Improving Efficiency of I.C. Engine using Secondary Fuel - Career Episode 1

Career Episode 1 describes a project that aimed to improve the efficiency of I.C. engines by using secondary fuel. The project involved identifying and analyzing an efficient secondary fuel source, managing the cost and output efficiency of the secondary fuel, reducing fuel utility, minimizing carbon decomposition, increasing engine life span and efficiency, reducing pollution, and managing project delivery within the estimated timeline and budget. The author's area of work involved developing the HHO generator and testing it on a diesel engine. The author also managed the project plan and was responsible for designing and testing the proposed modification of the oxidizer. The project was successful in developing an energy-efficient and environment-friendly approach to managing IC engines combustion and functioning.

COMPETENCY
DEMONSTRATION REPORT
Career Episode 1

CE 1.1 Project Information
Name of the project: Improving the Efficiency of I.C. Engine using Secondary Fuel
Location of the project: [PLEASE FILL]
Project Duration: [PLEASE FILL]
Organization: [PLEASE FILL]
Role and Designation during the time: Team Member
I observed that the fuel being consumed by the I.C engine can be an option for bringing
innovation in the field of the mechanical engineering. As a mechanical engineer, I successfully
delivered the project emphasizing on increasing the efficiency of the I.C engine through allowing
the users to utilize secondary fuel. I.C engines are widely used in the industries and hence, I
decided to propose a revolutionary product that is widely accepted by the individuals. The basic
details are provided in the above section and the technical and mechanical details are provided in
the following sections.
CE 1.2 Project Background
CE 1.2.1 Characteristics of the project
There is intense need of the secondary fuel that is cost efficient and that promotes the
sustainability and capable enough to be used as a replacement of the fossil fuels. I considered it
as a quality milestone that the secondary fuel should have same or greater efficiency as
compared to the ordinary fuels. I used HHO (hydroxyl or Browns Gas) gas as the secondary fuel

in this project. It can be produced through water electrolysis that splits the oxygen and the
hydrogen from electrolysis that can be used as per the demand without additional need of the
storage. This implies in the utilization of the secondary fuel that can be helpful in reducing the
fuel utility by 10m to 30 percent and also enhancing the life span and efficiency improvement.
CE 1.2.2 Objectives developed for the project
I was working in a team and so, it was my responsibility to contribute in the development
of set of the objectives that can be used as the path for successful and efficient delivery of the
project. Following are the objectives those were selected for the successful deployment of the
project:
 To identify and analyse an efficient secondary fuel source
 To manage the cost and output efficiency of the secondary fuel at maximum
 To use HHO as a secondary fuel
 To reduce the fuel utility from 10% to 30%
 To minimize the carbon decomposition
 To increase the life span and efficiency of the engines
 To reduce the pollution and increase the torque of the engine
 To manage the project delivery within the estimated timeline and budget
 To establish and effective communication between the different team members

CE 1.2.3 My area of work
I was assigned with the HHO generator development and the testing phase of the project
in manner to contribute in the development and execution of the selected project. I developed the
HHO generator after calculating all the mathematical variables and developed the model of the
generator for performing the electrolysis. I delivered the testing phase on the diesel engine
through using the HHO gas considering its application in various sectors and wide utilization in
different industries. My primary activity in the testing phase was to evaluation of the production
line of the engines considering the proper output, fuel consumption, working, and many more. I
collected following data after comparing the 10 ml fuel consumption without and with HHO in
diesel engine:
S.No Fuel Consumed Time Taken With Secondary Fuel
(HHO) (Sec)
Time Taken Under
Normal Fuel(Diesel)
(Sec)
1. 10ml 117 102
2. 10ml 115 104
3. 10ml 111 100
4. 10ml 113 102
5. 10ml 115 104
Average =114.2 Average = 102.4

CE 1.2.4 Project Group
CE 1.2.5 My responsibilities throughout the project
I was responsible for the development of the project plan and managing the managerial
constraints. So, I developed the project schedule, budget, communication pan, risk management
and handled all the major activities those were necessary for the smooth and effective flow of the
project. I was assigned to the two major sectors that include designing of the generator and the
testing phase and it was my responsibility to make sure that these sectors are being accomplished
in an efficient and effective manner. I had to evaluate the proposed model effectively for
assuring that the proposed model can fulfil the needs and requirements of the I. C. engines. I had
to assure that the developed project plan will be effective enough for deploying the project.

CE 1.3 Distinctive Activity
CE 1.3.1 Comprehending the theory of the project
The basic working of the ICE can be expressed as a heat engine where the fuels are
combusted with an oxidizer. This exchange of heat lead to the rise of high pressure and the
expansion of the temperature and thus, can be converted into mechanical energy and force can be
generated. This force can be applied to nozzle or rotor, turbine blades, or pistons and thus,
chemical energy is being converted into mechanical energy. However, the current practices of
combusting the fuels is not very efficient and can rise the population level that is influencing the
environment. The approach is being driven to propose a secondary fuel ‘HHO’ gas through water
electrolysis. I suggested to replace ait oxidizer with the HHO in manner to enhance the efficiency
and application of the IC engines. This replacement can be helpful in increasing the efficiency
and the life span of the engines. Moreover, the suggested transformation can be helpful in
reducing the pollution and managing the greenhouse effect.
CE 1.3.2 Engineering knowledge and skills applied in the project
While designing the generator, I calculated the energy in 1L of the HHO that can be
stored in limited volume of hydrogen within the engine:
Mass of hydrogen in 1L at STP;
mh2 = (P.v.MW)/R.T
= (101325X 667 X106 X 2.016)/ (8.3145X 298.15) = 55.0mg
Where, mH2 is the mass of hydrogen

V is volume of gas [m3]
P is the pressure of air [Pa]
MW is the molecular weight of hydrogen [g mol-1]
T is the temperature [K]
R is the ideal gas constant [J K-1 mol-1]
Energy in 1 litre of HHO in terms of the product of the higher heating value of hydrogen
(HHVH2):
EH2 = mH2 * HHVH2
= 55.0 * 10-6 * 141.86 *103 = 7.8 kJ {HHVH2 is the higher heating value of hydrogen [J/g]}
I performed the test on four stroke diesel engine through mechanical load using diesel
engine:
Sl.
No.
Brake
power
(kW)
Fuel
consumptio
n (Kg/hr)
Specific
fuel
consumptio
n
(kg/Kw.hr)
Indicated
power (kW)
ŋbt(%
)
ŋm(%
)
ŋit(%
)
1. 0.91 0.312 0.34 1.61 24 56 43.5
2. 1.73 0.50 0.28 2.43 29 71.1 41
3. 2.31 0.63 0.27 3.01 30 76 40.3
4. 0.43 0.25 0.58 1.13 14.5 38 38.1

5. 1.35 0.36 0.266 2.05 32 65 48
CE 1.3.3 Accomplishment and task performed
I developed the design of the HHO generator.
I tested the proposed transformation.
I gathered the results after testing that was satisfactory.
I managed the project plan, considering my leadership and managerial attributes.
I managed designing and testing of the proposed modification of the oxidizer and tried to
make the system efficient and long running device.
Other than above, I also performed the performance test of the four stroke diesel engine
using the HHO gas and gathered following results:
S.
No.
Fuel
consumptio
n (kg/h r)
Specific
fuel
consumptio
n (kg/k w.hr
Brake
power
(kW)
Indicate
d power
(kW)
ŋbt
(%)
ŋm
(%)
ŋit (%)
1. 0.26 0.286 0.91 1.61 22.8 56.52 42.5
2. 0.18 0.43 0.42 1.12 13.2 37.5 39.3
3. 0.309 0.228 1.35 2.05 31.6 65.8 47
4. 0.57 0.23 2.30 3.0 29.4 76.66 41.6
5. 0.42 0.25 1.73 2.43 30.5 71.1 43

CE 1.3.4 Identified issues and their solutions
1.3.4.1 Issues
The designing of the bubble bottle was the major concern through the project in manner
to manage the feasibility of the entire project and manage its efficiency. I identified that the
safety bubbler should be withstanding and flexible considering the little bit pressure and the
vibration; it should also transparent and should be at height.
1.3.4.2 Solutions
The above conditions need to be fulfilled and hence, simple water bottle made of plastic
was established for allowing the incoming and outgoing plumbing works. It can be demonstrated
by following figure:
I dipped the generated gas after electrolysis through HHO generator into the level below
the water and thereafter, kept the outgoing tube at the top of the bottle and tighten all the
arrangements. The introduced bubbler were helpful in resolving two major problems as the
generated bubbles washed HHO bubbles are avoided and washed the chemicals from
electrolyzing to flow into the engine.

CE 1.3.5 Plan to produce creative and innovative work
I suggested to replace ait oxidizer with the HHO in manner to enhance the efficiency and
application of the IC engines. This replacement can be helpful in increasing the efficiency and
the life span of the engines. Moreover, the suggested transformation can be helpful in reducing
the pollution and managing the greenhouse effect.
CE 1.3.6 Collaborative work
The team was comprised for five members and I was appointed as one of the team
member and I had to deliver the necessary deliveries within the team. Every member of the team
was responsible of different sections of the project as there were other sectors too other than
designing of generator and testing. Evaluation. Arrangement, fixing, and various other activities
were accomplished by the team members and I was assigned to these two sectors and every team
member was responsible for delivering their sector of jobs.
CE 1.4 Project Review
CE .4.1 Project Overview and Contribution
I developed a project that can be energy efficient and effective in managing the IC
engines combustion and functioning. The developed project can be helpful in conserving energy
and managing the same operational activities as it was being accomplished traditionally. I
contributed in the development of a project that is energy efficient and can be environment
healthy that previous approaches.

I had an amazing experience in this field as I get the chance to apply my theoretical
knowledge into practical job. I also used the mechanical engineering attributes for developing the
generator, mathematical calculation, and various other mechanical engineering responsibilities.
Other than the above, I had an interesting experience of leading a team and working in a
group. I learnt the necessary leadership attributes that can be further utilized for improving my
professional behaviour.