MATERIAL SELECTION

4.1 STAINLESS STEEL:

The materials used for this project is corrosion resistant and machineable.
The same material of stainless steel is used in the project for all project component.
The project were subjected to drilling, grinding and so the material is selected by
considering following aspects.

Corrosion Resistance:

Stainless steel is alloy having chromium content in it which corrosion

resistive in nature. Hence the stainless steel is used for aqua silencer.

Electrical And Thermal Conductivity:

Stainless steel is an excellent heat and electricity conductor and to is

weight is almost twice as good as copper. This has made Stainless steel the most
commonly used material to made utensil.

Reflectivity:

Stainless steel is a good reflector of noticeable light a well as heat, and

that together with is low weight makes it an ideal material for reflectors in, for

Example, light fittings or rescue blankets.

Ductility:

Stainless steel is ductile and has a low melting point and density. In a
liquid condition it can be processed in a number of ways. Its ductility allows
products of Stainless steel to be basically formed close to the end of the product"s
design.
Odorless:

Stainless steel is the metal itself is non-toxic and releases no aroma or

taste substances which make it ideal for packing sensitive product’s design.

Recyclability:

Stainless steel is 100 % recyclable with no downgrading of is qualities.

The re-melting of Stainless steel requires little energy only about 4 percent of the
energy required to produce the primary metal initially is needed in the reprocessing
process.

Weldability:

Stainless steel has high degree of weld ability. Hence it is used in many
industrial application.

4.2 ACTIVATED CARBON :

Activated carbon, also called activated charcoal, or activated coal, is a

form of carbon processed to have small, low-volume pores that increase the surface
area presented for adsorption or chemical reactions, Activated is sometimes
substituted with active.

Due to its high degree of micro porosity, just one gram of activated carbon
has a surface area in excess of 450 m2 , as determined by gas adsorption. An
activation level sufficient for useful application may be attained slowly from high
surface area however, further chemical action often enhances adsorption
properties. Activated carbon is usually derived from charcoal and is sometimes
utilized as bio char.
4.3 GAS PURIFICATION:

Filters with activated carbon are usually used in compressed air and gas
purification to eliminate oil vapors, odor, and other hydrocarbons from the air. The
most common designs use a l-stage or 2 stage filtration principle in which activated
carbon is embedded inside the filter media.

Activated carbon filters are used to retain radioactive gases within the air
vacuumed from a nuclear boiling water reactor turbine condenser. The big charcoal
beds absorb these gases and retain them while they quickly decay to non-
radioactive solid species. The solids are trapped in the charcoal particles, while the
filtered air passes through.

SIZE - 0.35 to 0.80 mm

SHAPE - Granular

4.4 WATER:

The AQUA SILENCER is fully based on use of water in it here the

exhaust gases get dissolved in water and the remained gases get accumulate in
Activated carbon and at last we got processed gasses.

THERMAL PROPERTIES OF WATER:

Maximum density - 1000 kg/m3

Specific weight - 9.80 KN/m3

Freezing point - 0oC

Boiling point - 100 o C

Latent heat of melting - 334 KJ/Kg

Latent heat of evaporation - 2.270 X 103 KJ/Kg

Specific heat - 4.187 KJ/Kg °K

Thermal expansion - 4 °C to 100 °C

COMPONENTS AND EXPLANATION:

5.1Perforated tube

Fig:8 Perforated tube

The perforated tube consists of number of holes of different diameters. It

is used to convert high mass bubbles to low bubbles. The charcoal layer is pasted
over the perforated tube.
5.2 Charcoal layer:

The charcoal layer has more absorbing capacity because it has more
surface area. This charcoal is called as Activated Charcoal . It is produced by
heating the charcoal above 1500 c for several hour in a burner. Its surface area gets
increased.

Fig9: Charcoal layer

5.3 Outer shell :

The whole setup was kept inside the outer shell . It is made up of iron or
steel . The water inlet outlet and exhaust tube was provided in the shell itself.
5.4 U Bend:

The bend is provided instead of a non- return valve which is a mechanical

device, which normally allows fluid (liquid or gas) to flow though it in only one
direction. The silencer was tilled will water and it is directly connected to the
exhaust pipe of the engine. There is a chance for the water to get enter into the
engine cylinder.

5.5 Flange:

A flange joint is a connection of pips, where the connecting pipes have

flange by which the parts are holed together. Here flange is used to connect the
silencer to the engine.

CONSTRUCTIONAL FEATURES :

Basically an aqua silencer consists of a perforated tube which is installed at

the end of the exhaust pipe. The perforated tube may have holes of different
diameters. The very purpose of providing different diameter hole is to break up gas
mass to form smaller gas bubbles the perforated tube of different diameter.
Generally 4 sets of holes are drilled on the perforated tube. The other end of the
perforated tube is closed by plug.

Around the circumference of the perforated tube a layer of activated

charcoal is provided and further a metallic mesh covers it. The whole unit is then
placed in a water container. A small opening is providing at the Top of the
container to remove the exhaust gases and a drain plug is provided at the bottom of
the container for periodically cleaning of the container. Also a filler plug is
mounted at the top of the container. At the inlet of the exhaust pipe a non-return
valve is provided which prevents the back flow of gases and water as well.
WORKING PRINCIPLE:

Fig12:Charcoal Silencer

As the exhaust gases enter into the charcoal silencer, the perforated
tube converts high mass bubbles in to low mass bubbles after that the passes
through charcoal layer which again purify the gases. it is porous and posses extra
free valence so it has high absorption capacity.

After passing over the charcoal layer some the gases ay dissolved into
the water and finally the Exhaust gases escape through the opening in to the
atmosphere. Hence aqua silencer reduces noise and pollution. Following chemical
reactions take place in aqua silencer:
Chemical Reaction 1 :

The obnoxious product of combustion is NOx - the (oxides of

Nitrogen) . Water will absorb the oxides of nitrogen to large extent. The following
chemical reactions will enhance the proof; for the above statement.

NO2+2H2O…….. 2HN02 + 2HN03 (diluted) ........ . ...... I

Chemical Reaction 2

If a small amount of lime water is added to scrubber tank further reaction

takes place as below.

Ca(OH)+CO2 - - 9 Ca(NO2)z + 2H2

Ca(OH)2+2HNO3…….. Ca(NO3)2=2H2O................ ll

Chemical Reaction 3

When the carbon-dioxide present it the exhaust gas comes in contact with
the line water, calcium carbonate will precipitate. The calcium carbonate when
further exposed to carbon-di- carbonate will be precipitated. The following is the
chemical reaction,

Ca(OH)+CO2 ……..CaCO3+H2O

CaCO3+H2O+CO2……. Ca(HCO3)2 …............. 111

Chemical Reaction 4

The sulphur -di - oxide present in the Diesel Exhaust ako react with the
lime water. But the small trace of sulphur-di-oxide makes it little difficult to
measure the magnitude of the chemical reaction, accurately. The following
equation gives the chemical reaction and calcium sulphate will precipitate.
 Ca(OH)2+SO2 --> CaSO3 + H2O

From calcium carbonate, calcium sulphate will precipitate and CO2 will
be by-product. Because of the small percentage and SO2 persence, the liberation of
carbon di-oxide is very less. But the liberated CO2 will again combine with
CaCO3 to form calcium bicarbonate.

DESIGN AND CALCULATION OF MUFFLER:

A muffler have been designed which is of supercritical grade type and

includes all the three attenuation principle i.e., reaction, followed by absorption
type muffler, and a side branch resonator. The interesting events of the design are
continuous volume reduction of chambers in the reactive part, the flow pipe cross-
sectional area is maintained constant throughout, a layer of insulation outside the
reactive part, the pacing of side branch resonator compactly, option for tuning the
resonator using a screw and cylinder.

8.1 Design Data :

For the experiment, an existing petrol engine has been used.

Calculations are done on the basis of data collected from the engine; however,
some data are applicable to all engines. For designing, the following data are
required.

1)Sound Characteristic (Without Silencer)

Rpm of the engine = 2026

2) Sound Analysis with Frequency Analyses (To obtain the Dominating
Frequency

Two dominating frequencies, the low level and the high level and the
highlevel have been obtained.

Low level - 270Hz

High level – 4000Hz

3) Diameter of Exhaust pipe of Engine/Inlet pipe of muffler

The Exhaust Pipe diameter : l. 5 inch

4) The Theoretical Exhaust None Frequency Range

From various expainents is has been found that the theoretical exhaust
noise frequency is 200-500Hz.

8.2 Reflective Part design .

The dimension to determine are that of the chamber length L and the body
diameter. To determine L, Three methods have been med. They are a follow:

I) First method used to determine L

Maximum attenuation occurs when L= n𝛾4 ...................... (1.1)

Where , 𝛾 = wavelengh of sound ( m or ft) n = 1,3,5 ..... (Odd integers)

Since , 𝛾 is related to frequency by the speed of sound, one can say that the
peak attenuation occurs at frequencies which correspond to a chamber length. The
range of frequency is obtained from the design data in section. The following table
of L has been constructed with this data.
Table 1: Calculated Wavelength

Frequency 𝛾 = C/f A n = odd integer L (inch)

L = n 𝛾/4
(inch)
N(min) 1.65 67.2 1 16.4
50.4
200Hz (𝛾 max) (𝛾 max) 3

N(max) 0.66 26.9 1 6.72

20.16
500Hz (𝛾 min) (𝛾 min) 3

From table, We can find that L has a range between 6.72 and 50. 4 inch.
Due to space limitation, the length of the small chamber has been chosen to be 6.72
inch and 20.16 or 20 inch for the whole of the chambers.

According to the load variations ound levelo f silencer also gets varies.
From table 2, we can see that as load increase sound level also increase.

Table 2 - Sound level

SOUND LEVEL
Without any load 104.5 dB
50% load 106.5 dB
100% load 107 dB
2) Range of change length considering the temperature of exhaust gas:

Another factor which must be considered expansion chamber design is

the effect of high temperature of exhaust gases. This factor can easily be included
in the design by using the following equation:

Where,

√R= absolute temperature of the exhaust gas

F = frequency of sound (Hz)

Let the temperature of exhaust is assumed to be 759.7 R

Putting this value in equation (1.2),

We obtains,

0.5 (49.03,√759.7) / 2𝜋270 < L > 2.6 (49.03,√759.7) / 2𝜋270

(Here, f==270 Hz for low frequency reactive muffler)

0.4 ft < L > 2.04 ft

From the 1st method, L -= 20 inch =1.67 ft.

So the condition. of 0.4 ft < 1.67 >2.04 ft. is satisfied

3) Range of chamber length according to ASHRAE Technical Committee 2.6

According to ASHRAE Technical Committee 2.6, muffler grades and

their dimensions, the requirement matches with the super critical grade.

lL = 35 to 45 dB

Body/Pipe = 3
Length/Pipe = l0 to 16

That is, 10 x pipe dia< L >16 X pipe dia

10 x l.5’’< L > l6 x 1.5 ‘’

15" < L > 24 ‘’

Again the chosen length L =20 inch, satisfies the above condition.

8.3 Tailpipe Design:

According to equation (I), resonance occurs when L=n/2. So, for an

economical construction , the value of n may be taken as 1. Then the tailpipe must
be less than 1/2. So hom the table e can find the tail pipe length 3.36 inch or less
than it.

8.4 Experimental Analysis and Result of Aqua Silencer:

Basically a perforated tube which is installed at the end of the exhaust

pipe. The perforated tube consists of number of holes of different diameter 8mm,
4mm and 2mm. It is used to convert high mass bubbles to low mass bubbles. It is
made from the stainless steel

The charcoal layer is pasted over the perforated tube. Bead activated
carbon is used as a charcoal layer. It is a process by which the carbon product
develops porous structure of molecular dimensions and extended surface area on
heat treatment in the temperature range of 800 to 1000 C in presence of suitable
oxidizing gases such as steam,CO2 Bead activated carbon is made from petroleum
pitch and supplied in diameters from approximately 0.35 to 0.80mm.it is also noted
for its low pressure drop, high mechanical strength and low dust content, but with a
smaller grain size. Its spherical shape makes it perforated for fluidized
applications.

Around the circumference of the perforated tube a layer of activated

charcoal is provided and further a metallic mesh covers it. The whole unit '6 then
placed in a water container. A small opening is provided at the top of the container
for periodically cleaning of the container. It is made up of iron or steel .The water
inlet outlet and exhaust tube was provided in the shell.

OPERATIONAL AND PHYSICAL PARAMETER:

9.1 Perforated Tube

Perforated tube diameter is 1.5 inch because engine exhaust manifold dia.
is same and 12 inch long as per design data and made from the stainless steel
because it has a high melting point l510° C.

9.2 Effect of Change in Porosity and Change in Diameter of Perforation Hole

on Backpressure

It is observed that for the smallest hole diameter of 5 mm the back

Pressure is as high as 13,837 Pa. If we increase the diameter of the hole back
pressure rapidly falls down and it is lowest i.e 788 Pa for the hole diameter 12.5
mm.

The pressure drop is very large which is 75% of highest backpressure for
rust two hole diameters viz. 5 mm and 7.5 mm For other hole diameters the
pressure drop is small but significant.

When the porosity is doubled than the conventional, backpressure drops

by 75% for first two hole diameters. While for other hole diameters it 's fairly the
same value with a difference of 20 Pa to 75 Pa. Thus it can be seen that the
backpressure value is high for small diameters as compare to bigger diameter holes
even if the porosity is doubled. But for higher diameters the Backpressurc value
remains the same even when the porosity is doubled.

9.3 Activated Carbon

Size -- 0.35too.80mm Shape -- Cylindrical palates

Fig3 :Palates

9.4 Specification Of Engine

Stroke Two stroke petrol engine

Type Air Air Cooled

No. of cylinder Single cylinder

Bore x Stroke 42.6 mm x 42 mm

Displacement 59.9 cc

Maximum Power 3.5 hp at 5500 rpm

Max. Torque 4.5 Nm at 5000 rpm

9.5 Water

Thermal properties of water

Maximum density 1000 kg/m3

Specific weight 9.807 mm

Freezing point 0°C

Boiling point 100°C

Latent heat of melting 334 CJ/Kg

Latent heat of evaporation 2270 KJ/KgK

Specific heat 4.187 KJ/KgK

Thermal expansion 4°C to 100°C

9.6 Effects of Dissolved Gases on Lime Water:

The lime water is a good absorbing medium. In aqua silencer the gases
are made to be dissolved in lime water. When these gases dissolved in water they
form acids, carbonates, bicarbonate etc.

a) Action of dissolved SOx :

When SOx is mixed in water, it form SO2, SO3, SO4, H2SO4 i.e.
sulphur Acid (H2 SO3), it forms Hydrogen Sulphide which causes rotten egg smell,
acidify and corrosion of metals.
b)Action of dissolved CO2 :

The dissolved carbon dioxide forms bicarbonate at lower PI and

Carbonates at higher This levels 40-400 mg/litre. The carbon dioxide mixes with
water to form Carbonic acid. It is corrosive to metals and causes greenhouse effect.
c) Effect of dissolved NOx :

The NOx in exhaust gas under goes Oxidation to form ammonia, Nitrate,
Nitrite, Nitric acid. This synthesis of protein and amino acids is effected by
Nitrogen. Nitrate usually occurs in trace quantities in exhaust gas.

d)Adsorption Process :

Activated charcoal is available in granular or powdered form. As it is

highly porous and Possess free valences. So it possess high absorption capacity.
Activated carbon is more widely used for the removal of taste and odorous from
the public water supplies because it has excellent properties of attracting gases,
finely divided solid particles and phenol type impurities, The activated carbon,
usually in the powdered form is added to the water either before or after the
coagulation with sedimentation. But it is always added before filtration Feeding
devices are similar to those used in feeding the coagulants .

MERITS AND DEMERITS :

10.1 Merits :

1. No vibration when the engine is running.

2. Start the engine easy.
3. Control emission and noise in greater level.
4. Carbon is precipitated.
10.2 Demerits :

1. Lime water filling is required once in a rear.

2. Silencer weight is more comparing to conventional silencer.
3. Additional space is required.

RESULTS AND DISCUSSION :

First we determine the amount of exhaust gas like hydrocarbons,

nitrogen etc. which is present in the single cylinder diesel engine is connecting
Zero emission silencer. And then aqua silencer(without lime water) is connected
on the exhaust and determine the amount of exhaust gas by smoke analyser. At last
the silencer (with lime water) which is connected to exhaust pipe and readings are
taken. The results which are obtained from the project analysis is given below in
the tables. Smoke analyser tests were carried out for analysing the performance of
the silencer.

11.1 Test using simple silencer:

The smoke from a single cylinder four stroke diesel engine is made to
pass through an aqua silencer by connecting it to the exhaust of the engine.

Pollution Analyser test in single cylinder four stroke diesel engine

Constituents Amount
Carbon Monoxide(CO) 15.00%
Hydrocarbon(HC) +22520 ppm
Carbon-di-oxide(CO2) +20.00%
Oxygen(O2) +0.00%
Nitrogen di oxide(NO2) 660 ppm
RPM/𝛾 0.959
11.2 Test using silencer with activated charcoal:

Activated charcoal is used it the sheer because of its high absorption

capability. It can absorb some portions of the toxic gas present it the exhaust.

During this test it is found that the amount of hydrocarbons and nitrogen
dioxide are reduced as compared to the previous test. This is because of the reason
that the charcoal embedded inside the silence has absorbed certain amount of the
gas. The changes in the amount of other gases are negligible.

Pollution Analyser test in single cylinder four stroke diesel engine

with Aqua Silencer
Constituents Amount
Carbon Monoxide(CO) 15.00%
Hydrocarbon(HC) +22654 ppm
Carbon-di-oxide(CO2) +20.00%
Oxygen(O2) +0.00%
Nitrogen dioxide(NO2) 559 ppm
RPM/𝛾 0.959

11.3 Test using Lime water:

In this test lime water is tilled inside the silencer. This test is found to
be more efficient. The amount of hydrocarbon has increased than that of the
previous test. This is due to the reason that, while applying line water the
temperature will be decreased inside the silencer. High temperature is needed for
the hydrocarbon to burn completely and this results it the incomplete combustion
of the hydrocarbon. But it is found that the there is a considerable reduction in the
amount of nitrogen dioxide. As nitrogen dioxide is more toxic than hydrocarbons,
this test is considered as more efficient.

Pollution Analyser test in single cylinder four stroke diesel engine

with Aqua Silencer(Lime water)
Constituents Amount
Carbon Monoxide(CO) 15.00%
Hydrocarbon(HC) +22822 ppm
Carbon-di-oxide(CO2) +20.00%
Oxygen(O2) +0.00%
Nitrogen dioxide(NO2) 460 ppm
RPM/𝛾 0.959

Bill of Materials:

Material cost

SL.NO Material Price per NO of unit Total cost

unit requires
1 Stainless Steel 800 2 1600
Pipe
2 Two Way Valve 300 3 900
3 Flange 500 1 500
Total cost 3000
Other Cost:

Sl .No Process Total cost

1 Welding 500
2 Painting 100
3 Labour cost 700
4 Other expanses 600
Total 1900

CONCLUSION :

The aqua silencer is more effective in the reduction of emission gases

from the engine exhaust using perforated tube, lime water and charcoal by using
perforated tube the back pressure will remain constant and the sound level is
reduced. By using perforated tube the fuel consumption remains same as
conventional system by using water as a medium the sound can be lowered and
also by using activated charcoal in water we can control the exhaust emission to a
greater level.

The water contamination is found to be negligible in aqua silencer. It is

smoke less and pollution free emission equivalent to the conventional to the
silencer. It can be also used both for two wheelers and four wheelers and also can
be used in industries.

SCOPE FOR FUTURE RESEARCH :

There has been at increasing concern it recent yes over the increasing of
transportation lid discharge of industrial waste waters into environment. The
engine emission contain it air pollutants and other species. Almost all pollutants
are toxic it nature Some of the exempts are CO. CO NOX. and Hydrocarbon.
Among the at pollutants, all we most effective pollutants. hence, the removal of
pollutants was selected for the present study. Several expensive techniques are
available it developed countries.

But it developing countries like India is not applicable since adsorption

technique is less expensive and economically feasible, it has been selected for the
present study using some cheap cost chemicals as an effective adsorbent. Therefore
the objective of the present study was to test the ability of some chemicals in
removing air pollutants horn engine emission .In future researches are going on to
develop an aqua silencer which can be fitted it to automobiles without effecting its
aerodynamics properties and efficiency.