Performance and Emission Analysis of a Diesel Engine Retrofitted with a Gunmetal-Based Porous Medium in the Cylinder Head
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Abstract
Diesel engines, despite their efficiency and durability, are major contributors to environmental pollution due to the emission of nitrogen oxides (NOₓ), carbon dioxide (CO₂), sulfur dioxide (SO₂), and particulate matter. Conventional emission control systems such as diesel particulate filters (DPFs) and catalytic converters are effective but costly and challenging to retrofit in existing engine platforms. This study aims to enhance combustion uniformity and reduce harmful emissions in a diesel engine by retrofitting a thermally conductive gunmetal porous medium (PM) into the cylinder head. A rectangular gunmetal porous insert (35 mm × 16 mm × 3 mm) was installed 6 mm ahead of the injector in a Kirloskar 5BHP single-cylinder, water-cooled, direct injection diesel engine. Experiments were conducted under varying load conditions (0–10 kg) using diesel fuel. Key performance metrics such as Brake Thermal Efficiency (BTE), Specific Fuel Consumption (SFC), Indicated Thermal Efficiency (ITE), and Mechanical Efficiency (ME) were recorded, along with NOₓ, CO₂, and SO₂ emission levels using a calibrated flue gas analyzer. The PM-integrated engine demonstrated an increase in BTE and ME across all load points. Notably, NOₓ emissions were reduced by up to 30%, while SFC showed an average decrease of 12%. CO₂ and SO₂ emissions also exhibited a downward trend, confirming improved combustion efficiency. The integration of a gunmetal porous medium offers a practical, scalable solution to improve diesel engine efficiency and reduce emissions. Its ease of retrofitting and compatibility with conventional engines makes it a promising approach for sustainable diesel applications.
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