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DEVELOPMENT OF AN ATMOSPHERIC COMBUSTOR TEST RIG FOR FIRING ENVODIESEL BLENDS NOOR EMILIA BINTI AHMAD SHAFIE UNIVERSITI TEKNOLOGI MALAYSIA

DEVELOPMENT OF AN ATMOSPHERIC COMBUSTOR TEST …eprints.utm.my/id/eprint/40604/1/NoorEmiliaAhmadShafieMFKM2012.pdfppm bagi gas karbon dioksida, karbon monoksida, oksida nitrogen dan

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DEVELOPMENT OF AN ATMOSPHERIC COMBUSTOR TEST RIG FOR

FIRING ENVODIESEL BLENDS

NOOR EMILIA BINTI AHMAD SHAFIE

UNIVERSITI TEKNOLOGI MALAYSIA

DEVELOPMENT OF AN ATMOSPHERIC COMBUSTOR TEST RIG FOR FIRING

ENVODIESEL BLENDS

NOOR EMILIA BINTI AHMAD SHAFIE

A thesis submitted in fulfillment of the

requirements for the award of the degree of

Master of Engineering (Mechanical)

Faculty of Mechanical Engineering

Universiti Teknologi Malaysia

SEPTEMBER 2012

iii

To my beloved mother, father and husband

iv

ACKNOWLEDGEMENTS

In preparing this thesis, I have been in contact with many people, researchers,

academicians and practitioners. They have contributed towards my understanding

and thoughts. In particular, I wish to express my sincere appreciation to my main

thesis supervisor, Professor Dr. Mohammad Nazri Bin Mohd Jaafar for his

encouragement, guidance, critics and friendship. I am also very thankful to my co-

supervisor Associate Professor Ir. Yahaya Bin Ramli for the guidance, advices and

motivation. Besides that, I would like to express many thanks to MD Interactive

Company, AZMA Global Company and Halira Company for supplying and

fabricating the research equipment. My sincere appreciation also extends to all my

colleagues and others who have provided assistance at various occasions. Their

views and tips are useful indeed. A special thanks to Ministry of Science,

Technology and Innovation (project no: 03-01-06-KHAS01) for financial support of

this research. Lastly I would like to thank my family and husband for the support

towards the completing of my thesis.

v

ABSTRACT

Liquid fuel combustion contributed to air pollution and global warming

problems. Combustion using fossil fuel e.g. petroleum diesel produces high

concentration of emissions such as carbon dioxide (CO2), carbon monoxide (CO),

nitrogen oxide (NOx) and sulphur dioxide (SO2). Palm biodiesel consists of palm

methyl ester and diesel has been used to reduce the emission value. However, the

production of biodiesel is expensive. Therefore, the direct blending method of palm

olein and diesel has been used to produce envodiesel without using the

transesterification process. The properties and characteristics of envodiesel have

been studied in order to determine the fuel performance during combustion. A 500

mm length and 152 mm diameter of combustor has been fabricated using stainless

steel tube for firing the envodiesel blends. Thermocouples type-K are placed axially

along the combustor length to measure the wall temperatures. Besides that, the gas

analyzer probe has been used to measure the emission gas during the testing. An

axial swirler of 45º angle with 8 blades, fuel injector system, electrode copper igniter

system, air blower and super heater are installed in the combustion system to burn

the envodiesel blends. As a result, envodiesel blends with 5% palm olein and 95%

diesel (B5) has higher wall temperature as compared to other blends. The result

shows the various percentages of envodiesel blends decrease the CO2, CO, NOx and

SO2 emission. The B25 has lowest of CO2, CO, NOx and SO2 values of 3%, 492

ppm, 8 ppm and 9 ppm respectively. It can be concluded the envodiesel blends have

lower emissions compared to diesel fuel.

vi

ABSTRAK

Pembakaran bahan api cecair menyumbang kepada masalah pencemaran

udara dan pemanasan global. Pembakaran yang menggunakan bahan api fosil seperti

minyak diesel telah menghasilkan kepekatan emisi yang tinggi seperti karbon

dioksida (CO2), karbon monoksida (CO), oksida nitrogen (NOx) dan sulfur dioksida

(SO2). Minyak sawit biodiesel yang mengandungi metil ester sawit dan diesel telah

digunakan untuk mengurangkan kadar pembebasan gas emisi. Walaubagaimanapun,

kos penghasilan minyak biodiesel adalah tinggi. Oleh itu, kaedah pengadunan

langsung telah digunakan untuk menghasilkan minyak sawit diesel (envodiesel)

tanpa melalui proses tindak balas pentransesteran. Ciri-ciri dan sifat minyak sawit

diesel telah dikaji bagi mengenalpasti potensi minyak ini dalam pembakaran. Kebuk

pembakaran sepanjang 500 mm telah dihasilkan menggunakan tiub keluli tahan karat

berdiameter 152 mm untuk membakar minyak sawit diesel. Pengganding-haba jenis-

K diletakkan secara memaksi di sepanjang kebuk pembakaran untuk merekodkan

suhu dinding. Selain itu, alat pengukuran emisi juga digunakan untuk mengukur

kadar pembebasan gas semasa eksperimen dijalankan. Pemusar udara aliran paksi

dengan sudut 45 darjah dan 8 bilah, muncung semburan bahan api, percikan api jenis

tembaga elektrod, alat pembekal udara dan pemanas udara telah dipasang pada alat

ujikaji pembakaran bagi membakar adunan minyak sawit diesel. Keputusan ujikaji

mendapati adunan 5% minyak sawit dan 95% minyak diesel mempunyai suhu

dinding kebuk pembakaran yang tinggi berbanding adunan minyak sawit diesel yang

lain. Keputusan menunjukkan minyak sawit diesel berbagai adunan telah

mengurangkan kadar pembebasan gas emisi. Minyak sawit diesel (B25)

mengurangkan kadar pembebasan gas emisi sebanyak 3%, 492 ppm, 8 ppm dan 9

ppm bagi gas karbon dioksida, karbon monoksida, oksida nitrogen dan sulfur

dioksida. Kesimpulannya minyak sawit diesel mempunyai kadar pembebasan gas

emisi yang rendah berbanding minyak diesel.

vii

TABLE OF CONTENTS

CHAPTER TITLE PAGE

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENTS iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES x

LIST OF FIGURES xi

LIST OF SYMBOLS xiv

LIST OF ABBREVIATIONS xvi

LIST OF APPENDICES xvii

1 INTRODUCTION

1.1 Introduction 1

1.2 Problem Statements 2

1.3 Objectives 3

1.4 Scopes 3

1.5 Thesis Outline 4

1.5 Flow of Research Methodology 5

viii

2 LITERATURE REVIEW

2.1 Introduction of Fossil Fuel 6

2.2 Introduction of Biodiesel 7

2.3 Introduction of Palm Oil Biodiesel 8

2.3.1 Production of Palm Oil Biodiesel 11

2.3.2 Properties and Characteristics of

Palm Oil Biodiesel 12

2.4 Production and Characteristics of Envodiesel 17

2.5 Introduction of Atmospheric Combustor Test Rig 19

2.6 Burner for Liquid Fuel Combustion 25

2.7 Development of Combustor Test Rig 29

3 EXPERIMENTAL APPARATUS AND RESEARCH

METHODOLOGY

3.1 Introduction 43

3.2 Experimental Apparatus 44

3.3 Combustor Test Rig Design Modification 48

3.3.1 Piping Selection of Combustor Test Rig 55

3.3.2 Air Fuel Ratio for Diesel and Envodiesel

Combustion 60

3.4 Fuel Preparation 66

3.5 Experimental Procedures 69

4 RESULTS AND DISCUSSION

4.1 Introduction 70

4.2 Fuel Pressure 71

4.3 Wall Temperature Profile at Different

Pre-Heated Air 72

4.4 Carbon Dioxide (CO2) Emission at Different

Pre-Heated Air 79

4.5 Carbon Dioxide (CO2) Emission at Different

Equivalent Ratios 80

ix

4.6 Carbon Monoxide (CO) Emission at Different

Pre-Heated Air 81

4.7 Carbon Monoxide (CO) Emission at Different

Equivalent Ratios 82

4.8 Nitrogen Oxide (NOx) Emission at Different

Pre-Heated Air 84

4.9 Nitrogen Oxide (NOx) Emission at Different

Equivalent Ratios 85

4.10 Sulphur Dioxide (SO2) Emission at Different

Pre-Heated Air 86

4.11 Sulphur Dioxide (SO2) Emission at Different

Equivalent Ratios 87

5 CONCLUSION AND RECOMMENDATIONS

5.1 Conclusion 88

5.2 Recommendations 89

REFERENCES 90

Appendices A-I 96-105

x

LIST OF TABLES

TABLE NO. TITLE PAGE

2.1 Vegetable oil production yield kg oil/hectare 9

2.2 Percentage of palm oil use in each sector 10

2.3 Properties of palm oil biodiesel (palm methyl ester) 12

2.4 Comparison of liquid fuel properties 13

2.5 Properties of envodiesel blends and diesel fuel 19

2.6 Sauter mean diameter using the experimental methods 22

2.7 Gas pressure on igniter energy release 24

2.8 Burners for liquid fuel and features 26

2.9 Advantages and disadvantages of developed test rig 41

3.1 Description of gas analyzer sensors 48

3.2 Test rig components and features 51

3.3 Piping dimension for each component test rig 58

3.4 Equivalent ratio of diesel fuel with different air flow rate 63

3.5 Equivalent ratio of diesel fuel with different fuel flow rate 63

3.6 Equivalent ratio of envodiesel blends with different air

flow rate 64

3.7 Equivalent ratio of envodiesel blends with different fuel

flow rate 64

3.8 Specific gravity of envodiesel blends 67

xi

LIST OF FIGURES

FIGURE NO. TITLE PAGE

1.1 Flow of research methodology 5

2.1 Fresh fruit bunches and fruits palm 8

2.2 Production of palm oil plant 9

2.3 Flow of processing palm oil biodiesel 11

2.4 Axial swirler (a) Front view, (b) Side view 20

2.5 Flame length at different swirl number (a) 0.6325, (b) 0.9417 21

2.6 Spray angle using computational fluid dynamic method

(a) Diesel, (b) B5, (c) B10, (d) B15, (e) B20, (f) RBDPO 23

2.7 Wall temperature at different pre-heated air temperature 27

2.8 Emission from combustion of cotton seed oil biodiesel 28

2.9 A schematic of combustion in a furnace with high pre-heated air 29

2.10 A schematic of a lab scale controlled air incinerator combustor 30

2.11 A schematic of furnace test rig 31

2.12 A schematic of combustor test rig using Baltur burner 32

2.13 A schematic of non-pressurized combustion test rig 33

2.14 A schematic of combustion in a boiler test rig 34

2.15 A schematic of pressurized cyclone combustor test rig 35

2.16 A schematic of combustor test rig for boiler sector 37

2.17 A schematic of combustor test rig for furnace sector 39

2.18 A schematic of combustion in a boiler using

pulverization burner 40

3.1 Equipment (a) Blower model ASS-125A, (b) Air regulator 44

xii

3.2 Super heater model BET-060 45

3.3 Thermocouple type-K along combustor 46

3.4 Thermocouple reader (a) Front view, (b) Back view 46

3.5 Telegan gas monitoring, Tempest-100 47

3.6 Schematic of combustor test rig 49

3.7 Combustor test rig 50

3.8 Axial swirler clamps inside combustor 52

3.9 Axial swirler and fuel injector component 52

3.10 Fuel pump system 53

3.11 Ignition system 54

3.12 Pressure losses at different pipe diameter and length 57

3.13 Schematic of experimental setup 59

3.14 Air fuel ratio of diesel and envodiesel blends 65

3.15 Blending machine 66

3.16 Hydrometer 67

3.17 Specific gravity of envodiesel blends 68

4.1 Fuel pressure of diesel and envodiesel blends 71

4.2 Wall temperature profile at 323 K pre-heated air 72

4.3 Wall temperature profile at 373 K pre-heated air 73

4.4 Wall temperature profile at 423 K pre-heated air 74

4.5 Wall temperature profile at 473 K pre-heated air 75

4.6 Wall temperature profile at 523 K pre-heated air 76

4.7 Wall temperature profile at 573 K pre-heated air 78

4.8 CO2 emission at different pre-heated air of equivalent

ratio 0.4 79

4.9 CO2 emission at different equivalent ratios at 573 K of

pre-heated air 80

4.10 CO emission at different pre-heated air of equivalent

ratio 0.4 82

4.11 CO emission at different equivalent ratios at 573 K of

pre-heated air 83

4.12 NOx emission at different pre-heated air of equivalent

ratio 0.4 84

xiii

4.13 NOx emission at different equivalent ratios at 573 K of

pre-heated air 85

4.14 SO2 emission at different pre-heated air of equivalent

ratio 0.4 86

4.15 SO2 emission at different equivalent ratios at 573 K of

pre-heated air 87

xiv

LIST OF SYMBOLS

A - Pipe area

Act - Actual

A/F - Air fuel ratio

Cv - Calorific value

cst - Centistoke

d - Pipe diameter

f - Friction

g - Gravity

hf - Head loss

hr - Hour

J - Joule

K - Kelvin

kg - Kilogram

kV - Kilovolt

kW - Kilowatt

L - Liter

l - Pipe length

MJ - Megajoule

MPa - Megapascal

m - Meter

xv

mm - Milimeter

ṁa - Mass flowrate air

ṁf - Mass flowrate fuel

m3 - Metercube

m3/hr - Metercube per hour

N - Newton

P - Pressure

Pa - Pascal

ppm - Parts per million

Q - Flow rate

Re - Reynold number

Stoic - Stochiometric

s - Second

T - Temperature

V - Voltage

� - Pipe velocity

x/L - Combustor length

µ - Dynamic viscosity

p - Density

∆P - Pressure loss

ε - Roughness of the piping

Ø - Equivalent ratio

% - Percentage

µm - Micrometer

ƩK - Minor friction loss

xvi

LIST OF ABBREVIATIONS

ABBREVIATION FULL NAME

B0 - 100 % Diesel Fuel

B5 - 5 % Palm Olein with 95 % Diesel (Envodiesel)

B10 - 10 % Palm Olein with 90 % Diesel (Envodiesel)

B15 - 15 % Palm Olein with 85 % Diesel (Envodiesel)

B20 - 20 % Palm Olein with 80 % Diesel (Envodiesel)

B25 - 25 % Palm Olein with 75 % Diesel (Envodiesel)

C - Carbon

CO2 - Carbon Dioxide

CO - Carbon Monoxide

H - Hydrogen

HHV - High Heating Value

LHV - Low Heating Value

N - Nitrogen

NOx - Nitrogen Oxide

O - Oxygen

RBDPO - Refined, Bleached, Deadorized Palm Olein

SMD - Sauter Mean Diameter

SO2 - Sulphur Dioxide

xvii

LIST OF APPENDICES

APPENDIX TITLE PAGE

A1 Rear and front clamps of axial swirler 96

A2 Axial swirler with fuel injector 97

B Combustor test rig 98

C Piping flanges for axial swirler test rig 99

D Piping flanges for combustor test rig 100

E Plan layout and system description 101

F Dimension of combustor test rig 102

G Combustor test rig view 103

H Super heater layout 104

I Chemical properties of envodiesel blends 105

1

CHAPTER 1

INTRODUCTION

1.1 Introduction

Petroleum oil and natural gas are fossil fuels that have been used to generate

energy for power plant, transportation, industrial and others. Petroleum oil e.g.

diesel fuel has been used in power plant because of its potential to generate high

power energy [1]. However, the price of fossil fuel is very high due to the demands

usage of this fuel. Combustion of fossil fuel tends to form pollutant gases. Fossil

fuel increases the carbon monoxide, carbon dioxide, sulphur dioxide, nitrogen oxide

and other emissions when burned [2]. Therefore, biodiesel is a promising fuel

because of its ability to reduce emission during combustion. Palm methyl ester is

one of the biodiesels used in combustion that could replace the diesel fuel.

Transesterification is the method used to produce palm methyl ester [3]. However,

the transesterification method is costly. Because of that, direct blending method is

inexpensive method used to mix the vegetable oil with petroleum diesel. The fuel

produced from this method is called envodiesel. In this research, properties and

characteristics of envodiesel are investigated using a combustor test rig device in

order to reduce the emission and also to reduce the cost of fuel production.

2

1.2 Problem Statements

The diesel fuel is usually used in combustion to generate energy for industrial

transportation and others. Diesel fuel could generate high power energy and high

efficiency when burned [4]. Because of its potential to generate energy for every

application, diesel fuel becomes demanded source energy. However the combustion

of diesel fuel contributes to emission gases e.g. carbon monoxide, carbon dioxide,

nitrogen oxide, sulphur dioxide and others. Liberation of these gases has a great

potential of an air pollution, greenhouse effect and global warming in this country. If

the problem persists, the air quality in this country will be more contaminated with

harmful gases and may also cause health problems to human.

In Malaysia, there is million tons of palm oil produced per year for various

kinds of products [5]. Therefore, it has been chosen due to the availability of this oil

for used in combustion application. This fuel known as an envodiesel consists of

palm olein that produced from palm oil. Based on previous study, the envodiesel

blends have lower carbon content which reduced the emission gases during

combustion [6]. Besides that, palm oil is clean and biodegradable [7]. Thus, the

properties and characteristics of envodiesel were studied in order to determine the

fuel performance during combustion. The testing was conducted using the

atmospheric combustor test rig device.

3

1.3 Objectives

The objectives of the research are:

1. To determine the properties (calorific value and ultimate analysis) of

envodiesel blends.

2. To fabricate the atmospheric combustor test rig for firing envodiesel blends.

3. To analyze the behavior of wall temperature and emission at various pre-

heated air in order to identify the performance of envodiesel blends during

combustion.

1.4 Scopes

The scopes of the research are:

1. Preparation of the testing apparatus:

i. Air blower

ii. Super heater

iii. Thermocouple reader and sensor

iv. Gas analyzer

2. Fabricate the atmospheric combustor test rig laboratory scale. The

component of fabrication includes:

i. Air supply system

ii. Combustion chamber

iii. Igniter system

iv. Fuel injector system

v. Axial swirler

4

3. Blending of palm olein and diesel, as producing envodiesel blends using

direct blending in order to determine the properties at different percentages.

4. Testing the envodiesel blends using different pre-heated atmospheric air

temperature.

1.5 Thesis Outline

The thesis is divided into five chapters. Chapter 1 includes the problem

statement, objectives and scopes of this research.

Chapter 2 is the literature study of this research. This study focuses on the

physical and chemical properties of diesel, palm oil biodiesel and envodiesel blends.

The fuel properties are the parameters that affected the combustion characteristics

such as wall temperature profile and emission. Besides that, the standard combustor

test rig and burner system have been studied in order to burn envodiesel blends fuel.

Chapter 3 describes the experimental apparatus, modification of combustor

test rig design, fuel preparation and experimental procedures.

Chapter 4 comprises the combustor wall temperature and emission results

using different envodiesel blends. The wall temperature, carbon dioxide, carbon

monoxide, nitrogen oxide and sulphur dioxide emission results are recorded using

thermocouple reader and gas analyzer during experiments. The testing is carried out

using 5%, 10%, 15%, 20% and 25% of envodiesel blends at various pre-heated air

temperatures.

5

Chapter 5 is the conclusion and recommendations of this research. This

chapter explains the overall results that have been obtained. The effectiveness of

envodiesel is concluded, while the potential of envodiesel in combustion elaborated

based on the wall temperature and emission results that obtained from standard

combustor test rig. Besides that, some recommendations have been explained in

order to improve this research.

1.6 Research Methodology

The flow of research methodology is shown in Figure 1.1.

Figure 1.1: Flow of research methodology

Design and fabrication of combustor test rig

Testing the envodiesel blends using combustor test rig

Preparation of the testing apparatus

Fuel preparation

Result and discussion

90

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