Recreation of water-cooled exhaust manifold to improve exhaust gas recirculation / Muhammad Irfan Asha'ari

Muhammad Irfan , Asha'ari (2021) Recreation of water-cooled exhaust manifold to improve exhaust gas recirculation / Muhammad Irfan Asha'ari. Masters thesis, Universiti Malaya.

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Abstract

The exhaust manifold is a component of the common internal combustion engine designed to help flow the exhaust gases away from the cylinder. Usually attached onto the cylinder head with gaskets, nuts and bolts; modern technology has made it possible to integrate the exhaust manifold into the cylinder head. This results in a reduction of cost to manufacture or outsource gaskets, nuts and bolts; lower weight, volume and size; improved fuel consumption; and improved warm-up times from initial start-up. A functional method of improving emissions of an internal combustion is the introduction of recirculated exhaust gases for combustion. The system that incorporates this concept is called Exhaust Gas Recirculation. Traditionally, hot exhaust gas is fed into an EGR valve which regulates the amount of EGR into the intake of a diesel engine. This results in the reduction of NOx emissions due to the lower combustion temperature. Another use of EGR is to cool it and then introduce into the intake. This leads to an increase of engine efficiency due to the lower density of the air-fuel mix. However, modern Spark-Ignited engines have started to incorporate EGR to improve fuel consumption, part-load throttle performance and emissions. Modern engines also incorporate turbocharging, this therefore leads to further design variations in cooling the temperature of exhaust gas. This paper discusses the application of Exhaust Gas Recirculation, Cooled Exhaust Gas Recirculation, Integrated Exhaust Manifold and its concepts to recreate an exhaust manifold suitable for retrofitting onto existing engines of various applications. This exhaust manifold aims to reduce exhaust gas temperatures for the applications stated above to reduce heat transfer and stress on other existing systems while improving fuel consumption and emissions. This reduction in heat transfer to the other components in the engine bay can be attributed to the flow of fluid in the water-cooled exhaust manifold which extracts heat from the walls of the exhaust ports and into the fluid which will then be cooled by a radiator.

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