DEPARTMENT OF MECHANICAL

ENGINEERING

Online Internship On
“Intelligent exhaust gas recirculation (iEGR)
technology used in BS VI Vehicle”

Under the guidance of

BHEEMA NAIK L .DME, BE, MTech.
Assistant Professor
 DEPARTMENT OF MECHANICAL
ENGINEERING

Online Internship On
“Advanced technologies used in BS VI Vehicle”

Under the guidance of

BHEEMA NAIK L .DME, BE, MTech.
Assistant Professor
Contents
1.Motor vehicle pollution
2.Sources of pollution
3.Pollution caused by exhaust gas
4.Sources of Nox pollution
5.effects of Nox
6.introduction to BS standards
7.Benefits of BS VI vehicles
8.introduction to IC engine , components, and working
9.Introduction to EGR
10.
Principle of EGR
11.
Working of EGR
12.
Parts of EGR
13.
Introduction to iEGR
14.
EGR in petrol engines
15.
Effects of EGR on engine performance
16.
Introduction to SCR System
17.
EATS( exhaust after treatment system)
18.
Conclusion
19.
Future scope
20.
References
What is motor vehicle pollution?
What is motor vehicle pollution?
 All motor vehicles release pollutants into the air, mostly through
the exhaust fumes that come out of the tailpipe when the engine
operates.

 Did you know that: more than 99.4% of all pollutant gases are
invisible your car releases emissions even when it's standing still
other fumes from petrol and lubricants evaporate into the air.

 Pollutants produced by vehicle exhausts include carbon

monoxide, hydrocarbons, nitrogen oxides, particles, volatile
organic compounds and sulfur dioxide.

 Hydrocarbons and nitrogen oxides react with sunlight and warm

temperatures to form ground-level ozone. Ground-level ozone, a
main ingredient in smog, can cause upper respiratory problems
and lung damage.
What is motor vehicle pollution?
SOURCES OF POLLUTION

Major contributor to air pollution

POLLUTION CAUSED BY EXAHUST GAS
 Major problem faced by today’s world is environmental pollution.

 Of these vehicular traffic is a major contributor .

Exhaust gases from vehicles includes CO,CO 2,HC,NOx

 Of these NOx is particularly very harmful.

 These are one of the chief constituents of smog, which have an

adverse effect on ecological systems.

 They also contribute to the formation of acid rain.

 NOx also cause breathing illness in human beings.

Sources of NOx Pollution
 NOx is produced from the reaction of nitrogen and
oxygen gases in the air during combustion, especially at
high temperatures.

 In areas of high motor vehicle traffic, such as in large

cities, the amount of nitrogen oxides emitted into the
atmosphere as air pollution can be significant.

 NOx gases are formed whenever combustion occurs in

the presence of nitrogen – e.g. in car engines; they are
also produced naturally by lightning.
Effects Nitrogen Oxides 
Long-termexposure:
Short- term exposure.
Long-term exposure to low levels of nitrogen
Irritation of the respiratory system, eyes, and dioxide can cause:
skin
Asthma
Aggravation of respiratory diseases,
Respiratory infections
particularly asthma
Health effects from very high levels of
Coughing and choking
nitrogen oxides can include:
Nausea
Death
Headache
Genetic mutations
Abdominal pain
Harm to a developing fetus
Difficulty breathing
Decreased female fertility
Skin and eye contact with nitrogen oxide
Spasms
gases or liquid nitrogen dioxide can cause
irritation and burns. Swelling of the throat
  Rapid pulse 
Dilated heart
Introduction to BS standards

 Bharat stage Emission Standards are emission

standards or Norms introduced by the Government
of India to regulate air pollutants coming out of
vehicles as a result of Combustion engines and
Spark-ignition engines.

 These standards are set by the Central Pollution

Control Board under the Ministry of Environment
and Climate change.
Introduction to BS standards

 In October 2016, India signed the Conference of Protocol,

also known as the Paris Climate Agreement.

 As per the agreement, in the next 12 years, India will bring

down carbon footprint by 33-55% as compared to 2005.
Thus in 2016, the Indian government announced that the
country would skip the BS-V norms completely and adopt
BS-VI norms by 2020.

 BS6 emission norms bring India at par with European and

U.S. standards of pollution control. 
Introduction to BS standards
BENEFITS OF BS VI

 Technology upgrades have been made for stringent

emission requirement which is ensured with extensive and
rigorous field tests in actual Indian driving conditions

 BS-VI compliant vehicle engine reduces nearly 25%

Nitrogen Oxides (NOx) emissions in petrol vehicles and
substantial 70% on Diesel vehicles

 Upgraded engine with the technological advancement of

Exhaust system ensuring a significant increase in its
durability
 ENGINE
ENGINE SECTION
 ENGINE
ENGINE SECTION
 Main Components of Engine
Cylinder Block Assembly
Cylinder Head Assembly
Piston and connecting rod
Crankshaft.
Oil Pan
Timing Chain Assembly
Fly Wheel
 Main Components of Engine
Cylinder Block Assembly
 Main Components of Engine
Cylinder HEAD Assembly
 Main Components of Engine
PISTON AND

CYLINDER
 Main Components of Engine
Cam shat and timing belt
 Main Components of Engine
Cam shat and timing belt
 Main Components of Engine
fly wheel
 Main Components of Engine
Oil pan
 Main parts of engine
1)Fuel systems
2)Lubrication systems
3)Air intake systems
4)Exhaust systems
5)Cooling systems
6)Electrical systems
 Main parts of engine
1)Fuel systems
 Main parts of engine
2)Lubrication systems
 Main parts of engine
3)Cooling systems
 Main parts of engine
4)Intake and exhaust system
Strokes of Diesel Engine
Working of diesel engine
 TECHNOLOGY USED IN BS VI
VEHICLE

1)EGR SYSTEM
2) SCR SYSTEM
3) HYBRID SYSTEM
 INTRODUCTION TO EGR SYSTEM
Diesel or CI engine
 Suction stroke-
 Piston moves down the cylinder bore from top dead center (TDC)
to bottom dead center (BDC)

 Intake valve is open, the exhaust valve is closed

 Downward piston motion creates a vacuum (negative air pressure)

that draws that air into the engine via the open intake valve
 (Compressed air from turbocharger via inter cooler enters to
engine cylinder through inlet valve)
 INTRODUCTION TO EGR SYSTEM
Diesel or CI engine
 Suction stroke-
 INTRODUCTION TO EGR SYSTEM
Diesel or CI engine
 Turbocharger
 INTRODUCTION TO EGR SYSTEM
Diesel or CI engine
 Turbocharger
Increased mechanical power
Overall efficiency
Improvement of the combustion process.
The engine size can be reduced
Improved fuel economy.
 INTRODUCTION TO EGR SYSTEM
Diesel or CI engine
 Inter cooler
 INTRODUCTION TO EGR SYSTEM
Diesel or CI engine

Importance of inter cooler

 excessive hot air ( miss fire)

 Improper combustion
 Damage to engine parts

 Decrease in density of air

 Decrease in volumetric efficiency

 INTRODUCTION TO EGR SYSTEM
 Compression stroke-
 Piston moves up the cylinder bore from bottom dead
center to top dead center
 Both the intake and exhaust valves are closed
 Upward piston motion compresses air/fuel mixture in
the combustion chamber 
 The pre compressed air is once again compressed inside
engine cylinder
 INTRODUCTION TO EGR SYSTEM
 Power stroke-
 At the end of the compression fuel injected in the form
of thin spray.
 Thin spray of diesel leads to auto ignition and burning
will starts
 This ignition/explosion forces the piston back down the
cylinder bore and rotates the crankshaft, propelling the
vehicle forward.
 Piston moves down the cylinder bore from top dead
center to bottom dead center
 Both the intake and exhaust valve are closed
 INTRODUCTION TO EGR SYSTEM
 Power stroke-

All of oxygen will burns at full load condition , the fuel injection
is sufficient to burn all oxygen atoms
 INTRODUCTION TO EGR SYSTEM
Power stroke-

In partial load condition fuel injection is less but oxygen is more

All oxygen are not utilized and remains in the cylinder
 INTRODUCTION TO EGR SYSTEM
Power stroke-

As the temperature is high inside the engine cylinder these atoms

react with the nitrogen present inside cylinder
 INTRODUCTION TO EGR SYSTEM
Power stroke-

As the temperature is high inside the engine cylinder these atoms

react with the nitrogen present inside cylinder, and forms
nitrogen dioxide
 INTRODUCTION TO EGR SYSTEM
Power stroke-

As the temperature is high inside the engine cylinder these atoms

react with the nitrogen present inside cylinder, and forms
nitrogen dioxide
 INTRODUCTION TO EGR SYSTEM
Power stroke-

By supplying less amount of air inside the cylinder it is not

possible to lead combustion process
 INTRODUCTION TO EGR SYSTEM
Power stroke-

Stopping the entry of nitrogen is also impossible

 INTRODUCTION TO EGR SYSTEM
 Principle of EGR
 INTRODUCTION TO EGR SYSTEM
 Principle of EGR
 INTRODUCTION TO EGR SYSTEM
 Principle of EGR
 INTRODUCTION TO EGR SYSTEM
 Principle of EGR
 INTRODUCTION TO EGR SYSTEM
 Working of EGR
 INTRODUCTION TO EGR SYSTEM
 Working of EGR on EGR system
 Exhaust Gas Recirculation is an efficient method to
reduce NOx emissions from the engine.
 It works by recirculating a quantity of exhaust gas back to
the engine cylinders.
 Intermixing the recirculated gas with incoming air
reduces the amount of available O2 to the combustion
And lowers the peak temperature of combustion.
 Recirculation is usually achieved by piping a route from
the exhaust manifold to the intake manifold.
 A control valve within the circuit regulates and times the
gas flow
 INTRODUCTION TO EGR
SYSTEM
 Parts of EGR
Most of the EGR system contains at least an:

1. EGR valve
2. EGR cooler (optional)
3. EGR cooler bypass (optional)
4. intake throttle valve
 INTRODUCTION TO EGR SYSTEM
1. EGR valve
 INTRODUCTION TO EGR SYSTEM
 EGR valve
 actual valve, which by opening/closing varies the gas
flow area
 actuator (electric), which provides the necessary force to
open/close the valve
 valve body, which holds the valve, the actuator, as well
as the return spring and other mechanical components
 position sensor, which transmits to the engine control
module the position of the valve
 case, which contains the position sensor and electrical
connections
 INTRODUCTION TO EGR SYSTEM
 EGR cooler
 INTRODUCTION TO EGR SYSTEM
 EGR cooler
 The  EGR cooler (radiator) lowers the temperature of
the exhaust gas before it is introduced into the air charge
stream.

 The lower the temperature, the higher the density, the

better the efficiency in reducing the NOx emissions.

 Cooling the exhaust gas prior to mixing with the intake

air lowers the combustion temperatures and increases the
oxygen mass.
 INTRODUCTION TO EGR SYSTEM
 EGR cooler bypass
 INTRODUCTION TO EGR SYSTEM
 EGR cooler bypass

 The  EGR cooler (radiator) lowers the temperature of

the exhaust gas before it is introduced into the air charge
stream.
 The lower the temperature, the higher the density, the
better the efficiency in reducing the NOx emissions.

 Cooling the exhaust gas prior to mixing with the intake

air lowers the combustion temperatures and increases the
oxygen to fuel ratio.
 INTRODUCTION TO EGR SYSTEM
 EGR throttle valve
Throttle valve is used in the intake

manifold operation.
Varying the throttle position (TP)

controls the
amount of exhaust
inside the engine,
 INTRODUCTION TO EGR SYSTEM
Advantages of EGR
 Reduce Nox
 Reduce knocking

 Reduce ignition lag

 Reduce misfire

 Helps in controlled combustion

 INTRODUCTION TO EGR SYSTEM
EATS (EXHAUST AFTER TREATEMENT SYSTEM)
1.DOC(Diesel oxidation catalyst)
2.DPF(Diesel particulate filter)

3.POC (Particle Oxidation Catalysts)

 INTRODUCTION TO EGR SYSTEM
How to decrease particle emissions?
Diesel oxidation catalyst (DOC)

Effective reduction of HC and CO

Some reduction of PM (reduction of VOF)
Typical PM reduction 10-30%
 INTRODUCTION TO EGR SYSTEM
Working of DOC (DIESEL OXIDATION CATALYST)
 INTRODUCTION TO EGR SYSTEM
Working of DOC (DIESEL OXIDATION CATALYST)
 Modern catalytic converters consist of a monolith honeycomb
substrate coated with platinum group metal catalyst, packaged in a
stainless steel container.

 The honeycomb structure with many small parallel channels

presents a high catalytic contact area to exhaust gasses.

 As the hot gases contact the catalyst, several exhaust pollutants are
converted into harmless substances: carbon dioxide and water.
 INTRODUCTION TO EGR SYSTEM
 The diesel oxidation catalyst is designed to oxidize carbon
monoxide, gas phase hydrocarbons, and the SOF fraction of diesel
particulate matter to CO2 and H2O:

 Diesel exhaust contains sufficient amounts of oxygen, necessary for

the above reactions. The concentration of O2 in the exhaust gases
from diesel engine varies between 3 and 17%, depending on the
engine load.

 The catalyst activity increases with temperature. A minimum

exhaust temperature of about 200°C is necessary for the catalyst to
"light off". At elevated temperatures, conversions depend on the
catalyst size and design and can be higher than 90%.
 INTRODUCTION TO EGR SYSTEM
Diesel Particulate Filters (DPFs)

 Diesel particulate filters (DPF) are devices that physically capture

diesel particulates to prevent their release to the atmosphere.

 Diesel particulate filter materials have been developed that show

impressive filtration efficiencies, in excess of 90%, as well as good
mechanical and thermal durability.

 Diesel particulate filters have become the most effective technology

for the control of diesel particulate emissions—including particle
mass and numbers—with high efficiencies.
 INTRODUCTION TO EGR SYSTEM
 Diesel Particulate Filters (DPFs) are one of the major additions to
exhaust systems in recent years.

 DPFs are designed to clean exhaust and eliminate soot, carbon, and
that characteristic diesel smell.
 INTRODUCTION TO EGR SYSTEM
Diesel particulate filter (DPF)
 Effective reduction of PM (soot)

 Typical PM reduction 80-95%

 Regeneration of filter needed (to avoid back pressure increase,
blocking risk)
 INTRODUCTION TO EGR SYSTEM
Diesel particulate filter (DPF)
 Effective reduction of PM (soot)

 Typical PM reduction 80-95%

 Regeneration of filter needed (to avoid back pressure increase,
blocking risk)
 INTRODUCTION TO EGR SYSTEM
Diesel particulate filter (DPF)
 The  process of cleaning and emptying a Diesel Particulate
Filter is called DPF regeneration.

 The soot created by the process of combustion which is collected in

the filter is burnt off to make sure that the filter does not become
blocked and that it can carry on trapping more soot
 INTRODUCTION TO EGR SYSTEM
Diesel particulate filter (DPF)
Passive Regeneration

When you drive for a long time at high speeds, the exhaust reaches

very high temperatures. Driving at 70mph or above for a while will
heat the exhaust enough to burn off the soot particles which have been
trapped by the DPF. But most drivers to not drive at high speeds often
enough or for enough time to rely on this passive regeneration to clear
the DPF of soot particles.
 INTRODUCTION TO EGR SYSTEM
Diesel particulate filter (DPF)
Active Regeneration
Since many drivers do not use their cars to drive long distances on the
motorway on a regular basis, manufacturers had to come up with a
different way to clear the DPF of particles. They came up with a
system in which active regeneration is activated when the amount of
soot gathered in the DPF reaches a certain level. In most cars, this level
is set at 45% of the DPF’s total capacity. When the soot gathered
reaches this amount, it triggers the process of post combustion fuel
injection which increases the temperature of the exhaust. This way,
even if the car is not travelling at high speed, the exhaust becomes hot
enough to burn off all of the soot which has collected in the DPF.
 INTRODUCTION TO EGR SYSTEM
Particle oxidation catalysts (POC)

Particle oxidation catalysts (POC) are devices that can capture and

store carbonaceous PM material for a period of time sufficient for its
catalytic oxidation, while having open flow-through passages that
allow exhaust gases to flow, even if the PM holding capacity is saturate
 INTRODUCTION TO EGR SYSTEM
EGR in petrol engines

 External Exhaust Gas Recirculation (EGR) has been used on diesel

engines for decades and has also been used on gasoline engines in
the past.

 It is recently reintroduced on gasoline engines to improve fuel

economy at mid and high engine load conditions, where EGR can
reduce throttling losses and fuel enrichment.
 INTRODUCTION TO EGR SYSTEM
EGR in petrol engines
Working of carburetor
 Working of carburetor
 Simple Carburetor work on the Bernoulli's principle.

 During the suction stroke, air is drawn into the cylinder through
venturi (also known as choke tube).

 Venturi tube is designed in such a way that it offers minimum

resistance to the air flow. When air passes through the venturi the
velocity of air increases and the pressure decreases
 Working of carburetor
 At venturi throat the velocity of air reach maximum and the
pressure reach minimum. There will be a pressure difference
between the float chamber and venturi throat.

 Because of this pressure difference fuel is discharged to air stream

through fuel discharge nozzle.

 The amount of fuel discharged depend upon the size of fuel

discharge nozzle/ fuel discharge jet.
EGR in petrol engines
 Methods of EGR
Low pressure EGR
 Methods of EGR
High pressure EGR
 Effects of EGR on engine performance
Effects of EGR on Engine Parts:
Effects on engine head
.
 Effects of EGR on engine performance
Effects of EGR on Engine Parts:
Effects on piston

.
 Effects of EGR on engine performance
Effects of EGR on Engine Parts:
Effects on atomizer

.
 Effects of EGR on engine performance
Effects of EGR on Engine Parts:
The effects of EGR system on the engine parts are shown in the
various pictures.

It can be clearly seen that carbon deposits on the various parts of the
engine operated with EGR system is significantly more than that of
engine operated without EGR.

The higher carbon deposits in the EGR system seem to be because of

higher soot formation.
 Effects of EGR on engine performance
Effects of EGR on SFC and BMEP
 Effects of EGR on engine performance
Effects of EGR on BTE and BMEP
 Effects of EGR on engine performance
Effects of EGR on EGT and BMEP
 Effects of EGR on engine performance
Effects of EGR on VE and BMEP
 Effects of EGR on engine performance
Effects of EGR on BP and BMEP
 EGR analysis
Advantage of vehicle
without EGR system:-
 Low cost of the vehicle
 or engine.
 No complicated design of
 the engine.
 No more cooling required.
 No more space required.
 Small radiator size.
Disadvantage of vehicle without
EGR system:-
 Formation of toxic gases.
 Air pollution and harmful
for human.
 Waste of fuel of the engine.
 Thermal efficiency decrease of
the engine.
 Obtained less power
 EGR analysis
Advantage of vehicle with
EGR system:-
 No formation of toxic gases.
 Control on air pollution.
 Reduce NOx level.
 Complete combustion of fuel.
 Fuel consumption improves.
 Increase the efficiency of
engine.
 Obtain high power.
Disadvantage of vehicle with EGR
system:-
 High cost of the engine.
 Complicated design of engine.
 More cooling required.
 More space required.
 15-20% bigger radiator size
required.
SCR (Selective Catalytic Reduction)
 SCR (Selective Catalytic Reduction)
SCR has been used for decades to reduce stationary source emissions.

In addition, marine vessels worldwide have been equipped with SCR

technology, including cargo vessels, ferries and tugboats.

With its superior return in both economic and environmental benefits,

SCR is also being recognized as the emissions control technology
particularly helpful in meeting the emission standards.

In the case of selective catalytic reduction, a catalytic converter

converts the nitrogen oxides contained in the exhaust gas into water
vapor and nitrogen.
 SCR (Selective Catalytic Reduction)
For this purpose, a reducing agent is continually injected into the
exhaust gas flow using a metering module. In the exhaust gas flow, the
fluid reacts within a fraction of a second to produce ammonia (NH3).
This chemical compound then converts the nitrogen oxides in the SCR
catalytic converter.
SCR (Selective Catalytic Reduction)
 Conclusion
There are several examples of companies which are uses the
turbocharged EGR system for heavy and also light vehicles.
These companies are following:

 Ashok Leyland for heavy and light vehicles.

 Tata Motors also for heavy and light vehicles.

 All the light vehicles companies like Hyundai, Mahindra, Honda,

and Toyota etc.
 Conclusion
The following major findings from using the EGR system with
turbocharged engine:

 Increasing the thermal efficiency of the engine when EGR system is

used in the modern vehicles.

 Improvements in the fuel economy and also control the emissions

using EGR system.

 Using the EGR system with turbocharged engine NOx production

reduced in the cylinder of the engine
 FUTURE SCOPE
Today automobiles companies are use the pollution control
technologies in the engine for the human health.

In the modern vehicles to control the emissions EGR system is used

and also for better efficiency of the engine turbocharging technique is
implemented.

So today in the modern vehicles turbocharged EGR system is used.

Some automobile industries are used the advanced technologies for

increase the efficiency of the engine and also for the reduction of
pollutants created by the engine.
 FUTURE SCOPE
Low pressure EGR
 FUTURE SCOPE
High pressure EGR
 Future scope
Advance turbocharging, electric turbocharging and turbocharged EGR
system with catalytic convertor are the advanced technologies.
Advanced engine control technologies
 Advanced TWC (three way catalyst)
 Ammonia slip catalyst
 Advanced Air/Fuel ratio control
 Port fuel injection
 Advanced injection timing
According to the Volkswagen Company diesel engines are the only
engine which pollutes the environment widely. So Volkswagen moving
away from diesel engine and for clean environment Volkswagen
develops the electric and hybrid cars.
.

Thank you