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10 1016@j Matpr 2020 03 247
10 1016@j Matpr 2020 03 247
a r t i c l e i n f o a b s t r a c t
Article history: An increase in the economic rapid development worldwide creates a problem of shortage of energy and
Received 13 December 2019 hence conservation of energy is the need of an hour. A recent survey shows that a considerable amount of
Received in revised form 24 February 2020 energy is released in the form of waste heat from internal combustion engines which creates another
Accepted 12 March 2020
issue of air pollution. According to the study, the conversion rate of energy supplied to an engine into use-
Available online xxxx
ful power output that is mechanical work is around 30–40%. It means that the exhaust gases contribute to
about 33% and engine cooling capacity about 30% to that of the energy supplied which results in an
Keywords:
increase in entropy and other serious environmental problems. Indeed more and more energy should
Waste heat
Phase change material
be converted into useful work. The present work consists of thermal energy storage from the exhaust
Twin-cylinder 4-stroke diesel engine gas of twin-cylinder four-stroke diesel engines with the help of sodium nitrate being used as the
Thermal energy storage Phase Change Materials (PCM) and the energy available in exhaust gas without Phase Change
Materials. The test of fuel used as diesel for both with and without PCM. The exhaust gases from the
twin-cylinder four-stroke diesel engine without PCM contain 45.1% energy transferred to the atmo-
sphere. The exhaust gases with a thermal energy storage system exchanging of heat to the PCM. The
PCM stored thermal energy 5.5% of total energy from the exhaust during the charging process and
reduced emission control by reducing energy transferred to the atmosphere form 45.1% to 39.5%. The
thermal energy from the PCM discharged and used to generation of steam which can be used for different
applications. The process without PCM gives more harmful gases and hazardous to humans and the envi-
ronment, but the system with PCM gives minimum exhaust gas temperature which is minimum harmful
to humans and the environment. The utilization of waste heat and its recovery reduces the fuel required
to run the engine and lesser emission of greenhouse gases to the environment.
Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 2nd International Con-
ference on Advances in Mechanical Engineering and Nanotechnology.
1. Introduction combustion engine, the heat carried away by the cooling water
and exhaust gases is around 30% to that of the total input energy
The high capacity diesel engines which run most commonly on is supplied to run the internal combustion engine. This waste heat
the road energy requirement in India has increased more rapidly energy should be conserved through waste heat recovery systems.
due to its economic and industrial growth. There are various The combustion of fuel in the engine generates waste heat. The
energy sources available in nature; however, they create some energy conservation of this waste heat may result in the saving
uncertainty about their uses and thus, effective utilization of all of fuel. Nowadays, a modern technique of waste heat recovery
the energy sustainable resources need to be done. One such energy from the engine exhaust is to store the heat in the form of thermal
resource is high capacity diesel engines which run most commonly energy storage which later on can be used for numerous applica-
on roads [1]. A recent study shows that in the case of an internal tions [2].
Out of the energy storage, the latent heat storage contributes
more to store the energy in the thermal energy storage. It is
⇑ Corresponding author. because of its heat storage properties at constant temperature
E-mail address: prateek.malwe@walchandsangli.ac.in (P.D. Malwe). and the ability to ensure high energy storage density factor [3].
https://doi.org/10.1016/j.matpr.2020.03.247
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 2nd International Conference on Advances in Mechanical Engineering and Nanotechnology.
Please cite this article as: G. S. Wahile, P. D. Malwe and A. V. Kolhe, Waste heat recovery from exhaust gas of an engine by using a phase change material,
Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.03.247
2 G.S. Wahile et al. / Materials Today: Proceedings xxx (xxxx) xxx
Table 1
Comparison of sensible and latent heat.
Please cite this article as: G. S. Wahile, P. D. Malwe and A. V. Kolhe, Waste heat recovery from exhaust gas of an engine by using a phase change material,
Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.03.247
G.S. Wahile et al. / Materials Today: Proceedings xxx (xxxx) xxx 3
A eutectic material gets formed by melting the two or more erating vapors and other for generating the superheated vapors
components of a material, each of which melts and freezes to form respectively. The output of such systems produces an additional
a mixture and the same comes out as crystals due to the process of power production of 10%, 9%, and 8% by using water, ammonia,
crystallization. As eutectic aluminum freezes very near to the tem- and R134a respectively as the organic fluids.
perature of the mixture of the crystals, it always melts and freezes Shameer et al. [1] propose and implements a thermoelectric
without being superheated and hence leaves very little margin of waste heat energy recovery system for internal combustion engine
error for the components to separate. It is followed by the melting automobiles, including gasoline vehicles and hybrid electric vehi-
of both the components which again are unlikely to separate. If cles. The key is to directly convert the surface heat energy from
phase-change material segregates, then these are usually called automotive waste heat to electrical energy using a thermoelectric
as eutectics. generator (TEG). The experimental results demonstrate that the
proposed system can work well under different working condi-
tions, and is promising for the automotive industry.
2. Literature review Akbarzadeh et al. [4] described herein utilizes thermoelectric
generators (TEGs) and heat pipes with its key advantage being it
Orr et al. [9] presented a theory that an effective conversion of is a passive solid-state design. The use of heat pipes allows for
chemical energy of fuel into mechanical energy in an internal com- more flexible designs as the TEG location is not limited to the
bustion engine which requires an efficient heat conversion system. exhaust pipe surface. Testing was undertaken on a car with a 3.0
A major portion of the energy gets distributed in the form of waste L V6 engine. In all test conditions, the power loss due to pressure
heat to the engine coolant and to the exhaust gases. Instead of effi- drop in the exhaust duct was always lower than the electrical
ciency improvement of the engine directly, the focus has been power output.
shifted towards the indirect improvement of the engine efficiency Yasin et al. [13] focus on determining the effect of EGR and palm
by connecting a waste heat recovery system. It may require to use biodiesel on fuel consumption (SFC), exhaust gas temperature
heat pipes and electric generators which are silent, durable, pas- (EGT) and exhaust emissions (NOx, CO, UHC, and CO2). Experimen-
sive, candle and are present in solid-state. tal works using a multi-cylinder diesel engine with EGR and simu-
Chintalaa et al. [10] discussed the method of implementation of lated works using Diesel-RK were performed at a constant engine
the Organic Rankine Cycle (ORC) as a means of extraction and uti- speed of 2500 rpm in full load condition. The results showed that,
lization of waste heat recovery from compression ignition engines. from the simulated and experimental works, palm biodiesel signif-
It results in the production of an additional useful power output to icantly increased fuel consumption, increased NOx and slightly
run the engine. A thorough study on the capability of the waste decreases in other emissions including CO2, CO, and unburned
heat coming out of the exhaust gases is carried out. Engine-ORC hydrocarbon (UHC). However, the use of EGR shows a significant
system assorted with certain research challenges like suitable reduction in the NOx emission and exhaust temperature but
organic fluid selection, design of evaporator and condenser as heat increases in fuel economy, CO, CO2, and UHC emissions.
exchangers, provision to deal with backpressure issue arises due to Panigrahi et al. [14] carried an experimental investigation on a
the mounting of components in the line of exhaust gas system, etc. four-stroke single-cylinder diesel engine fuelled with the blends of
The design of the evaporator for the engine-ORC system should be Mahua oil methyl ester (MOME) and diesel. The performance emis-
done according to the availability of exhaust gas temperature (with sion, energy, and Exergy analysis has been carried out in B20
variation in the mass flow rates and exhaust gas temperatures).
The above combination yields to about lower thermal efficiency
3. Experimental setup
(10–25%); the reason being the lower operating temperatures in
the ORC.
The experimental setup consists of a twin-cylinder 4-stroke die-
Singh et al. [11] focused on the technologies and modern
sel engine and its specifications are given in Table 2:
changes in the area of waste recovery systems of exhaust gases
PCM assembly with PCM in between outer and inner copper
coming out of automobiles. The primary objective was to analyze
pipe. The line diagram and the photograph of the experimental
a waste heat recovery technology necessary for internal combus-
setup showed in Fig. 2(a) and (b) respectively. A container of
tion engines. Such systems require a turbocharger and a turboelec-
PCM assembly can store about 5 L of water. An outer pipe tube hav-
tric generator fitted across the exhaust gas pipings. Of the total
ing 47.5 mm inner diameter, inner pipe tube having outer diameter
heat input energy supplied to run the engine, nearly 30 – 40% gets
32.5 mm, 580 mm length, 80 mm height and 3 mm thickness of
converted into useful mechanical work and the remaining 60–70%
inner and outer pipes. It houses the PCM in between outer and
is carried away in the form of heat due to friction, engine cooling
inner copper tubes and allows the heat transfer between the
systems and so on. This waste heat in the form of exhaust gases
exhaust gas and PCM and also heat transfer to the water (heat
harms the environment as it releases hazardous fumes. The long-
transfer fluid). The tank is made of 18 mm thick mild steel sheet
term effects of the above are seen in the form of phenomena like
greenhouse effects, global warming, and an increase in the entropy
of the universe. Hence, by utilizing the waste heat, one can not only
control environmental pollution but also conserves the fuel Table 2
Specifications of the twin-cylinder 4-stroke diesel engine.
required to run the engine.
Shekh et al. [12] stated that additional power can be produced Parameter Specifications
by running a separate Rankine cycle by extracting the waste heat Brake Horse Power 10 BHP
coming out of exhaust gases from a 40 kW diesel engine generator Speed 1500 RPM
set. Accordingly, trials and experiments were conducted on this. Cubic Capacity 1106 cc
Bore 80 mm
The performance investigation of shell and tube type as a heat Stroke 110 mm
exchanger with water as the working fluid is also done. The opti- Number of cylinders 02
mization of the above heat exchanger is being done with the help Dynamometer Rope Brake (Mechanical) Type
of a computer simulation. This heat exchanger produces additional Drum diameter 28 cm
Rope diameter 30 mm
power by considering the actual turbine efficiency into considera-
Orifice diameter 25 mm
tions. Two distinguished heat exchangers were used – one for gen-
Please cite this article as: G. S. Wahile, P. D. Malwe and A. V. Kolhe, Waste heat recovery from exhaust gas of an engine by using a phase change material,
Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.03.247
4 G.S. Wahile et al. / Materials Today: Proceedings xxx (xxxx) xxx
Fig. 2. (a) Line diagram of the experimental setup; (b) Photograph of the experimental setup.
metal. The PCM is provided in 2 tubes; each tube contains 1.25 kg The PCM contained in each set of the pipe is 1.25 kg; the total
of PCM by weight. PCM contained in the setup is 2.5 kg. After filling the PCM, the
The tubes are placed at a distance of 8 cm apart. The setup con- pipes are sealed by gas welding so as not to leak the PCM. Fig. 4
sists of 2 PCM tubes. A thermocouple is provided in copper tubes (a) and (b) represents an actual photograph of PCM assembly high-
for temperature measurement of PCM. The PCM used is industrial lighting the water, steam outlets and setup during PCM filling
grade granulated NaNO3 (Sodium Nitrate) having a melting point respectively.
range of 307 °C and water is used as heat transfer fluid. The tem-
perature of the PCM and heat transfer fluid is continuously 4. Results and discussions
recorded.
The PCM is selected on the basis of the temperature of the The performance investigation of a twin-cylinder 4-stroke die-
exhaust, phase change properties, and availability. Here, the spec- sel engine is carried by extracting the heat from the engine exhaust
ifications of selected PCM Sodium Nitrate and that of copper piping gases. The experiments are performed in two sets: without and
are tabulated in Table 3 and Table 4 respectively. with the use of PCM. This is done in order to study the impact of
The copper is selected as the material for tubing/piping in order using PCM as a means of waste heat recovery.
to store PCM; the reason being its higher thermal conductivity and
to enhance the heat transfer coefficient as shown in Table 5. Also, it
4.1. Testing of actual exhaust gas temperature without PCM
can be easily bent and arranged in any preferred shape. Fig. 3(a)
and (b) shows different views and copper pipe arrangement inside
In this case, experiments are conducted without PCM by vary-
the PCM assembly.
ing the net load on the engine from 0 to 14 kg by maintaining a
constant speed of 1500 RPM. The variation of the temperature of
exhaust gases coming out from the engine is recorded.
Fig. 5 and Table 6 show the variation in temperature of exhaust
Table 3
Specifications of the selected Phase Change Material. gas coming out of twin-cylinder 4-stroke diesel engines with
respect to load variations (without using PCM). The fuel consump-
Parameter Specifications
tion and temperature of exhaust gases linearly increase with a cor-
Selected PCM Sodium Nitrate (NaNO3) responding increase in the net load of the engine. When the engine
Melting Point 307 °C
runs at 11 kg load, it rejects 45.1% of energy to the atmosphere.
Specific Heat Capacity 93.05 J/mole-K
Density 2.257 g/cm3 This results in an increase in the concentration of greenhouse
Boiling Point 380 °C gases, which affects the environment and human beings. According
to the analysis of exhaust gas temperature, we choose sodium
nitrate as the PCM having a 305 °C melting point.
Parameter Specifications In this case, Sodium Nitrate is being used as a PCM. The exper-
iments were performed by fixing the net load on the engine as
No. of copper pipes 4 (2 inner & 2 outer)
Inner pipe diameter 32.5 mm 11 kg and a constant speed of 1500 RPM is maintained. The varia-
Outer pipe diameter 47.5 mm tion of temperature of exhaust gases coming out from the engine
Length of every pipe 580 mm with respect to time on part load with the use of PCM is recorded
as shown in Table 7 and Table 8. Accordingly, there causes a signif-
icant change in the temperatures of PCM (temperature reduces)
with time during the discharging process. This heat from PCM is
Table 5 absorbed by water being used as a heat transfer fluid. The highest
Specifications of the selected PCM module box with the water inlet and steam outlet.
steam temperature is found to be 118 °C for PCM and water tem-
Parameter Specifications peratures of 71 °C and, 146 °C respectively.
Length of box 580 mm Fig. 6(a) and Table 7 shows a graph of the charging process of
Height of box 80 mm PCM and the variation in exhaust inlet temperature, exhaust outlet
Breadth of box 300 mm temperature and PCM temperature at a load of 11 kg. It is observed
Hole provided for the water inlet 25 mm
that, with an increment in time, the inlet and outlet exhaust tem-
Maximum temperature of steam coming out 120 °C
peratures increase linearly with a corresponding increase in tem-
Please cite this article as: G. S. Wahile, P. D. Malwe and A. V. Kolhe, Waste heat recovery from exhaust gas of an engine by using a phase change material,
Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.03.247
G.S. Wahile et al. / Materials Today: Proceedings xxx (xxxx) xxx 5
Fig. 3. (a) Photograph of side and top view of copper pipes in PCM assembly; (b) Copper pipe arrangement inside the PCM assembly.
Fig. 4. (a) Photograph of PCM assembly with the water inlet and steam outlet; (b) Photograph of setup during PCM filling.
Please cite this article as: G. S. Wahile, P. D. Malwe and A. V. Kolhe, Waste heat recovery from exhaust gas of an engine by using a phase change material,
Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.03.247
6 G.S. Wahile et al. / Materials Today: Proceedings xxx (xxxx) xxx
Table 6
The variation of temperature of exhaust gas coming out from twin-cylinder 4-stroke diesel engine with respect to varying load.
Sr. No. Net Load (kg) Speed (RPM) Time to consume 20 cc of fuel (s) Temperature of exhaust outlet (°C) Manometric height (cm)
1 0 1500 40 255 8
2 3 1500 31 260 8.1
3 6 1500 29 300 8.2
4 9 1500 27 320 7.8
5 11 1500 21 360 8.5
6 14 1500 18 390 9.2
Table 7
The variation in temperatures of exhaust inlet and outlet and PCM (Sodium Nitrate with time and load of 15 kg).
Sr. No. Time (min) Load (kg) Inlet exhaust temperature T1 (°C) Outlet exhaust temperature T2 (°C) Temperature of PCM (°C) Speed (RPM)
1 10 11 381 365 121 1500
2 20 11 403 384 149 1500
3 30 11 435 403 178 1500
4 40 11 452 415 211 1500
5 50 11 466 424 245 1500
6 60 11 472 429 252 1500
7 70 11 487 435 263 1500
8 80 11 493 441 278 1500
9 90 11 531 452 310 1500
Table 8
The variation in temperatures of water and PCM with time during the discharging process.
Sr. No. Time (min) Temperature of PCM (°C) Water temperature T4 (°C) Steam temperature T5 (°C)
1 3 310 39 –
2 6 265 56 –
3 9 215 72 –
4 12 175 90 –
5 15 145 102 68
6 18 102 126 102
7 21 71 146 118
Fig. 6. (a) The variation in temperature variation of PCM, exhaust inlet and outlet temperature at 11 kg load (engine speed = 1500 rpm) (b) The variation in temperature
variation of PCM and water while discharging process.
The application of the process to generation of steam. The cost The rapid development with relative energy shortage is the
required for the entire process is the cost of the PCM box (thermal motivation for waste heat recovery from exhaust gas using PCM.
storage system), PCM and fuel (diesel) consumed to charge the PCM The proposed system has benefits as well as certain practical chal-
is Rs. 11,120/- which is minimum cost than other processes like a lenges. It can be summarized as:
steam power plant and stem generation by using an electric heater.
Please cite this article as: G. S. Wahile, P. D. Malwe and A. V. Kolhe, Waste heat recovery from exhaust gas of an engine by using a phase change material,
Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.03.247
G.S. Wahile et al. / Materials Today: Proceedings xxx (xxxx) xxx 7
Copper tubes increase the heat transfer rate. PCM is melted in Acknowledgments
minimum time and charging done in minimum time. It takes
90 min to charge the PCM at 11 kg engine load. The authors would like to acknowledge the Mechanical Engi-
The PCM stored thermal energy 5.5% of total energy from the neering Department, K.I.T.S. Ramtek for providing the facility to
exhaust during the charging process. Due to the use of PCM, perform the experimentations in the laboratory. Further, to
there is a decrease in heat rejection to the atmosphere from Vidyavardhini College of Engineering and Technology Vasai road
45.1% to 39.5%. Mumbai and Walchand College of Engineering, Sangli for assisting
The thermal energy from the PCM discharged and is used to to publish this paper. This work didn’t receive any funding assis-
generation of steam which can be used for different applica- tance to carry out research work.
tions. The process of discharging PCM requires 20 min during
which it gives only 1.6% of energy to the water for the genera- References
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Declaration of Competing Interest
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Please cite this article as: G. S. Wahile, P. D. Malwe and A. V. Kolhe, Waste heat recovery from exhaust gas of an engine by using a phase change material,
Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.03.247