Diesel Engine Exhaust Emissions Treatment Heavy Duty Vehicle

Workshops

By
Belay EldoErja

A Proposal Submitted to Department of Mechanical Systems and

Vehicle Engineering
School of Mechanical, Chemical and Materials Engineering

Program: MSc. in Automotive Engineering

Office of Graduate Studies
Adama Science and Technology University

Adama, Ethiopia
September, 2020
Diesel Engine Exhaust Emissions treatment Heavy duty vehicle
Workshops

By
Belay EldoErja

A Proposal Submitted to department of Mechanical Systems and

Vehicle Engineering
School of Mechanical, Chemical and Materials Engineering

Program: MSc. in Automotive Engineering

Office of Graduate Studies
Adama Science and Technology University

Adama, Ethiopia
September, 2020
 APPROVAL SHEET

A: Candidate

Name of Student Signature Date

B: Approved by

Advisor Signature Date

Co-Advisor Signature Date

Head of the Department Signature Date

School Dean Signature Date

Dean, Graduate Studies Signature Date

 Table of Contents
Contents Page
List of Tables and Figure ................................................................................................................ ii
EXECUTIVE SUMMARY ........................................................................................................... iii
CHAPTER ONE ............................................................................................................................. 1
INTRODUCTION .......................................................................................................................... 1
1.1Background of the Study ........................................................................................................ 1
1.2 Statement of the Problem ...................................................................................................... 3
1.3 Objectives .............................................................................................................................. 4
1.3.1 General Objective ........................................................................................................... 4
1.3.2 Specific Objective........................................................................................................... 4
1.4 Significance ........................................................................................................................... 4
1.5 Scope of the Thesis Work ..................................................................................................... 4
1.6 Organization of the Proposal ................................................................................................. 4
CHAPTER TWO ............................................................................................................................ 5
LITERATURE REVIEW ............................................................................................................... 5
2.1 Automobiles and Urbanization there Pollution ..................................................................... 5
2.2 Pollution Monitoring Methods .............................................................................................. 5
2.3 Air Monitoring ...................................................................................................................... 5
2.4 Health Effects, Major Exposures and Safety Hazards at Workshops ................................... 6
2.5 Environmental, Health and Safety Regulations .................................................................... 6
2.6 Motor Vehicle Repair Workshops (MVRW) and Maintenance Garages ............................. 7
2.7According to International ..................................................................................................... 8
CHAPTER THREE ...................................................................................................................... 10
MATERIALS AND METHODS .................................................................................................. 10
3.1 Materials .............................................................................................................................. 10
3.1.1 Materials Required for Manufacturing the Mixer ........................................................ 10
3.2 Methods ............................................................................................................................... 10
CHAPTER FOUR ......................................................................................................................... 13
BUDGET ...................................................................................................................................... 13
CHAPTER FIVE .......................................................................................................................... 14
WORK PLAN ............................................................................................................................... 14
References ..................................................................................................................................... 15

i
List of Tables and Figure
Page
Fig.3.1. Block diagram of the proposed Research methodology. ................................................. 12
Table 1: Materials and facility cost ............................................................................................... 13
Table2: Machine rent and labor cost ............................................................................................. 13
Table 3: Work is shown in table below ........................................................................................ 14

ii
 EXECUTIVE SUMMARY
The rapid incensement of number of vehicle, urbanization and industrial growth are causing
serious environmental challenges. This paper attempts to give a general view about the existing
auto repair workshop activities in Ethiopia Industrial Area with respect to clean production
concepts. It concentrates on the auto repair activities with regard to the generated wastes; its
volume, amount, and the general methods of their processing and disposal of this Ethiopia
industrial area. These paper deals with the main challenge air pollution in auto repair
workshop. This problem was hazardous situation for the worker and their community. The paper
was presented design of diesel engine exhaust emission treatment in heavy duty vehicle
workshop. The exhaust gas which is released from heavy duty vehicle at repair center can cause
of different problem of the works. The waste product from vehicle was CO2,HC,diesel
particulate, carbon soot and so on. These was affect the worker health and pollute the work shop
air. To minimize the effect pollutant which is come through the exhaust system will treated after
the end of tail pipe. This can be done using fixable hose, different type of metallic pipe, one way
valve, radiator and metallic filter element using water cooled the system underground and the
process will takes place after the exhaust gas will cooled by water the metallic filter element was
clean carbon soot and diesel particulate will minimize the pollutionof air in the workshop.

iii
 CHAPTER ONE

INTRODUCTION

1.1Background of the Study

Cleaner production is the continuous application of an integrated preventive environmental

strategy to processes, of products and services to increase overall Efficiency, and reduce risks to
humans and the environment and reducing the quantity and toxicity of all emissions and wastes
before they leave a process. A key to cleaner production is to know the flow processing of work
at automotive workshop so as to be aware of material balances in terms of input of water, energy
and raw materials, and output as production of desired products, services, and generation of
wastes (air, liquid and solid wastes). Only by knowing the inputs, process streams and outputs,
will it be possible to efficiently manage an optimization of inputs and products and a
minimization of waste generation in our rapidly developing industry and society, traditional end-
of-pipe solution of environmental problems is no longer acceptable. It is typically more
expensive, less effective, and carries the social shame of a reactive approach, as a treatment after
the harm has been done. Modern societies do not want Environmental remediation, they want to
prevent pollution and identify waste before it is generated. Cleaner production stakeholders have
a strong desire for industry to consider cleaner production opportunities in their facilities and to
follow through on their implementation. This paper look at local and international initiatives
stakeholder community (including government, non-government organizations, consultants,
industry) that contributes to the initiation and implementation of cleaner production in
automotive service.

Diesel engines are widely used for transport and power-supply and, therefore, occupational
exposure to diesel exhaust is common. In 2012, the International Agency for Research on Cancer
(IARC) classified diesel exhaust as carcinogenic to humans, mainly based on the increased lung
cancer risk observed in epidemiological studies. In recent years, tightened emission regulations
in the EU and other parts of the world have caused a significant evolution of diesel technologies,
resulting in a change in the emission and composition of the exhaust. Among chemical hazards,
are volatile compounds from fuel, used gasoline oils, solvents and paints, isocyanates and
chromium from paint operations, and dust and silica exposure from sanding and sand blasting.

1
Among physical hazards noise, fire and explosion, flying objects, dust cutting tools oil and
grease spills and lifts are important. These hazards cause adverse health effects like respiratory
ailments, acute injuries, eyes injuries, hearing loss, backache, and musculoskeletal disorders
(Brosseau, 2012).

Vehicles are a major source of environmental pollution after industries. Air contamination is
serious issue from the public health point of view. Polluted air causes unexpected physical and
physiological effects on human health. Air pollution can be defined as addition of unwanted
material to our atmosphere, which will have a speedy effect on life of living things upon our
planet. The main pollutants contributed by engine exhaust are carbon monoxide (CO), un-burnt
hydrocarbon (UBHC), oxides of nitrogen (NOx) and Lead.

Emissions may be divided into two group 1) Invisible emission and 2) Visible emission. Major
emissions in exhaust gas are as follows

1. Invisible emission.

a) Un-burnt hydro-carbon (HC)

b) Oxides of carbon (COX)

c) Oxides of sulphur. (SOX)

d) Oxides of nitrogen. (NOX)

2. Visible emission

a) Soot and Smoke (carbon particles)

b) Particulates

2
1.2Statement of the Problem

Diesel engines produce a mixture of toxic gases and particulates from the combustion process.
These toxic gases and particulate which is released from heavy duty vehicle exhaust Emissions
in a garage or vehicle repair workshop can causes of health risk and environmental problem. To
create clean and safe working environment by reducing the emission released from the
vehicle.Due to this problem working environment was polluted and the working efficiency of the
worker will reduce and their health was affected due to the untreated exhaust gas of vehicle.

3
1.3Objectives

1.3.1 General Objective

The general objective of this proposal is design of diesel engine exhaust emissions treatment
heavy duty vehicle workshops.
1.3.2 Specific Objective
The objective of this thesis proposal will be achieved through the following specific objectives:
 To designexhaust gas cooling system in the workshop.
 To improve health condition and cleaner environment
 To treat toxic gas which is release from vehicle in workshop
 To Installing this system in workshop without affecting other systems.
 To make clean working environment.

1.4Significance

The significance of the proposed thesis work is;

 Reduce the emission work shop.
 Clean and safe work shop.
 Minimize environmental impact the outside of tail pipe.

1.5 Scope of the Thesis Work

 The spatial scope of this thesis will to design of diesel engine exhaust emissions
treatment of heavy duty vehicle at workshops
 Design of diesel engine exhaust emissions treatment of heavy duty vehicle at workshops
which is integrate with the exist infrastructure.

1.6Organization of the Proposal

The proposal is organized with the following chapters.

Chapter one: Introduction
Chapter two: Literature review
Chapter three: Materials and methods
Chapter four: Budget
Chapter five: work plan

4
 CHAPTER TWO

LITERATURE REVIEW

2.1Automobiles and Urbanization there Pollution

(Rostogi et al., 1991). Due to increase in automobiles and urbanization in towns and cities in the
world, there is an exponential increase in urban air pollution with traffic being the major
pollution contributor (Patil et al., 2004). Among major air pollution sources are traffic related air
pollutants, which pose a serious challenge in the present era due to increasing number of
automobiles in our cities throughout the globe.

2.2Pollution Monitoring Methods

(Ashmore et al., 2000)The type and quantity of pollutants in ambient air is measured by
systematic methods known as ambient pollution monitoring. Whereas measurement of
particulate and gases from a specific source is called emission measurement. The main reason to
carry out monitoring is to ensure compliance with local, national and international legislation, to
review the degree of pollution, to provide data for modeling and to evaluate controls. Many
different methods are available, ranging from simple passive technique to highly delicate remote
sensing devices that can measure any pollutant depending upon given data and reliability.

(Afroz et al., 2003)Monitoring stations are totally dependent on reason for monitoring. While
designing monitoring networks, the main objective is to protect human health, this is the reason
that monitoring stations are established in population centers.

2.3Air Monitoring

(Coleman, 1983; Sheldon et al., 1985; Akland et al., 1985; Ott et al., 1986)Direct Approach to
Exposure Assessment: Very sensitive and portable light weight device known as personal
portable monitor is used to detect small quantities of pollution. Personal monitoring technique
are used to measure large population exposures by selecting a small sample size (Underhill,
1984; Kring et al., 1984). According to different studies SO2, CO, NOx, formaldehyde, organic
vapors, and reparable particles can be measured easily by this method.

5
(Ott, 1986; Sexton et al., 1983)Indirect approach to exposure assessment: It refers to fixed-site
monitors combined with data on time activity patterns for exposure assessment. It estimates
integrated exposure by adding pollutant concentrations taken at fixed sites along with workers
time spent in different environment diaries and data log.

2.4Health Effects, Major Exposures and Safety Hazards at Workshops

(Schwartz, 1987)According to statistics, announced by Bureau of Labor Statistics USA, almost

1.5 million servicemen were recruited in automobile repairing and gas service stations industry
in 1985. Such statistics is not patently available for employments in Saudi Arabia. This industry
covers various dimensions of services including muffler, brake, ignition, glass, body and paint
shops. The most catered services are lubricating oils and greases. Workers face chemical
exposures from gasoline vapor, epoxies, fiberglass, solvents, asbestos, and fumes from welding,
vehicles exhaust, paints, adhesives and benzene.A normal trend, as observed, is that automobile
mechanics and gas station workers have similar experience of workmanship. This is because they
often work together in the same workplaces and they have similar kind of duties. The population-
based proportionate mortality ratio (PMR) studies and case reports about these workers have
helped in collecting findings about their death rates (Schwartz, 1987).These case studies show
aplastic anemia, excesses of leukemia multiple sclerosis, nonmalignant respiratory disease,
cancers of the buccal cavity, testicular and kidneys, esophagus, duodenal ulcers, suicide and
injuries among automobile mechanics and gasoline service station workers (Schwartz, 1987).

2.5Environmental, Health and Safety Regulations

(Evans et al., 1988; Chawla and Lavania, 2008)Vehicular exhaust is the worst type of exhaust as
it is emitted at ground near the breathing level, and it gives maximum human exposure. Traffic
exhaust contains different noxious oxides of sulphur (SO2), nitrogen (NOx), carbon (CO),
volatile organic compounds (VOCs) and suspended particulates. These traffic related pollutants
may have direct or indirect health effects on public as well as on different occupational workers
in urban areas. The most vulnerable are those who spend most of their time in traffic / vehicle
congested environment and road sides like petrol stations, vehicle workshops, bus stops, and
road wanderers.

6
2012 (WHO 2014) the indoor and outdoor air pollution exposures have caused around 7 million
deaths globally only in. Around 4.3 million deaths were correlated to indoor air pollution
whereas 3.7 million deaths were attributed to outdoor air pollution.

2.6Motor Vehicle Repair Workshops (MVRW) and Maintenance Garages

Motor vehicle repair workshops (MVRW) and maintenance garages help to maintain the
vehicles on the roads. Commercial and domestic customers also do repairing and
maintenance of motor vehicle at road sides as well as in MVRW and maintenance
garages. The demand for MVRW is increasing due to significant increase in number of
motor vehicles on roads worldwide.Common work related accidents in MVRW are slips,
trips and falls and the resulting occupational injuries are serious often. Every year due to
collapsing of under repaired vehicles trigger fatal accidents. Serious burns, fire eruption
and some fatal accidents have been caused and reported at petrol fuel related workplaces.
Occupational illness and diseases are also reported such as disabling dermatitis in
MVRW workers due to the use of toxic substances like paints containing isocyanates.
Such paints were considered as the main cause of occupational asthma in UK in the past.
Use of power tools in MVRW industries causes white finger and physical vibration
(HSE, 2009).

(Balashanmugam et al., 2012)The environmental pollution exposure is more critical for

workers, such as drivers of motor vehicles, fuel station workers, petrochemical based
industry workers, petrol police personals, parking attendants, tunnel workers, road side
vendors, and roadside workshop workers in trafficked areas, who are at higher risks of
illness and diseases. Especially, the air pollution is severely harmful for fetus, children,
old people, cardiovascular and angina pectoris patients.

Functions of significant parts of body such as heart and brain are also disturbed due to air
pollution and its effect can be fatal especially at higher concentrations.

MVRW operations such as welding, gas cutting and petrol-engine exhausts emit nitrogen
dioxide, which can cause emphysema, lung irritation, pneumonia, pulmonary edema,

7
asthma, bronchitis, and respiratory infections. Combustion of products emit sulfur
dioxide, responsible for low atmospheric visibility, acid rain, smog and disturb human
respiratory system and lungs function.

(Heer et al., 2011; Caldwell, 2000)Motor vehicles have become essential part of today’s
life. Vehicles repair and maintenance need has led to the emergence of a really large
sector named repair and maintenance, which is also known as workshop. This is an
informal sector also categorized as small and medium size enterprise. It’s a labor-
intensive sector, and its size of enterprise, number of workers and job characterization
vary considerably.

(Caldwell, 2000).Employs of all ages are routinely seen at these workshops. From health
and safety point of view, this is the tough sector to tract and supervise. Hundreds and
thousands of risks and hazards go unnoticed. Common occupational hazards such as
physical, ergonomic, biological and chemical are found in MVRW activities, due to
heavy machinery, petroleum fuels/ oils, high use of solvents, smoke, particulate matter
and various other pollutants. These hazards become more critical when there is a lack of
awareness, controls measures and implementation of health and safety rules and
regulations

(Tadesse&Admassu, 2006)Globally, workers safety and protection at workplace has been a great
concern for employees, employers, governments and the entire society for years. Safe work place
not only promote physical, mental and social wellbeing but also saves considerable amount of
money that can be attributed to medical bills, insurance claims, loss of work, loss of experienced
personals, corporate reputations and integrity of organization.

2.7According to International

(Isaac et al., 2014)Labour Organization (ILO) statistics annually 270 million work related
accidents, and 2 million deaths are reported worldwide.

8
(Tadesse&Admassu, 2006; ILO, 2005; Punnett&Wegman, 2004)Also some severe accidents
leave victims paralyzed, loss of body parts, muscoskeletal disorders, skin diseases, neurological,
psychological, mental and respiratory diseases.

Many research studies proved that small scale industry workers are more prone to work place
hazards, risks and ill health effects (Adei et al., 2011) which can be somehow attributed to less
resources, low technical capacity, lack of knowledge and awareness regarding occupational
health safety guidelines.

9
 CHAPTER THREE
MATERIALS AND METHODS

3.1 Materials

The materials required for the proposed thesis work are listed below.

3.1.1 Materials Required for Manufacturing the Mixer

 Mild steel sheet
 Electrode
 Welding device
 Flexiblehose
 Wiring filtering element
 Water pump
 Radiator
 Metallic filter element
 Vacuum pump and radiator fan
 Gasket
 One way valve
 Bolt and nut
 Sheet metal
3.2 Methods

In order to show the general and specific objectives of this design of diesel engine exhaust
emissions treatment heavy duty vehicle workshops methodology will be followed. Different
steps included in the methodology are listed below and summarized. Fig.3.1.

a. Data collection
The necessary data will be collected by using primary or secondary data collection through
visiting various governmental owned heavy vehicle workshop, different garages, and different
industry.

10
 b. Literature review and problem identification
Searching different literature about the effects of diesel engine exhaust emissions ofheavy duty
vehicle workshopsand how they try to face such kind of problem. Also what type of
methodology that uses to minimize the effect of diesel engine exhaust emissions of heavy duty
vehicle workshopsand also effect in Ethiopia. These proposals that will help to the effect of
diesel engine exhaust emissions of heavy duty vehicle workshopsin Ethiopia workshop and
identify how much the problem was series and try to solve the problem.
c. Lay the system
First look the work shop and measure the area and design the layout using the AutoCAD soft
ware
d. Manufacturing
Manufacture the part assembly.
e. Test and measure the emission.
Using exhaust gas analyzer tests the emission.

11
F. Procedure and working flow of the thesis

Prepare for the thesis Start by data collection from different organization

Analysis data collected

Review different literature

Design of diesel engine exhaust emissions treatment

heavy duty vehicle workshops.

Purchase the material

Test the design

Produce prototype

Assembly

Fig.3.1. Block diagram of the proposed Research methodology.

12
 CHAPTER FOUR
BUDGET

The estimated cost of this thesis work is listed in the following

Table 1: Materials and facility cost

No Items Quantity Unit price (birr) Total price (birr)
1 Paper 1 pack 150 150
2 Pen ½ pack 120/pack 60
3 Printing and documentation - - 2000
4 Publication 2 2000 4000
5 MS sheet 1/4 2400/sheet 600
6 Electrode 1 pack 200 200
7 Transportation - - 6000
8 Filtering element 1 300 300
9 Sell and selling compound 2 400 800
10 Water pump 1 3000 3000
11 Vacuum pump and radiator 2 3500 7000
fan
12 Gasket kit 1000 1000
13 One way valve 1 1500 1500
Total 26610

Table2: Machine rent and labor cost

No Item Cost/hr in birr Time required to Total cost in birr
finish (hr)
1 Welding machine 200 4 800
2 Grinder 100 1 100
3 Exhaust gas analyzer 100 2 200
4 Welder 60 5 300
5 Lab. Assistant 150/day 8 day 1200
Total 2600
The estimated total cost of the proposed thesis work is approximately 29,210.00 birr.

13
 CHAPTER FIVE
WORK PLAN

Prior planning of work is necessary for successful achievement of the set objectives within the
set time. The scheduled timetable of this work is shown in table below.

Table3: Work is shown in table below

SNo September2020– January 2021

month
Task 1 2 3 4 5 6 7 8 9 10 11 12
1 Submitting Project Proposal

2 Defending Project Proposal and

improving

3 Reviewing additional literature and data

collection

4 Collecting materials and preparation of

Proto type

5 Testing

6
Analysis

7 Preparation of thesis

8 Thesis Submission

Thesis Defence

14
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