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Purpose:
To reduce the weight per horse power of the engine as required in aero engines
To reduce the space occupied by the engines as required in marine engines.
To have better turbulence and it ensures more complete combustion giving greater
power and low specific fuel consumption.
To improve volumetric efficiency of the engine at high altitudes, as in aero engines,
and at high speeds as in race cars.
To maintain the power of a reciprocating IC engines even at high altitudes where less
oxygen is available for combustion.
Principle of working:
A turbocharger is driven by a gas turbine. Exhaust gas from the engine flows along
the exhaust manifold and through nozzle box assembly and it enters into the blades of the gas
turbine where the mechanical work is done by the gas engines.
The wheel of the gas turbine and the impeller of the supercharger are mounted on one
common shaft. Thus, the supercharger compresses the atmospheric air in case of diesel
engines or air fuel mixture in case of petrol engines and it enters the engine cylinder. By
using a turbocharger, the engine fuel economy is improved by the use of the kinetic energy of
exhaust gases. The turbocharger output can be controlled for its optimum performance by
introducing by-pass passage and disc valve on both inlet and outlet passages as shown in
figure.
Methods of turbocharging:
1. Constant pressure turbocharging
2. Pulse turbocharging
3. Pulse converter turbocharging
4. Two-stage turbocharging
5. Miller turbocharging
6. Hyperbar turbocharging
2. Pulse turbocharging:
A part of blow-down energy is converted into exhaust pulse immediately when the
exhaust valves open. These pulses enters into the turbine where more energy is recovered.
Dissimilar to constant pressure turbocharging, the exhaust of all cylinders does not hinder
with each other due to the use of separate exhaust pipe for each cylinder.
3. Pulse converter turbocharging:
This method of turbocharging combines the advantages of both pulse turbocharging
and constant pressure turbocharging. It is achieved by connecting the various branches of
manifolds together. Then it is connected with a specially designed venture junction called
pulse converter. It is done before the turbine.
4. Two-stage turbocharging:
5. Miller turbocharging:
Miller system increases the expansion ratio relative to compression ratio in such a
way to early closure of inlet valve when the boost pressure is increased. This method is not
popular due to frequency exhaust valve failure.
6. Hyper turbocharging:
This type of turbocharging consists of diesel engine, turbine, by-pass control and
auxillary combustion chamber. In diesel engine, low compression is obtained and high
pressure ratio is maintained in turbine. The auxillary combustion chamber is placed between
direct exhaust valve and turbine.
First, the turbocharger is started using an electrical starter. It is running by passing air.
Then it is injected into the auxillary combustion chamber when the engine is idle condition.
The amount of by passed and fuel injection are controlled according to the operating
conditions. After reaching sufficient pressure and temperature, the diesel engine is started.
Variable Geometry Turbochargers (VGT)
In a turbocharger, the exhaust gas generated by the engine spins the turbine. The
turbine wheel rotates the compressor via a shaft which in-turn forces more air (known as
boost) into the combustion chamber. With proportionately higher amount of fuel being
delivered, the engine can now produce more power without altering its inherent displacement.
Turbochargers allow manufacturers to build small yet powerful engines, which produce more
power; efficiently and reliably.
This is because the ‘Aspect Ratio (A/R) of a FGT is not variable’. What is an aspect
ratio? You may certainly ask! It is the ratio of the exhaust intake area of the turbocharger to
the radius of the turbine wheel. Basically, a smaller inlet area allows the turbo to spool up
quicker. A larger inlet area increases the spool up time but at maximum flow level it allows
the engine to breathe more easily. That’s not all; a conventional turbo requires a valve known
as a ‘wastegate’ to regulate excess turbine speed by limiting the flow of exhaust gas through
the turbocharger. So how do variable geometry turbochargers get around these issues?
Variable geometry turbochargers solves this issue with movable vanes (fins) to direct
exhaust flow on to the turbine blades. The angle of the vanes is controlled via an actuator (a
motor that works off pneumatic or hydraulic pressure). The advantage here is that the angle
of the vanes is controlled remotely and there is no need for a wastegate. It helps in optimizing
the behavior of the turbine across the powerband (engine RPM range).
This reduces the ‘lag time’ to spool up the turbine to create boost quickly at lower
engine speeds or between gear changes. It also improves the efficiency of the engine by
allowing it to burn more air and fuel in every cycle. Materials generally used to construct a
variable geometry turbochargers cannot withstand the heat over prolonged usage. This is why
these turbos are commonly found in diesel engines because petrol engines have a higher
exhaust gas temperature. In India, variable geometry turbochargers are commonly used in
popular diesel cars such as the Hyundai Verna and Maruti Swift.
Waste Gate Turbocharger (WGT)
This feature in the turbocharger consists of a bypass valve. It circumvents some part
of the exhaust gas going to the turbine and releases them into the outlet. The wastegate
turbocharger has a bypass valve built into the turbine housing. It diverts some of the exhaust
gases away from the turbine wheel through this valve.
The internal construction of the turbine consists of the wastegate valve and hollow
passage within the turbocharger. So, it allows some of the boost pressure to enter into this
passage. Then, the exhaust system automatically routes the bypassed exhaust gases to
the catalytic converter and tailpipes.
In this system, the speed of the turbine wheel determines the diversion of the exhaust
gases. The wastegate unit reduces the high boost pressure developed by the compressor to the
desired level. Thus, it delivers the optimum engine performance with controlled peak cylinder
pressure.
Furthermore, the wastegate regulates the pressure of the relief valve. It, in turn, limits
the boost pressure in the turbocharger system. This is helpful in preventing the engine from
potential mechanical damages caused by the high pressure. Furthermore, the system
automatically opens the wastegate valve when the pressure reaches the pre-set levels. Then, it
allows all the high-pressure exhaust gases to escape the turbine wheel and enter into the
downstream/outlet. Thus, it prevents the exhaust gas pressure from rising more than required.
Moreover, with petrol engines, the wastegate turbochargers are typically used in the
racing cars to limit the amount of boost pressure. Additionally, the race-car drivers can sense
the change in pressure thru’ a tube inserted into their helmets.
The wastegate turbocharger has four main types which depend upon how the wastegate valve
operates:
1. Manual
2. Pneumatic
3. Electric
4. Hydraulic
The wastegate system has many advantages which include the following:
Nitrogen gas (N2) - Air is 78-percent nitrogen gas, and most of this passes right
through the car engine.
Carbon dioxide (CO2) - This is one product of combustion. The carbon in the
fuel bonds with the oxygen in the air.
Water vapor (H2O) - This is another product of combustion. The hydrogen in the
fuel bonds with the oxygen in the air.
These emissions are mostly benign, although carbon dioxide emissions are believed to
contribute to global warming. Because the combustion process is never perfect, some smaller
amounts of more harmful emissions are also produced in car engines. Catalytic converters are
designed to reduce all three:
In the catalytic converter, there are two different types of catalyst at work, a reduction
catalyst and an oxidation catalyst. Both types consist of a ceramic structure coated with a
metal catalyst, usually platinum, rhodium and/or palladium. The idea is to create a structure
that exposes the maximum surface area of catalyst to the exhaust stream, while also
minimizing the amount of catalyst required, as the materials are extremely expensive. Some of
the newest converters have even started to use gold mixed with the more traditional catalysts.
Gold is cheaper than the other materials and could increase oxidation, the chemical reaction
that reduces pollutants, by up to 40 percent.
Most modern cars are equipped with three-way catalytic converters. This refers to the
three regulated emissions it helps to reduce.
The reduction catalyst is the first stage of the catalytic converter. It uses platinum and
rhodium to help reduce the NOx emissions. When an NO or NO2 molecule contacts the
catalyst, the catalyst rips the nitrogen atom out of the molecule and holds on to it, freeing the
oxygen in the form of O2. The nitrogen atoms bond with other nitrogen atoms that are also
stuck to the catalyst, forming N2. For example:
2NO => N2 + O2
Or
2NO2 => N2 + 2O2
The oxidation catalyst is the second stage of the catalytic converter. It reduces the
unburned hydrocarbons and carbon monoxide by burning (oxidizing) them over a platinum and
palladium catalyst. This catalyst aids the reaction of the CO and hydrocarbons with the
remaining oxygen in the exhaust gas. For example:
2CO + O2 => 2CO2
There are two main types of structures used in catalytic converters --
honeycomb and ceramic beads. Most cars today use a honeycomb structure.
EMISSION NORMS
European emission standards
European emission standards define the acceptable limits for exhaust emissions of
new vehicles sold in the European Union and EEA member states. The emission standards are
defined in a series of European Union directives staging the progressive introduction of
increasingly stringent standards. The final standard is Euro 7, which will be followed by phase-
out of fossil fuel vehicles.
In the European Union, emissions of nitrogen oxides (NO
x), total hydrocarbon (THC), non-methane hydrocarbons (NMHC), carbon monoxide (CO)
and particulate matter (PM) are regulated for most vehicle types, including cars, trucks
(lorries), locomotives, tractors and similar machinery, barges, but excluding seagoing ships and
aeroplanes. For each vehicle type, different standards apply. Compliance is determined by
running the engine at a standardised test cycle. Non-compliant vehicles cannot be sold in the
EU, but new standards do not apply to vehicles already on the roads. No use of specific
technologies is mandated to meet the standards, though available technology is considered
when setting the standards. New models introduced must meet current or planned standards,
but minor lifecycle model revisions may continue to be offered with pre-compliant engines.
Along with Emissions standards the European Union has also mandated a number of
computer on-board diagnostics for the purposes of increasing safety for drivers. These
standards are used in relation to the emissions standards.
In the early 2000s, Australia began harmonising Australian Design Rule certification
for new motor vehicle emissions with Euro categories. Euro III was introduced on 1 January
2006 and is progressively being introduced to align with European introduction dates.
The standards, based on European regulations were first introduced in 2000. Progressively
stringent norms have been rolled out since then. All new vehicles manufactured after the
implementation of the norms have to be compliant with the regulations. Since October 2010,
Bharat Stage (BS) III norms have been enforced across the country. In 13 major cities, Bharat
Stage IV emission norms have been in place since April 2010 and it has been enforced for
entire country since April 2017. In 2016, the Indian government announced that the country
would skip the BS V norms altogether and adopt BS VI norms by 2020. In its recent judgment,
the Supreme Court has banned the sale and registration of motor vehicles conforming to the
emission standard Bharat Stage IV in the entire country from 1 April 2020.
While the norms help in bringing down pollution levels, it invariably results in
increased vehicle cost due to the improved technology and higher fuel prices. However, this
increase in private cost is offset by savings in health costs for the public, as there is a lesser
amount of disease-causing particulate matter and pollution in the air. Exposure to air pollution
can lead to respiratory and cardiovascular diseases, which is estimated to be the cause for
620,000 early deaths in 2010, and the health cost of air pollution in India has been assessed at
3% of its GDP.
Motor vehicles
To regulate the pollution emitted by cars and two-wheelers, the government of India
has placed forth regulations known as Bharat Stage Emission Standards (BSES). The Central
government has mandated that every vehicle manufacturer, each two-wheels and four-wheels,
ought to manufacture, sell and register solely BS6 (BSVI) vehicles from 1 April 2020.
Both BSIV and BSVI area unit emission norms that set the most permissible levels for
pollutants emitting from an automotive or a two-wheeler exhaust. Compared to the BS4, BS6
emission standards area unit stricter, whereas makers use this variation to update their
vehicles with new options and safety standards, the largest or the numerous modification
comes within the type of stricter permissible emission norms.
The below table offers Associate in Nursing insight into the modification within the
permissible emission levels of BS6 vehicles compared to BS4 vehicles:
Fuel Type Pollutant Gases BS6 (BSVI) BS4 (BSIV)
Petroleum Distillate
Nitrogen Oxide (NOx) Limit 60mg 80mg
Vehicle
These area unit emission standards set by the organization Bharat Safety Emission
commonplace (BSEB) to manage the output of pollutants from vehicles plying on the road.
The Central Pollution electrical device, below the Ministry of surroundings and Forest and
global climate change, sets the permissible pollution levels and timeline to implement an
equivalent by vehicle makers.
The abbreviation of ‘BS’ is Bharat Stage and is suffixed with the iteration of the
actual emission norms. The Indian emissions standards area unit supported the lines of
European norms unremarkably called monetary unit a pair of, EURO 3, and so on. the
primary rules with the soubriquet Asian nation 2000 were introduced in 2000, with the
second and third iteration introduced in 2001 and 2005 with the soubriquet BSII (BS2) and
BSIII (BS3), severally.
The fourth iteration BSIV or BS4 was introduced in 2017, and therefore the delay
between the introduction of BS3 and BS4 resulted in fast-tracking the BSVI or BS6 emission
rather than BSV or BS5 norms. every of those emission norms has stricter emission standards
compared to its predecessors.
History
The first emission norms were introduced in India in 1991 for petroleum distillate,
and 1992 for diesel vehicles. These were followed by making the Catalytic
converter mandatory for petrol vehicles and the introduction of unleaded petrol in the market.
On 29 April 1999, the Supreme Court of India ruled that all vehicles in India have to
meet Euro I or India 2000 norms by 1 June 1999 and Euro II will be imperative in
the NCR by 1 April 2000. Car makers were not prepared for this transition and in a
subsequent judgement the implementation date for Euro II was not enforced.
Based on the recommendations of the committee, the National Auto Fuel policy was
announced officially in 2003. The roadmap for implementation of the Bharat stage norms
were laid out until 2010. The policy also created guidelines for auto fuels, reduction of
pollution from older vehicles and R&D for air quality data creation and health administration.
1991 – Idle CO limits for petrol vehicles and free acceleration smoke for diesel
vehicles, mass emission norms for petrol vehicles.
1992 – Mass emission norms for diesel vehicles.
1996 – Revision of mass emission norms for petrol and diesel vehicles, mandatory
fitment of catalytic converter for cars in metros on unleaded petrol.
1998 – Cold start norms introduced.
2000 – India 2000 (equivalent to Euro I) norms, modified IDC (Indian driving cycle),
Bharat Stage II norms for Delhi.
2001 – Bharat Stage II (equivalent to Euro II) norms for all metros, emission norms
for CNG and LPG vehicles.
2003 – Bharat Stage II (equivalent to Euro II) norms for 13 major cities.
2005 – From 1 April, Bharat Stage IV (equivalent to Euro IV[citation needed]) norms for
13 major cities.
2010 – Bharat Stage IV emission norms for 2-wheelers, 3-wheelers and 4-wheelers
for the entire c0ountry, whereas Bharat Stage IV (equivalent to Euro IV) for 13 major
cities for only 4-wheelers. Bharat Stage IV also has norms on OBD (similar to Euro
III but diluted).
2017 – Bharat Stage IV norms for all vehicles.
2018 - Bharat Stage VI fuel norms from 1 April 2018 in Delhi instead of 2020.
2020 – Bharat Stage VI fuel norms from 1 April 2020 nationwide switching India to
world's cleanest diesel and petrol.