i

ENGINE PERFORMANCE AND EMISSION LEVEL INVESTIGATION OF

VEHICLE RUNNING WITH DIFFERENT TYPES OF RON FUEL GRADES AND

FUEL BRANDS

MUHAMMAD AMIN BIN DZULKIFLI

This report is presented in

Partial fulfilment of the requirements of the

Degree of Bachelor of Mechanical Engineering (Automotive)

Faculty of Mechanical Engineering

Universiti Teknikal Malaysia Melaka

May 2012

ii

SUPERVISOR DECLARATION

“I hereby declare that I have read this thesis and in my opinion this report is

sufficient in terms of scope and quality for the award of the degree of

Bachelor of Mechanical Engineering (Automotive)”

Signature : ...................................

Supervisor : Dr.Noreffendy B. Tamaldin

Date : ...................................

iii

DECLARATION

“I hereby declare that the work in this report is my own except for summaries and

quotations which have been duly acknowledged”

Signature :……………………….

Author : MUHAMMAD AMIN BIN DZULKIFLI

Date :……………………….

iv

ACKNOWLEDGEMENT

I am sincerely appreciative to my lecturer, Dr Noreffendy Tamaldin for

serving as my supervisor and for providing guidance while conducting the research

and the writing of this ‘Projek Sarjana Muda’(PSM).

I would like to thanks and convey special appreciation to the laboratory

management especially Engine Performance Testing Laboratory, the lab technicians

for their cooperation and support especially to Mr.Ridzuan Bin Ahmad who had been

involves in providing technical data on the chassis dynamometer. I also want to

thank my beloved family for their continous support and encouragement in

everything I do. All these years of education have been made possible by their

support and love.

Last but not least, I thank to everyone who involved directly and indirectly in

this project. The sacrifice and commitment given towards me earning my bachelor’s

degree are desirable and without them, this PSM thesis would have been impossible.

v

ABSTRACT

The goal of this project is to analyse the performance of engine and emission

level produced by vehicle by using different type of RON fuel grades and brands.

This analysis involves chassis dynamometer for engine performance and using

automobile exhaust gas analyzer for emission testing. For performance engine

analysis, the engine first is tested by using chassis dynamometer with different type

of RON fuel grades and brands. The result by running of chassis dynamometer will

show the graph performance of engine include the power, torque and brake specific

fuel consumption (bsfc). Next, the emission test is also performed to analysis and

compares the data of emission level produced by vehicle. This emission test will be

conducted with vehicle on idle and rapid acceleration by using chassis dynamometer

with different type of RON fuel grades and brands. This project also targeted on

developing the standard of procedure of fuel and emission testing using chassis

dynamometer. At the end of the project, the result shows which type of RON fuel

grades and brands produced greater engine performance and less emission level.

Further experimental testing can be done for better output result such as using engine

dynamometer which can obtain more accurate result for the fuel consumption.

vi

ABSTRAK

Matlamat projek ini ialah untuk menganalisis, ujian eksprementasi prestasi

enjin dan kadar gas pencemaran dari kenderaan yang menggunakan jenis-jenis gred

minyak RON dan jenama minyak yang berbeza. Analisis ini melibatkan penggunaan

casis dynamometer untuk ujikaji minyak dan menggunakan penganalisis exhaust gas

kenderaan untuk ujikaji tahap gas pencemaran. Untuk ujikaji prestasi engine

kenderaan, kenderaan diuji menggunakan casis dinamometer untuk mendapatkan

data prestasi enjin. Hasil data tersebut dapat dilihat melalui graf prestasi iaitu

termasuk kuasa, tork dan penggunaan minyak yang specific. Seterusnya, bagi ujikaji

kadar gas pencemaran pula data yang diambil setelah ujikaji akan dianalisis dan

dinilai. Ujikaji kadar pencemaran akan dijalankan pada situasi kenderaan pada tahap

setara dan juga ketika kenderaan menjalani ujian pada casis dinamometer disamping

menggunakan jenis gred minyak RON dan jenama minyak yang berbeza. Projek ini

juga untuk membangunkan langkah-langkah ujikaji yang standard untuk ujikaji

prestasi enjin dan kadar gas pencemaran menggunakan casis dinamometer. Setelah

sempurna projek ini, hasil kajian akan dapat dilihat apakah jenis gred RON minyak

dan jenama minyak yang menghasilkan kuasa atau prestasi enjin yang tinggi juga

menghasilkan kadar gas pencemaran yang paling rendah. Eksperimentasi ujikaji

lanjutan boleh dijalankan untuk mendapatkan data dan hasil kajian yang lebih baik

dan tepat seperti menggunakan enjin dynamometer.

vii

CONTENTS

CHAPTER SUBJECT PAGE

DECLARATION iii

DEDICATION iv

ACKNOWLEDGEMENT v

ABSTRACT vi

ABSTRAK vi

CONTENTS vii

LIST OF TABLES xi

LIST OF FIGURES xii

LIST OF SYMBOLS xiii

CHAPTER 1 INTRODUCTION

1.1 Project Background 1

1.2 Objective 2

1.3 Project Scope & Limitation 2

1.4 Problem Statement 3

viii

CHAPTER SUBJECT PAGE

CHAPTER II LITERATURE REVIEW

2.1 Research Octane Number (RON) 4

2.2 Internal Combustion Engine (ICE) 6

2.2.1 Working Principle 6

2.2.2 Engine Parameter 8

2.2.3 Graph of Performance 11

2.3 Dynamometer 13

2.3.1 Working Principle 14

2.4 Emission 15

2.4.1 Hydrocarbons 16

2.4.3 Carbon Monoxide (CO) 17

2.4.4 Oxides of Nitrogen (NOx) 18

ix

CHAPTER SUBJECT PAGE

CHAPTER III METHODOLOGY

3.0 Introduction 20

3.1 Whole Project Flow Chart (PSM I) 21

3.2 Whole Project Flow Chart (PSM II) 22

3.3 Experimental Project Flow Chart 23

3.4 Experimental Method 24

3.4.1Engine Performance Testing 24

3.4.1.1 Chassis Dynamometer 25

3.4.2 Emission Testing 30

3.4.3 Test Matrix 34

CHAPTER IV RESULT AND DISCUSSION

4.0 Introduction 35

4.1 Engine Performance Result 36

4.1.1 Fuel ESSO RON 95 & RON 97 37

4.1.2 Fuel PETRONAS RON 95 & RON 97 39

4.1.3 Fuel BHP RON 95 & RON 97 41

4.2 Analysis of Engine Performance 44

x

CHAPTER SUBJECT PAGE

4.2.1 Calculation of Bsfc 48

4.3 Emission Test Result 51

4.3.1 ESSO Fuel-Emission Result 52

4.3.2 PETRONAS Fuel- Emission Result 53

4.3.3 BHP Fuel- Emission Result 54

4.4 Analysis of Emission Test Result 55

4.4.1 Method I- Running Chassis Dynamometer 55

4.4.2 Method II- Idle Condition 57

CHAPTER V CONCLUSION & RECOMMENDATIONS

5.0 Conclusion 59

5.1 Recommendation 60

REFFERENCES 62

BIBLIOGRAPHY 64

APPENDIX 65

xi

LIST OF TABLES

NO. TITLE PAGE

3.1 Tested Vehicle Specification 27

3.2 Automobile Exhaust Gas Analyzer Specification 32

3.3 Test Matrix of Engine Performance and Emission Testing 34

3.4 Comparison Matrix of Fuel RON and Fuel Brands 34

4.1 Tested Fuel Power and Torque Result 43

4.2 Brake Specific Fuel Consumption (BSFC) Results 49

5.1 Result of the Best Fuel for Engine Performance and Emission 5

xii

LIST OF FIGURES

NO. TITLE PAGE

2.1 Four Stroke ICE Cycle ( Pulkrabek , 2004) 7

2.2 Graphs of Typical Torque, Power, Brake Fuel Consumption (Bsfc) 11

2.3 Graph of Torque and Power-Sample Result 12

2.4 Graph of Bsfc vs Engine Speed, depand on compression ratio 12

2.5 Mechanism of Dynamometer 14

3.1 Whole Project Flow PSM I 21

3.2 Whole Project Flow PSM II 22

3.3 Experimental Project Flow Chart 23

3.5 Custom Fuel Tank Installation to Test Vehicle 27

3.6 Tested Vehicle on the Chassis Dynamometer Drum 29

3.7 Custom Fuel Tank Connected to Engine Fuel Intake 29

3.8 Sample Graph of Performance/ Result from WinPeP7 software 30

3.9 Automobile Gas Analyzer 31

3.10 Sampling probe enter into exhaust pipe 33

3.11 Cooling Fan during Emission Test 33

4.1 Graph of Power and Torque vs Speed for ESSO RON 95 37

4.2 Graph of Air/Fuel Ratio vs Speed for ESSO RON 95 37

4.3 Graph of Power and Torque vs Speed for ESSO RON 97 38

NO. TITLE PAGE

xiii

4.4 Graph of Air/Fuel Ratio vs Speed for ESSO RON 97 38

4.5 Graph of Power and Torque vs Speed for PETRONAS RON 95 39

4.6 Graph of Air/Fuel Ratio vs Speed for PETRONAS RON 95 39

4.7 Graph of Power and Torque vs Speed for PETRONAS RON 97 40

4.8 Graph of Air/Fuel Ratio vs Speed for PETRONAS RON 97 40

4.9 Graph of Power and Torque vs Speed for BHP RON 95 41

4.10 Graph of Air/Fuel Ratio vs Speed for BHP RON 95 41

4.11 Graph of Power and Torque vs Speed for BHP RON 97 42

4.12 Graph of Air/Fuel Ratio vs Speed for BHP RON 97 42

4.13 Comparison Data of Fuel RON 95 Power 44

4.14 Comparison Data of Fuel RON 97 Power 44

4.15 Comparison Data Fuel RON 95 & RON 97 (Power) 45

4.16 Comparison Data of Fuel RON 95 Torque 46

4.17 Comparison Data of Fuel RON 97 Power 46

4.18 Comparison Data Fuel RON 95 & RON 97 (Torque) 47

4.19 Graph of BSFC Vs Fuels 50

4.20 Data Emission Test Fuel ESSO -Method I 52

4.21 Data Emission Test fuel ESSO- Method II 52

4.22 Data Emission Test Fuel PETRONAS -Method I 53

4.23 Data Emission Test Fuel PETRONAS -Method II 53

4.24 Data Emission Test Fuel BHP -Method I 54

4.25 Data Emission Test Fuel BHP -Method II 54

4.26 Comparison of value CO (%)-Method I 55

4.27 Comparison of value HC (ppm)-Method I 55

4.28 Comparison of value NOx (ppm)-Method I 56

4.29 Comparison of value CO (%)-Method II 57

4.30 Comparison of value HC (ppm)-Method II 57

xiv

LIST OF SIMBOLS

�̇� = Engine power

�̇�𝑏 = Brake power

Vd = Displacement volume

n = Number of revolution per cycle

N = Number of revolution per minute(RPM)

Nc = Number of cylinder

B = Bore size

S = Stroke size

�̇�𝑓 = Mass flow rate of fuel

�̇�𝑎 = Mass flow rate of air

𝜌𝑎 = Air density evaluated at atmospheric conditions outside the engine

QHV = Heating value of fuel

𝜂Rf = Fuel conversion efficiency

𝜂Rc = Combustion efficiency

Ap = Piston area

mep = Mean effective pressure

bmep = Brake mean effective pressure

𝑈�𝑝 = Piston speed

T = Torque (Nm)

P = Power (kW)

xv

LIST OF APPENDIX

NO. TITLE PAGE

A Gantt Chart PSM I 66

B Gantt Chart PSM II 67

C Chassis Dynamometer Data 68

D ICEI2012 Paper 74

1

CHAPTER I

INTRODUCTION

1.1 Project Background

Nowadays, in our market, there are two types of fuel RON available in

Malaysia namely RON 95 and RON 97. A couple of years ago, government had

introduced RON 95 fuel in our country because of the global fuel price increase

sharply within short period of time. RON 97 fuel still remains in our market with a

higher price than RON 95. People prefer the RON 95 fuels to be filled in their

vehicles but questions arise about the performance of engine and fuel consumptions.

This final year project will discuss about the performance and emission study

with different type of RON grades and fuel brands using a chassis dynamometer. The

engine performance of vehicles will be analysed the graph of performance after fuel

test using a chassis dynamometer. Emission test will conduct using portable

combustion analyzer, and the data will be analysed to decide which type of fuel

RON and brands gives higher performance and less emission level.

2

1.2 Objective

Below are the objectives for this project:

I. To compare the performance of engine with different types of RON fuel

grades and brands.

II. To compare the emission level from vehicle by using different types of

RON fuel grades and brands

III. To develop the standard of procedure of fuel testing by using chassis

dynamometer, at FKM, UTeM.

1.3 Project Scope and Limitations

The scopes of this project are:

I. To analyze the performance of engine by using graph of performance

(power, torque and brake specific fuel consumption (BSFC)).

II. To analyze the amount of emission gasses produced by different type of

RON fuel grades and brands.

III. Using chassis dynamometer and portable combustion analyzer to make

comparison of engine performance and emission level.

IV. Using two types of RON which RON 95 & RON 97 from three types of fuel

producer (ESSO, PETRONAS, BHP).

3

1.4 Problem Statement

The general public nowadays still does not fully understand about to choice

of fuel in their car between RON 95 and RON 97, which one will better deliver

engine performance and also fuel consumption. There have been claims that RON 97

fuels performs than RON 95 fuels, and also helps clean engine components better.

Some also said that the emission gasses output from a vehicle also affected by using

different types of RON fuel grades. Therefore, the problem statements for this

project are:

I. The effect of different of RON fuel grades and different brands to the vehicle

remain unknown to the public.

II. Emission level produced from different RON grade and fuel brands also

varies.

III. The vehicle performance (power, torque and brake specific fuel

consumption) resulting from this RON grades and fuel brands also not fully

understood.

4

CHAPTER II

LITERATURE REVIEW

2.1 INTRODUCTION

Fuel-related sources of engine performance problems include excessively

high or low volatility, water absorption, improper storage and handling, enleanment,

reduced motor octane, and materials compatibility. Performance problems can occur

for a variety of reasons, and tracing performance problems to a specific cause

is difficult, and often impossible. Potential engine performance problems resulting

from fuel-related sources include rough engine operation, overheating, damaged

pistons, vapour lock, starting difficulty, plugged fuel filters, fouled spark plugs, fuel

leaks, hesitation during acceleration, flooding, stalling, and engine fires.

(D.J.Kortom, L.Haslett, L.Beard, K.Liechty, M.Coryell, C.Bruner-Fuel Economy

and Engine Performance Issues)

5

2.1 RESEARCH OCTANE NUMBER (RON)

The Research Octane Number (RON) is a number that is awarded to

different grades of fuel with present to its capability to resist auto-ignition or known

as knocking. RON is determined by running the fuel in a test engine with a variable

compression ratio under controlled condition, and the result is compared with

mixtures of iso-octane and n-heptane. The other words, is a rating used to measure a

fuels knocking resistance in spark-ignition internal combustion engines. The lower

of RON the easier it becomes for fuels to ignite in the engine. Therefore, the fuels

with a higher octane number will eliminate knocking, which have high compression

ratio and gain more power in the engine. Below are the basic about available fuel:

a) Unleaded Petrol (ULP)

Unleaded Petrol or ULP has a Research Octane Number (RON) of between 91 and

93. Vehicles that use ULP operates with a catalytic converter because of the emitted

gasses from exhaust are too high.

b) Premium Unleaded Petrol (PULP)

This premium petrol is a special blend of petrol with a higher octane rating which

can produce higher engine power. So it gives more performance to the vehicle as

well as knock-free performance and assisting the vehicle to run at its optimum.

PULP has a Research Octane Number (RON) of 95 or 96.

6

c) Ultra Premium Unleaded Petrol (UPLUP)

Ultra means ultimate or it is a fuel have high octane unleaded fuel that maximises

engine power and performance. The fuel burns cleanly as well as producing less

pollution. UPULP which has a RON of 98 commonly recommended for imported

high performance vehicles.

In practice, it is believed that the higher octane rating makes engines better in

performance. This attracts people to use higher-octane gasoline in their engines.

Although, it has been explained that using correct gasoline is the best for the engines,

people still prefer to use higher-octane gasoline.(Toyotasa, 2000). Another study

clearly reported that octane number plays an important role on exhaust emission. The

results demonstrated that as the octane number was increased from 91 to 93, CO

emission boosted nearly 5 %.(C.Sayin,& I.Kilicaslan, 2006).

7

2.2 INTERNAL COMBUSTION ENGINE (ICE)

This section will cover the working principle and engine parameter of the 4

stroke ICE.

2.2.1 Working Principle

Internal combustion engine (ICE) is a heat engine that converts chemical

energy in a fuel into mechanical energy, commonly made available on rotating

output shaft. Chemical energy of fuel is first converted to thermal energy by means

of combustion or oxidation with air inside the engine. This thermal energy raises the

temperature and pressure of the gasses within the engine, and the high pressure gas

then expands against the mechanical mechanism of the engine. This expansion is

converted by the mechanical linkages of the engine to the rotating crankshaft, which

is the output of the engine. The crankshaft, in turn, is connected to a transmission or

power train to transmit the rotating mechanical energy to the desire final use. Most

of the ICE is reciprocating engines having pistons that reciprocate back and forth in

cylinders internally within the engine.

Figure 2.1: Four Stroke ICE Cycle ( Pulkrabek , 2004)

8

Below are the four-stroke SI engine cycle detail descriptions of internal combustion

engine as shown in Figure 2.1:

a) First Stroke: Intake Stroke or Induction

The piston moves downward that draws a combustible mixture of fuel and

air past the throttle and intake valve into the cylinder. At this stroke, the intake valve

open and the exhaust valve closed.

b) Second Stroke: Compression Stroke

During the Compression stroke, the piston moves upward, compressing the

fuel/air mixture. The entire valve closed, and it will raise the temperature of the

mixture. A spark ignites the mixture toward the end of the compression stroke.

c) Third Stroke: Expansion or Power Stroke

At power stoke, the spark plug fires, ignites the compressed fuel. As the fuel

burns it expands, driving the piston downward. The expansion or power stroke

resulting from combustion of the fuel-air-mixture. At this stroke, both intake and

exhaust valve closed.

d) Fourth Stroke: Exhaust Stroke

At the bottom of the power stroke, the exhaust valve is opened by the

cam/lifter mechanism. The upward stroke of the piston drives the exhausted fuel out

of the cylinder. At this stroke, the intake valve closed and the exhaust valve open.

9

2.2.2 Engine Parameter

Engine parameters are used to determine a performance evaluation of the

engine after run the engine testing.

Torque

The engine torque 𝜏 is a measure of the work done per unit rotations (radians) of the

crank. It also a good indicator of an engine’s ability to do work. Unit of torque are

Nm or lbf-ft.

τ = bmep. Vd/2πn .............(1)

Power

Power is defined as the rate of work of the engine. Unit for the power is kW.

(1 kW = 1.341 hp)

�̇� = 𝑊𝑁𝑛

.............(2)

�̇� = 2𝜋𝑁𝜏 .............(3)

�̇� = � 12𝑛� (𝑚𝑒𝑝)�𝐴𝑝��𝑈�𝑝� ..............(4)

Air Fuel Ratio and Fuel Air Ratio

Define as the mass ratio of fuel present during combustion

AF = f

a

mm

= .

.

f

a

m

m

……… (5)

FA = a

f

mm

= .

.

a

f

m

m =

AF1

……… (6)