AIR ENGINE

A SEMINAR REPORT

submitted to

MALAVIYA NATIONAL INSTITUTE OF TECHNOLOGY JAIPUR

by

VIJENDRA JAIN

in partial fulfillment for the award of the degree

of

BACHELOR OF TECHNOLOGY

in

MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

MALAVIYA NATIONAL INSTITUTE OF TECHNOLOGY
JAIPUR
J L N MARG, 302017,
RAJASTHAN, INDIA.

JULY 2014
 ACKNOWLEDGEMENT

I would like to extend a warm and grateful acknowledgment to Prof. G. Agrawal,

Prof. Rakesh Jain and Dr. Gunjan Soni for their invaluable comments, editorial help,

and overall support in the completion of this seminar. I also thank my colleagues at

the Institute who contributed in the production of this seminar, either through

pointing us in the right direction for the more technical aspects of the analysis, or by

way of general discussion.

 ABSTRACT

In the present energy scenario the fossil fuel sources are fast depleting and their

combustion products are causing global environmental problems. There are couples

of option of alternative fuel such as solar power, tidal power, geo-thermal power,

etc. and one of them is Compressed Air. Compressed Air Powered Engine is an

alternative technology which uses compressed air to run the engine and thus

eliminates the use of fossil fuels. Exhaust temperature of it will be slightly less than

atmospheric temperature (i.e. 20-25°C) and thus helps in controlling global warming

and reducing temperature rise caused due to other means.

Air Engine can be used to produce power to run automobile, generators

etc. This paper review contains study of a compressed air engine. This engine does

not require any of the fossil fuels like petrol, diesel, CNG, hydrogen etc. to run

engine and no power is required to start the engine, only, compressed air valve is to

be opened. It is pollution free and 100% eco-friendly.

 CONTENTS

Title Page

ACKNOWLEDGEMENTS ...................................................................................... i
ABSTRACT ............................................................................................................. ii
LIST OF TABLES .................................................................................................. iii
LIST OF FIGURES .................................................................................................iv
ABBREVIATIONS ...................................................................................................v
NOMENCLATURE ................................................................................................vi

CHAPTER 1 INTRODUCTION

1.1 Flow Through Inlet Manifold ........................................................................3

1.2 Simulation Using Computational Fluid Dynamics .........................................5

CHAPTER 2 LITERATURE SURVEY

2.1 Introduction ..................................................................................................8

2.2 Diesel Engine Flow Modeling .......................................................................9
2.2.1 Effect on Engine Configurations .....................................................................9
2.3 Diesel Combustion Model ...........................................................................25
...........................................................................................................................................
……………………………………………………………………………………………
……………………………………………………………………………………………
REFERENCE .........................................................................................................50
LIST OF PUBLICATIONS ....................................................................................55
 LIST OF FIGURES

Figure Title Page

4.1 Layout of Air Engine .......................................................................................9

4.2 Complete cycle of a two stroke air engine ........................................................12

6.1 A conventional SI Engine ................................................................................15

6.2 The Air Powered Engine ....................................................................................16

 ABBREVIATIONS

TDC Top Dead Center

BDC Bottom Dead Center

IC Internal Combustion

SI Spark Ignition
 CHAPTER 1

INTRODUCTION AND OVERVIEW

1.1 Introduction

Fossil fuels (i.e., petroleum, diesel, natural gas and coal) which meet most of the world's energy

demand today are being depleted rapidly. Also, their combustion products are causing global

problems, such as the greenhouse effect, ozone layer depletion acid rains and pollution which are

posing great danger for environment and eventually for the total life on planet. These factors are

leading automobile manufactures to develop cars fueled by alternatives energies. Hybrid cars, Fuel

cell powered cars, Hydrogen fueled cars will be soon in the market as a result of it. One possible

alternative is the air powered car. Air, which is abundantly available and is free from pollution,

can be compressed to higher pressure at a very low cost, is one of the prime option since

atmospheric pollution can be permanently eradicated. Compressed air utilization in the pneumatic

application has been long proven. Air motors, pneumatic actuators and others various such

pneumatic equipment are in use. Compressed air was also used in some of vehicle for boosting the

initial torque. Turbo charging has become one of the popular techniques to enhance power and

improve the efficiencies of the automotive engine that completely runs on compressed air.
 CHAPTER 2
FOSSIL FUELS: A BLACK PAST

2.1 Scarcity of Fossil Fuels

Fossil fuels, as the name suggests, are very old. Although humans probably used fossil fuels in

ancient times, as far back as the Iron Age, it was the Industrial Revolution that led to their wide-

scale extraction. About 100 years ago, the major source of energy shifted from recent solar to

fossil fuel (hydrocarbons). Technology has generally led to a greater use of hydrocarbon fuels,

making civilization vulnerable to decreases in supply. The current study made in the year 2004,

predicts that if the oil is consumed at the current rates, then by 2020, we will be consuming 80%

of the entire available resource.

Latest studies and projections available indicate that the crises of fossil fuel in near future is

inevitable and alternative to fossil fuel must be looked for. Some of the studies made in this

regard are detailed ahead.

1. When the wells run dry, We use more oil than we find, and if producers are fixing their

figures the end could be closer than thought, by Adam Porter, The Guardian [2005 May

25]

"Predicting the end of the age of oil can be a sticky business. The Association for the Study

of Peak Oil and Gas (Aspo), a collection of industry figures, politicians and academics, this

week held its annual meeting at the Gulbenkian Museum in Lisbon..."

2. Peaking of World Oil Production: Impacts, Mitigation, & Risk Management, by Robert L.

Hirsch, SAIC, Roger Bezdek, MISI, Robert Wendling, MISI for the National Energy

Technology Laboratory of the US Department of Energy [2005 February]

 "The peaking of world oil production presents the U.S. and the world with an

unprecedented risk management problem. As peaking is approached, liquid fuel prices and

price volatility will increase dramatically, and, without timely mitigation, the economic,

social, and political costs will be unprecedented. Viable mitigation options exist on both

the supply and demand sides, but to have substantial impact, they must be initiated more

than a decade in advance of peaking."

3. Expert says Saudi oil may have peaked, by Adam Porter [2005 February 22] : "As oil prices

remain above $45 a barrel, a major market mover has cast a worrying future prediction.

Energy investment banker Matthew Simmons, of Simmons & Co International, has been

outspoken in his warnings about peak oil before. His new statement is his strongest yet,

'we may have already passed peak oil."

4. U.S. Energy Policy: A Declaration of Interdependence, by David J. O'Reilly Chairman and

CEO, ChevronTexaco Corporation [2005 February 15] "Simply put, the era of easy access

to energy is over. In part, this is because we are experiencing the convergence of geological

difficulty with geopolitical instability... We are seeing the beginnings of a bidding war for

Mideast supplies between East and West."

5. New Oil Projects Cannot Meet World Needs This Decade, by Oil Depletion Analysis

Centre [2004 November 16] "World oil supplies are all but certain to remain tight through

the rest of this decade, unless there is a precipitous drop in demand, according to the results

of a study by the London-based Oil Depletion Analysis Centre (ODAC). "The study found

that all of the major new oil-recovery projects scheduled to come on stream over the next

six years are unlikely to boost supplies enough to meet the world’s growing needs."
2.2 Influence of Fossil Fuel on Environment

It is observed that with increasing pace of civilization, uses of transport have become essential part

of life and increasing in geometrical progression. This is leading to very hazardous condition due

to high rate of pollution. Many of the environmental problems our generation faces today result

from our fossil fuel dependence. These impacts include global warming, air quality deterioration,

oil spills, and acid rain.

Emissions from an individual car are generally low, relative to the smokestack image many people

associate with air pollution. But in numerous cities across the country, the personal automobile is

the single greatest polluter, as emissions from millions of vehicles on the road add up. Driving a

private car is probably a typical citizen’s most “polluting” daily activity. Gasoline and diesel fuels

are mixtures of hydrocarbons, compounds which contain hydrogen and carbon atoms. In a

“perfect” engine, oxygen in the air would convert all the hydrogen in the fuel to water and all the

carbon in the fuel to carbon dioxide. Nitrogen in the air would remain unaffected. In reality, the

combustion process cannot be “perfect,” and automotive engines emit several types of pollutions

like CO, NOx, SO2, Volatile Organic Compounds,O3 etc.

2.3 Influence of Fossil Fuel on Economy

Oil, the master energy resource, is the driver of economic growth. But our financial system is wired

for economic growth. This is the challenge. It is structural change that is needed. Over the last 150

years relatively cheap oil has enabled economic growth to happen. It has transformed agricultural

methods, enabled world population to grow, and powered transport. So now, not only are we

required to adapt to life with less oil, but the very enabler of economic growth - is becoming more

and more unaffordable.

Our economy may well recover somewhat, but that recovery will lead to increased oil use, which

leads to increased prices, which will lead to another economic contraction. And this cycle will

repeat – with each subsequent recovery being weaker than the last. So no amount of optimism or

wishful thinking can bring back economic growth. Future economic growth will be impeded by

the depletion of critical, natural resources, the increased costs of extraction and its associated

negative environmental impacts, and ever mounting debt. This is not a temporary phenomenon, it

is the start of a long series of cyclical recessions, and it signifies the end of growth. It is a great

disruption to our normal patterns.

2.4 Search for an Alternative Fuel

Many research works are being carried out to find the alternative to fossil fuel. Alternative fuels,

known as non-conventional or advanced fuels, are any materials or substances that can be used as

fuels, other than conventional fuels. Conventional fuels include: fossil fuels (petroleum (oil), coal,

and natural gas). Some well-known alternative fuels include biodiesel, bioalcohol (methanol,

ethanol, butanol), chemically stored electricity (batteries and fuel cells), hydrogen, non-fossil

methane, non-fossil natural gas, vegetable oil, propane, and other biomass sources. Compressed

Air is one of the important and freely available alternative fuel.

2.5 Fossil Fuel: Context to India

India is developing country. Still per capita income of average person is very low to meet out the

minimum requirement of person. Maximum population of country is still living in villages. There

transport is still either bi-cycle or Motor Bike. Current hike of fossil fuel is going tremendously

high up to 30-40 % every year. With this pace up to 2010 prices may go double than what is today
and by 2030-40, it may fetch to Rs.1000 per litre. A time will come when common person would

not be able to purchase fuel to even run the Motor-Bike. It is not only due to rate of increase of

vehicles in India. It is worldwide problem that 80 % of fossil fuel is being consumed in transport

with increasing mobility of persons to day and daily consumable materials are being transported

through Road Transport. Thus it is need of day to explore possibility of alternative for fossil fuel

to make environment free from emission & make children healthy.

With high rate of consumption of fossil fuel it also necessary to make sustainable energy or in

other words of our Hon. PRESIDENT of INDIA Dr. APJ Abdul Kalam make INDIA energy

freedom by 2030, which he has spoken in his speech on the eve of 14th Aug.’2005 of Independence

day. So we need a focus on Alternative Fuel Research.

 CHAPTER 3

COMPRESSED AIR: A GREEN FUTURE

3.1 Compressed Air

Compressed air is a gas, or a combination of gases, that has been put under greater pressure than

the air in the general environment. Current applications using compressed air are numerous and

diverse, including jackhammers, tire pumps, air rifles, and aerosol cheese. According to

proponents, compressed air also has a great deal of potential as a clean, inexpensive, and infinitely

renewable energy source. Its use is currently being explored as an alternative to fossil fuels.

3.2 Basic Principle: Thermodynamic Analysis

Compressed air is clean, safe, simple and efficient. There are no dangerous exhaust fumes of or

other harmful by products when compressed air is used as a utility. It is a non-combustible, non-

polluting utility. When air at atmospheric pressure is mechanically compressed by a compressor,

the transformation of air at 1 bar (atmospheric pressure) into air at higher pressure (up to 414 bar)

is determined by the laws of thermodynamics. They state that an increase in pressure equals a rise

in heat and compressing air creates a proportional increase in heat. Boyle's law explains that if a

volume of a gas (air) halves during compression, then the pressure is doubled.

Charles' law states that the volume of a gas changes in direct proportion to the temperature. These

laws explain that pressure, volume and temperature are proportional; change one variable and one

or two of the others will also change, according to this equation:

(P1 V1) / T1 = (P2 V2)/T2

Compressed air is normally used in pressure ranges from 1 bar to 414 bar (14 to 6004 PSI) at

various flow rates from as little as 0.1 m (3.5 CFM - cubic feet per minute) and up.

3.3 Availability

Air is natural source and available freely in atmosphere, which can be stored after compressing it

to desired pressure. This is the only source which can be stored at very high pressure and can be

retained without any loss after lapse of passage of time, which can drive so many domestic

appliances such as vacuum cleaner, mixy and pumps, running Power generator when electric

power is off instead of using inverter to have clumsy arrangements of battery etc.

3.4 Compressed Air to Fuel a Car

It is hard to believe that compressed air can be used to drive vehicles. However that is true, and

the “air car”, as it is popularly known, has caught the attention of researchers worldwide. It has

zero emissions and is ideal for city driving conditions. MDI is one company that holds the

international patents for the compressed air car.

A proved fact: “Research by MDI shows that an Air Powered Car can travel 171 km by using

electricity costing about Rs. 80-100 which would cost about Rs. 570 for a normal S.I. engine car

giving an average of 15 kmpl.”

 CHAPTER 4

COMPRESSED AIR ENGINE

4.1 Construction

The construction of compressed air engine mainly consist of pneumatic cylinder, pneumatic

solenoid valve, compressor and crank shaft.

A typical layout of an Air engine is as shown in figure 4.1.

Figure 4.1 A layout of Air Engine

The main components of the Compressed Air Engine are as follows-

4.1.1 Pneumatic Cylinder

Pneumatic cylinders are mechanical devices which produce force, often in combination with

movement, and are powered by compressed gas. To perform their function, pneumatic cylinders

impart a force by converting the potential energy of compressed gas into kinetic energy. This is

achieved by the compressed gas being able to expand, without external energy input, which itself

occurs due to the pressure gradient established by the compressed gas being at a greater pressure

than the atmospheric pressure. This air expansion forces a piston to move in the desired direction.

Once actuated, compressed air enters into the tube at one end of the piston and, hence, imparts

force on the piston. Consequently, the piston becomes displaced by the compressed air expanding

in an attempt to reach atmospheric pressure.

4.1.2 Pneumatic solenoid valve and working

The term solenoid usually refers to a coil used to create magnetic fields when wrapped around a

magnetic object or core. In engineering terms, the solenoid describes transducer mechanisms used

to convert energy into motion. Solenoid valves are controlled by the action of the solenoid and

typically control the flow of water or air as a switch. If the solenoid is active (current is applied),

it opens the valve. If the solenoid is inactive (current does not exist), the valve stays closed. The

action of the pneumatic solenoid is controlled by the use of pneumatics. The opening or closing of

a valve is referred to as "changing state."

4.1.3 Compressor

A gas compressor is a mechanical device that increases the pressure of a gas by reducing its

volume. Compressors are similar to pumps: both increase the pressure on a fluid and both can
transport the fluid through a pipe. As gases are compressible, the compressor also reduces the

volume of a gas.

Compressed air Piston range operates between 0.75 kW to 420 kW (1hp to 563 hp) producing

working pressure at 1.5 bar to 414 bar (21 to 6004psi). Compressed air Vane compressors operate

between 1.1 kW to 75 kW (1.5 to 100hp), producing working pressures of 7 to 8 and 10 bar (101

to 145psi).

4.1.3 Crank shaft

The crankshaft translates reciprocating linear piston motion into rotation. To convert the

reciprocating motion into rotation, the crankshaft has "crank throws" or "crankpins", additional

bearing surfaces whose axis is offset from that of the crank, to which the "big ends" of the

connecting rods from each cylinder attach.

4.2 Working of Air Engine

A compressed-air vehicle is powered by an air engine, using compressed air, which is stored in a

tank. Instead of mixing fuel with air and burning it in the engine to drive pistons with hot expanding

gases, compressed air vehicles use the expansion of compressed air to drive their pistons. The

complete cycle of a two-stroke air engine is as shown in figure 4.2.

When the piston is at the top position (Fig. 4.2a) its spindle opens the ball valve, the compressed

air fills the space of cylinder. The air exerts pressure on surface of the piston, causing its

movement down and rotate the crankshaft (Fig. 4.2b). The valve closes when piston is moving

down, but the air is still expanding and exerts a force on the piston. In the lower turning point

(Fig. 4.2c) piston is opening outlet window and releasing air outside. Exhaust temperature of it
will be slightly less than atmospheric temperature (i.e. 20-25°C) and thus helps in controlling

global warming and reducing temperature rise caused due to other means.

The shaft is starting to move by inertia (Fig. 4.2d) then pushes the piston to the top and closing

the off window. In the cylinder are small amounts of air, so the piston moves upwards until it

will again open the ball valve and the cycle repeats.

Figure 4.2 Complete cycle of a two stroke air engine

 CHAPTER 5

ADVANTAGES OF COMPRESSED AIR ENGINE

5.1 Technical Benefits

Air Powered Engine is an alternative technology which uses compressed air to run the engine and thus

eliminates the use of fossil fuels. Exhaust temperature of it will be slightly less than atmospheric

temperature (i.e. 20-25°C) and thus helps in controlling global warming and reducing temperature rise

caused due to other means. As we are going to convert the already existing conventional engine into an air

powered one, this new technology is easy to adapt. Another benefit is that it uses air as fuel which is

available abundantly in atmosphere.

Apart from above other technical benefits are as follows:

 The temperature of the engine while working will be slightly less than the ambient temperature.

 Smooth working of the engine due to very less wear and tear of the components.

 There is no possibility of knocking.

 No need of cooling systems and spark plugs or complex fuel injection systems.

5.2 Economic Benefits

Some major economic benefits of Air Engine are listed below

 No use of expensive fossil fuels as the free air is compressed and taken to use.

 For this reason people can easily shift to the new technology.

 Compressors use electricity for generating compressed air which is relatively much cheaper

and widespread.

 Smooth working will lead to less wear & tear, so lesser maintenance cost.
  Compressed air is most sustainable. It has no volatility or temperature or much weather

effect .Once compressed air is stored through compressor, it will be available at any time

without any loss of Pressure.

5.3 Environmental Benefits

Compressed air may be definitely as an alternate for running light vehicle, which is presently

creating emission due to use of fossil fuel and ultimately effects public health hazard. The major

benefits of Air Engine in the direction of environmental safety are as follows:

 As the exhaust temperature of this engine will be slightly less than the atmospheric temperature

(i.e. 15-25oC). So this will help in cooling the environment.

 And if this technology is widely used than it will help in controlling global warming. These are

some green bytes associated with this technology.

 Exhaust gases leaving the engine will be only air having low temperature. So this will eliminate

the problem of harmful emissions, in conventional engines. This gives us environmental benefit

of using this engine.

 Also as there will be no thermal radiations produced, radar can’t detect these vehicles. So this will

help our army too.

 CHAPTER 6

CONVERTING A CONVENTIONAL IC ENGINE INTO AN

AIR POWERED

6.1 Necessary Changes

The normal 4 stroke SI engine is shown as:

Figure 6.1 A conventional SI engine

To convert a conventional IC engine into an Air Powered one, few components are to be replaced.

First of all replace the spark plug with a pulsed pressure control valve which can create required

pressure. Now the pulsed air firing in this valve is controlled by controlling the supply of electrical

signal to the plunger. For this we require an electronic timing circuit which can control the flow
of electrical supply to the plunger of this valve. This can be achieved by using PLC circuit. Now

speed of the engine will be controlled by controlling this input signal.

Now fuel tank is to be replaced with air vessel, as it requires pressurized air as input. And two

things are to be taken care while designing air vessel:

1. First is its strength to withstand high internal pressure, which exists due to compressed air.

For this outer body of it should be made of a material, having high strength, like carbon

fiber.

2. Second is its capacity to store air and its weight. Now replace cam with a modified cam.

This is to be done, so that both the inlet and outlet valves open and close at the same time.

Main advantage of doing this is to achieve better scavenging system. Also this will result

in conversion of 4 stroke engine into 2 stroke air engine, which in turn gives us the benefit

of low mean effective pressure requirement in addition to other operational benefits.

The new Air Powered engine, after modifications would look like as follows:

Figure 6.2 The Air Powered Engine

6.2 Operation

Initial torque is supplied from the DC exciter motor, and then the engine operation starts.

Stage 1: When the piston is in the TDC, compressed air is injected through the pulsed air firing

valve, which pushes the piston to BDC.

Stage 2: Due to the motion of the engine and its inertia, the piston moves back to TDC, pushing

the air out of the valves.

The plunger of the pulsed firing valve is controlled by a timing circuit which is specifically a PLC

programmed circuit. It supplies the electronic signals by which the plunger moves so that it opens

and closes the pulsed firing valve.

6.3 Comparison between the Old and New Engine

6.3.1 Difference in Working

On comparing it with the working of normal SI 4 stroke engine, we can say that:

 “Stage 1” of the air engine comprises of the combined operation of “Suction stage” and

“Power stage” of the normal 4 stroke SI engine.

 “Stage 2” of the air engine comprises of the combined operation of the “Compression

stage” and “Exhaust stage” of the normal 4 stroke SI engine.

6.3.2 Advantages of Air Powered Engine over Conventional Engine

 Air, on its own, is non-flammable, abundant, economical, transportable, storable and, most

importantly, nonpolluting.

 Compressed air technology reduces the cost of vehicle production by about 20%, because

there is no need to build a cooling system, fuel tank, spark plugs or silencers.
 High torque for minimum volume. The mechanical design of the engine is simple and

robust.

 Low manufacture and maintenance costs as well as easy maintenance. Lighter vehicles

would mean less abuse on roads, thus, resulting in longer lasting roads.

 The price of fueling air powered vehicles will be significantly cheaper than current fuels.

 When the air is being compressed at reasonable speeds, it heats up. The heat given off

during compression could be reclaimed for space heating or water heating,

 Transportation of the fuel would not be required due to drawing power off the electrical

grid. This presents significant cost benefits. Pollution created during fuel transportation

would be eliminated.

 Compressed-air vehicles are comparable in many ways even to electric vehicles and their

potential advantages over electric vehicles include:

 Compressed-air vehicles are unconstrained by the degradation problems associated with

current battery systems

 Much like electrical vehicles, air powered vehicles would ultimately be powered through

the electrical grid which makes it easier to focus on reducing pollution from one source, as

opposed to the millions of vehicles on the road.

 Compressed-air tanks can be disposed of or recycled with less pollution than batteries.

 The tank may be able to be refilled more often and in less time than batteries can be

recharged, with refueling rates comparable to liquid fuels.

 The tanks used in a compressed air motor have a longer lifespan in comparison with

batteries, which, after a while suffer from a reduction in performance.