Combustion Engines

Faculty of Engineering
Department of Maritime Studies
Prof. Dr.– Ing. Karsten Wehner
Mail: karsten.wehner@hs–wismar.de
www.sf.hs-wismar.de
EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 2

Module Agenda

History of Diesel Air Supplying Combustion and this

Engine Process

Fuel Mixture and Forces and Super

Combustion Moments Charging

Heat Characteristic Maps of

Transmission Diesel Engines
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 3

Separation of Energy Parts

Power 2 stroke 4 stroke

[%] [%]
Pe 50 30 – 40

Exhaust gas 25 30

Cooling 23 24
systems
Convection/ 2 4
radiation
Aux. drives ----- 2-4
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 4

Task of Cooling Systems

 Reducing of process temperature

 Decreasing the applied load of parts

 Avoiding of NOx exhaust emission ↷ lower environment

pollution
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 5

Alternative Materials Ceramic

Pros
+ Heat resistant ⇒ part temperature up to 1500 K
+ Non cooling system required
Cons
- Decreasing of air supply rate λs ↷ increasing of charge effort
- Higher fuel consumption due to higher heat transmission
coefficient
- More NOx emission due to higher temperatures ↷ cooling
necessary
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 6

Temperatur Distribution on Cylinder Station

Chilled parts
 Cylinder head

 valves, nozzle's

 Piston

 Cylinder liner

 upper part
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 7

Additional Task of Cooling

 Keep the part temperature in certain limits

 heat resistance of materials
 limitation of part expansion due to temperature
 viscosity and thermal load of lubrication oil
 valves; avoiding of heat- and acid corrosion
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 8

Additional Task of Cooling

 Keep constant temperature field

4 – stroke temperature deviation between 330 K …1700 K

 Improved power (better charge)

 Decreasing of fuel oil consumption
 Decreasing of harmful substance emission
 Improving of TC compressor efficiency
 Improving of safety
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 9

Temperature March
 Mostly used of liquid cooling medium
 Cylinder = indirect cooling ⇒ water ⇒ air
combustion chamber cylinder wall cooling room heat exchanger wall ambient
Temperature [K]

Tcylinder Trefri Tambient

air,
gas water sea
water

engine ⇒ refrigerant refrigerant ⇒ ambient

 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 10

Special Cases – Lubrication – Oil

Using of oil as refrigerant

Pros

+ Only one heat exchanger necessary

+ Non water inside of engine
+ Non freezing
Cons
- Decreasing of oil quality due to thermal over load
- Heat transfer to oil worse than water
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 11

Heat Transfer Requirements

Heat transfer must carry out failure free

 enough cooling medium
 non dead water zones
 non steam buffer
 avoiding of film boiling
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 12

Energy Calculation

α = heat transfer coefficient cp = specific heat capacity

α is influenced by - ability of heat transmission
- chemical consistence
- nucleate boiling
- vibration cavitation

- current conditions
That leads to local different heat transfer conditions
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 13

Vertical & Horizontal Current Design

Vertical current Horizontal current
Large diesel engine Small diesel engine

 Low current speed < 1 m/s

 Nucleate boiling on hot surfaces ↷ α raise up to 20
kW*(m2*K)-1 ↷ pulsation current
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 14

Relation & Calculation of Heat Transfer Coefficient

 Reynolds number

Indipendent Nußelt number Nu*

indipendent Nußelt number

 heat transmission coefficient

Reynolds number Re
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 15

Effects of Modern Cooling System Design

 Ducts and water jacket forms complicated design
 low forced current speed
 high thermal load ↷ nucleate boiling ↷ saturated
temperature locally exceeded due to hot surfaces
 middle cooling water temperature < saturated temp
 bubbles are carry over by current ↷ intensive pulsation
current  increasing of current speed
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 16

Heat Transfer Coefficient

 Higher current speed ↷ higher α

 Some values for α
 free convection α = 400 … 2,000 W/(m2K)
 forced convection α = 1,000 … 4,000 ===``===
 nucleate boiling α = 2,000 … 10,000 ===``===

 Nucleate boiling occurs on all high applied load areas

 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 17

Effect of Nucleate and Film Boiling

 Self-protection of engine
 Low heat admission ↷ low α
 High heat admission ↷ high α
 Wall temperature increasing not fast Free Bubbles Film
convection evaporation

 Strictly avoiding of film boiling

 Otherwise α fell down, risk of
thermal overload
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 18

Troubles with Water Cooling

Remarks:
 During bubble boiling high temp gradients ↷ danger of
deformation and tension
 Danger of cavitation by water cooling systems in areas of
cylinder liner during high acceleration as result of piston
tilt over
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 19

Cooling Desings
 Good current conditions by using of bore holes
 With variation of distance, diameter, distance to walls and
flow it‘s possible to adjust each temperature on surfaces
 Application piston cooling
 limitation of thermal expansion
 fatigue endurable of piston materials
 using of lubricating oil for cooling
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 20

Piston Cooling with Oil

 Shaker cooling
 oil is delivered by crankshaft
 Targeted cooling
 fixed nozzle = injection to the piston bottom
 cooling ducts behind piston ring area are supplied by
adjustable nozzle to decreasing of temp in areas of
o reinforce
o hub
o piston cavity edge
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 21

Piston Cooling with Oil

 Targeted cooling
 Cooling loops (not more in using)
 Cooling space  compound piston
 good effect
 supplying from outside take away inside

 delivered via piston rod or piston tube (flexible joint)

 hedgehog bores for large diesel engine

o danger of coking, demand maintenance

o injection via nozzle’s
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 22

Cooling of Injection Nozzle

 Earlier
 water

 Nowadays
 fuel oil
o add preheating
o keep temperature level during stops
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 23

Cooling of Valves

 Intake valve
 scavenge air
 Outlet valve
 via valve seating ring and special bores
 valve shaft no cooling
 high thermal load of outlet valve
 special materials (nymonic/ inconel)
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 24

Calculated Analyze of Heat Transmission

 Computational programs like FEM /CFX / Fluid Dynamics
 Calculation of models and temperature areas
 Forecast in construction phase
 Variation of parameter and improving of geometrical design
 speed distribution

 pressure conditions and distribution

 recognize of dead water zones

 forecast heat transfer coefficient

 material applied load, fatigue, expansion

 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 25

Hot Cooling
 Higher temperature level of refrigerant
 Outlet temperature approx. 150 °C
 Water pressure > 5 bar
 difficult to sealing, no leakage only steam
 Other mediums
 ethylene glycol; worse α

 oil; demanding of synthetic oils, expensive, worse α, 130°C

upper limit
 In part load: lower consumption, better viscosity of lube oil
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 26

Evaporation Cooling

 Simple physical principle

 Cooling due to latent heat
 Immanent temperature controlling
 Refrigerant evaporated on hot surfaces
 Bubble boiling good heat transmission
 No forced current required
 α >> than forced turbulent current
 Small heating areas even big cooling power
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 27

Evaporation Cooling

 Conducted heat = evaporating heat

 Part temperature 10 … 20 K higher than boiling temp
 Temperature division more constant
 Few load depend temperature deviation in refrigerant
 Boiling temperature = f(pressure)
 Temperature level can adjusted
 Part load, high temp level, less losses
 Full load same temp like liquid cooling
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 28

Evaporation Cooling
 Closed cooling system, required condenser for steam
 High evaporating heat means only 3% mass flow of refrigerant

 Small pumps and low mass

 Troubles: refrigerant is not azeotropic, during evaporation

separation of water and additives

 Design of cooling space

 free escape for steam

 avoiding of film boiling

 Add water separator before condenser

 Big cross section of steam pipes

 No price advantages
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 29

Oil Cooling

 No freezing, operating area -50°C till 150°C

 No corrosion, no cavitation
 Operating temperature oil 130°C water 95°C
 Density 15 % lower than water
 Specific heat capacity 50 % ======´´=====
 Heat transmission ability 80 % ======´´=====
 Heat transfer coefficient 70 % ======´´=====
 Bigger cross section of cooling ducts
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012 Heat Transmission 30

Oil Cooling

 Specific heat power of engine is only 21 kW/ liter << H2O

 Maximum output power of engine 65 KW
 Lower temperature gradient in parts
 No accumulation
 Decline of viscosity
 Oil oxidation
 EM 11 Combustion Engines Prof. Dr.-Ing. K. Wehner / Taufik Fajar Nugroho M.Sc.

04/2012
Thank you for your attention!
Heat Transmission 31
31

 specific heat power only 21 KW/ liter << H2O

 lower temp gradient in parts
 maximum output power 55 KW