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Small single & two cylinder diesel engines, still have primitive technical design features and extensively used in India and various Asian countries to power small and light motor vehicles viz., three wheelers, light duty four wheelers. These vehicles have become inevitable for the transport for both urban and rural areas. Vehicles with small single & two cylinder engines have high market demand in commercial transport due to restrictions on entry of Heavy Commercial Vehicles (HCV) in congested cities roads. Due to ever rising market demand for higher power and torque requirement along with better fuel economy, vehicle manufacturer are developing high Brake Mean Effective Pressure (BMEP) engines or replacing single cylinder engine by two cylinder engine, similarly two cylinder engine by three cylinder engines. Further, these engines should meet the present and forthcoming stringent emission limits.

Following global trends of increasingly stringent greenhouse gas (GHG) and criteria pollutant regulations, India will likely introduce within the next decade equivalent Bharat Stage (BS) regulations for Diesel engines requiring simultaneous reduction in CO2 emissions and up to 90% reduction in NOx emission from current BS-VI levels. Consequently, automakers are likely to face tremendous challenges in meeting such emission reduction requirements while maintaining performance and vehicle total cost of ownership (TCO), especially in the Indian market, which has experienced significant tightening of emission regulation during the past decade. Therefore, it is conceivable that cost effective approaches for improving existing diesel engines platforms for future regulations would be of high strategic importance for automakers.

Currently, on-road transport contributes nearly 12% of India’s total energy related carbon dioxide (CO2) emissions that are expected to be doubled by 2040. Following the global trends of increasingly stringent greenhouse gas emissions (GHG) and criteria emissions, India will likely impose equivalent Bharat Stage (BS) regulations mandating simultaneous reduction in CO2 emissions and nearly 90% lower nitrogen oxides (NOx) from the current BS-VI levels. Consequently, Indian automakers would likely face tremendous challenges in meeting such emission reduction requirements while balancing performance and the total cost of ownership (TCO) trade-offs. Therefore, it is conceivable that cost-effective system improvements for the existing internal combustion engine (ICE) powertrains would be of high strategic importance for the automakers.

The Objective of the work is to upgrade existing series of multi cylinder DI turbocharged intercooled diesel engines to meet revised stringent Stage-II emission norms for diesel genset application. In this engine tuning activity, focus is given on optimization of engine without any major modification on engine design features. In recent years, the demand use and penetration of diesel operated generating sets for the power generation application has sharply rise in India. These sharp rises in the DG engines have made the high impact on pollutants emitted by these sets. Hence, concerned authorities have first enforced the limits on the pollutants emitted by these sets in the year 2004. Further these emission limits were tightened recently and reduced the emissions from diesel engines. Concerned authorities implemented the revised emission norms with effective from July 2014. The reduction in NOx+HC emission is around 62% for the engines having rated power above 75 kW.

Single cylinder and two cylinder diesel engines are widely used as a source of power generation, three wheelers, agricultural machines and in small house-hold applications in India as well as other Asian countries. Use of high end technologies in such engines are very expensive and also becoming complex. Therefore simple mechanically controlled components are used for these engines which make them simple in operation and maintenance. In order to meet stringent emission norms, there is a need for the development of these engines. In the present work, an existing two cylinder naturally aspirated DI diesel engine is upgraded with Turbocharged & Intercooled (TCIC) version to meet the revised stringent stage-II emission limits. The two cylinder diesel engine has been upgraded with optimum selection of turbocharger, intercooler and EGR valve to control the EGR mass flow rate.

Single cylinder and two cylinder diesel engines are having prevalent applications for as a source of power generation, three wheelers, agricultural machines, small house-hold applications as well as in mobile towers in India and other south Asian countries. As emission limits for these segment of engines are becoming stricter than the existing limits, it is necessary to upgrade these engines to meet the various emission limits applicable. The design features & technical characteristics of these engines are very simple and primitive, hence, it is extremely difficult and challenging to make these engines emission compliant. By using the relevant simulation tools, the task of emissionising these engines can be made simple to a greater extent. It gives a greater flexibility and ease in analyzing, designing, and operating complex engine systems.