indicated power (kW); IMEP = Indicated Mean Effective Pressure (kN/m2);
L = length of stroke (m); A =

Cross section area of piston (m2); n = number of power strokes n = N / 2 for four strokes;
and N = for two strokes; N =

Crankshaft speed (revolutions per minute); K = number of cylinders; Mechanical

efficiency: η MECHANICAL = BP / IP; Speed (m/s): V= rpm x (2π rad)/ rev x (r/rad);

Theoretical calculation: Sample calculation (using experimental method):

Bore dia. (dc)=57 mm; Stroke (L) = 56.4mm; Compression ratio = 9.5; RPM = 8500;
Petrol calorific value = 45.6 MJ/Kg; Acetylene calorific value = 56 MJ/Kg; Cylinder
Swept Volume (Vs) : Vs = Cylinder area x Stroke length
Compression ratio = 9.5;

F. ADVANTAGES

 In a country like India, there are very high chances of success rate if this product is
brought up as a start-up.
 Owing to gasoline consumption, pollution generation and demand for vehicles in
India, this product can be a new beginning to cheaper transportation along with lesser
pollution.
 A small size kit of this system can be made which can be attached to a conventional
gasoline engine without making large modifications.
 Per kilometer cost of fuel consumed in this system would be much lesser than price of
gasoline because of which it becomes cost friendly to large part of society.

G. LIMITATIONS

 Extra components like vaporizer and modification of intake manifold of

existing engine may be required making the overall system complex.
 The engine will still emit a considerable amount of carbon dioxide gas, to
prevent which some catalytic arrangement has to be provided at the
exhaust of the engine.

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  The system doesn't look feasible in sport bikes as it doesn't fit to the
aesthetic considerations.

H. APPLICATIONS OF SYSTEMS

• Usage of alternate fuels in internal combustion engines aren’t much entertained in

Indian automobile production. Because of cheaper running cost, this system brings a
newer transformation in automobile sector.
• As the system uses gaseous fuel, the problem associated with cold start has been
eliminated.
• The calcium oxide slurry formed as a bi-product can be sold or reused as it has got its
own benefits.

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 CHAPTER: 2

Parts drawing and assembly drawing

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DESIGN OF ACETYLENE PRODUCING CYLINDER

[19]
[20]
 CHAPTER:-3

MATERIAL COSTING

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 Component Estimated Cost (₹)

Acetylene cylinder with pressure 3000

gauge and flange (20 ltr.)

Welding machine -

High pressure tubes 90 * 4 mts. = 360

Calcium carbide powder and distilled 200/kg.

water

Vaporizer 1500

Petrol engine ( Bajaj CT 100 ) 7000

Fully functional with pre-attached

carburettor

FRL unit for cleaning gas 800

Digital Tachometer 880

Brass ball valve ¾ inch 350

TOTAL : ₹ 14,090

TOTAL COST OF PROJECT = 14,090 RUPEES (Tentative)

[22]
 CHAPTER – 4

SPECIFICATION OF PARTS

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Specification of IC engine: -

MAKE: Bajaj CT100 4 Stroke single cylinder.

Torque = 8.05 Nm @4500rpm
Power = 8.1 bhp @7500rpm
Bore * stroke = 53mm * 45mm

Specification of cylinder: -
20 litres water capacity.
Material: mild steel (6mm thick)
Diameter: 160mm
Length: 360mm
Covered with flange fastened with 4 * 8mm bolts

Specification of hose pipes: -

Material: Poly vinyl chloride.
Used for supplying acetylene (Gas Welding machine )
Size: ¾ inch
Length = 12 to 20 meters.

Specification of Electronic Tachometer: -

Measuring up to 13000 rpm.

Directly attachable to ignition coil.

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CANVAS EXERCISE

[25]
EMPATHY

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IDEATION

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AEIOU

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PRODUCT DEVELOPMENT

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CHAPTER – 8

REFERENCES

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  Name of website:

• The conventional spark ignition engine uses gasoline as fuel which is becoming more
and more costly. Our system uses acetylene gas produced using water and calcium
carbide which is much more economical than gasoline.
• Gasoline engine uses carburettor for vaporizing the fuel and mixing it with air. But as
our system uses acetylene gas, it mixes readily with air inside the throat section.
• Usage of two spark plugs would be made so chances of knocking are decreased inside
the combustion chamber.

 REFERENCES BOOKS: -

o Internal Combustion Engines by V Ganesan

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