2.1. Materials
The liquids under examination are diesel fuel, fatty acids methyl esters (FAME) of rapeseed oil (B100), and diesel-FAME blends (B6 and B12, i.e. the concentration of FAME is 6 wt.% and 12 wt.%, respectively, from the mass of diesel fuel). Table 1 lists the mass concentrations of components for the production of FAME and diesel-biodiesel blends.
Table 1
Components for producing FAME and blends of biodiesel samples
Fuel | Components | Mass Concentration (wt.%) |
FAME (B100) | Methanol | 24.75 |
Potassium hydroxide | 1 |
Rapeseed oil | 74.25 |
B6 | FAME | 6 |
Diesel fuel | 94 |
B12 | FAME | 12 |
Diesel fuel | 88 |
Diesel | Diesel fuel | 100 |
FAME is produced from refined rapeseed oil, methanol (chemically pure) as an esterifying agent, and potassium hydroxide (chemically pure) as a catalyst. The choice of substances is due to the fact that methyl esters, unlike ethyl esters, show higher power output and torque in engine tests. When using ethanol, problems arise when washing biodiesel from excess alcohol, since ethanol forms a stable emulsion. Methyl esters are stored much longer than ethyl esters. Potassium hydroxide (KOH) is used as the catalyst, since the base catalysts are preferable to acid ones due to increased activity and reduced reaction temperature.
2.2. Biodiesel preparation using a self-developed nanofiber-based membrane reactor
At the first stage of preparation, 4 g of KOH is dissolved in 100 ml of methanol. Then, 300 ml of rapeseed oil is added to the resulting mixture. After that, this mixture is poured into a nanomembrane reactor manufactured at the in-house multichannel electrospinning unit “NIKE-1” from a spinning solution – a mixture of N, N-dimethylformamide (DMF) and acetone in a ratio of 15/85 wt.%, to which polyvinylidene fluoride (PVDF) and a copolymer of vinylidene fluoride with tetrafluoroethylene (VDF-TeFE) are added in a ratio of 50/50 wt.% with a total polymer ratio in solution of 8 wt.%. Cylindrical polymer nanomembrane has the following dimensions: inner diameter of 100 mm, 150 mm in length, 320 µm in thickness. According to scanning electron microscopy (SEM) performed using the TESCAN VEGA 3 SBH instrument (Tescan, a.s., Czech Republic), the nanomembrane is formed by randomly intertwining fibers with an average diameter of 1.03 ± 0.04 µm. The surface area of pores is 147.41 ± 10.13 µm2, and the surface porosity of nanomembranes is 34.57 ± 2.41%. According to the Brunauer–Emmett–Teller (BET) method for the mathematical characterization of the physical adsorption of gas molecules on a solid surface, the specific surface area of the nanomembrane is 4.6498 m2/g, the pore volume is 0.008549 cm3/g, and their average size is 7.35403 nm. In the reactor, the liquids are mixed using an overhead stirrer US-8100 (a speed of rotation of 100-3,000 rpm is set with an accuracy of ± 2%) at a given rotation speed of 650 rpm. To maintain a constant liquid temperature of 70°C, a coiled heat exchanger is placed in the reactor. An external circuit of a cryostat (an operating temperature range from − 30°C to + 200°C, an accuracy of ± 0.1°C) is connected to the exchanger. As a result, during the chemical reaction, FAME of rapeseed oil – biofuel B100 – pass through the porous walls of the reactor and collect in a laboratory beaker for further use.
2.3. Liquid properties
To determine the cetane number, an octane meter with a measuring range from 30 to 60 units and a measurement error ± 2.0 units is employed. The octane meter sensor is immersed in a test tube with a biofuel sample, after which the cetane number of the test sample is measured. Three series of measurements are performed for each sample, and the average value is calculated.
The flash point is determined by the Pensky-Martens closed-cup test. The measurements are performed at regular intervals when the temperature of the test sample increases by 1°C. The lowest temperature, at which the fuel vapors are ignited, is the flash point under atmospheric pressure.
To measure fuel viscosity at 40°C, an external circuit of the cryostat is connected to the Brookfield DV3T-LV viscometer (an accuracy of ± 1%, a measuring range of 1...6·106 mPa·s). In particular, to maintain a fuel temperature of 40°C, this circuit passes through the Small sample adapter (SSA) in which the fuel sample is located at the measurement. Temperature is monitored by a thermocouple built in the SSA (an operating temperature range from − 15°C to + 100°C). Measurements at 40°C are carried out in a range of shear rates from 100 s− 1 to 250 s− 1 in 1 s− 1 increments. In this range of shear rates, the torque is 10–100 N\(\cdot\)m. For all biofuels, the three measurements are made for each shear rate.
The density of biofuel is measured by the pycnometric method using the average density values in three measurements using the Vibra AF 225DRCE analytical scales with a sensitivity of 10− 6 g.
The surface tension factor is measured using the Kruss K20 tensiometer with a measuring range of 1...999 mN/m and a resolution of 0.01 mN/m by the Wilhelmy plate method. For each biofuel, a series of five measurements is performed with a further automatic calculation of the average values.
Table 2 reports the results of measuring the properties of the studied biofuels. The properties of diesel fuel are documented in the product passport received at the local gas station “Gazpromneft". The detailed properties are given in Table A1 in Supplementary materials.
Table 2
Properties of the considered liquid fuels
Parameter | Fuel |
Diesel | B6 | B12 | B100 (FAME) |
Cetane number, units | 53 | 55.7 | 57.6 | 71 |
Closed-cup flash point, °C | 66 | 62 | 63 | > 170* |
Viscosity at 40°C, mm2/s | 3.07 | 2.53 | 2.54 | 3.81 |
Density, kg/m3 | 841 | 830 | 834 | 869 |
Surface tension factor, mN/m | 28.1 | 27.4 | 27.5 | 30.5 |
* The upper limit of the thermometer measurement is 170°C. The flash point was not recorded up to this temperature.
2.3. Test rig
Figures 1a and 1b demonstrate the scheme and photograph of a test rig with a swirl burner, respectively. It is equipped with a combustion chamber with optical access (see design information in Fig. A1 in Supplementary materials) and the EGR system. The test rig allows the analysis of the characteristics of atomization (number, size, velocity and trajectory of liquid droplets) and combustion (flame temperature and structure), and the concentrations of such gaseous combustion products as CO, NOx, CO2, O2).
The fuel storage tank (8) is a metal cup (see design information in Figs. A2 and A3 in Supplementary materials). The following components are installed in the upper part of the cup: a pressure gauge (5), a fuel loading unit (6), a gas outlet pipe to the atmosphere with a control valve (4) and a gas tank filling pipe with a control valve (3). The tank is filled with gas using a nitrogen cylinder (2) and a pressure regulator (1). Fuel is atomized through a Danfoss 0.4 x 60 S 030F6904 diesel nozzle with a spray angle of 60° (13), above which ignition electrodes (12) are installed to form a spark. To control the fuel atomization, an electric valve (10) and a ball valve (9) are used. A designed axial-vane swirler of a gas-liquid flow (25) is installed in front of the combustion chamber (23) to enhance air-fuel mixing (see the insert of Fig. 1a). An oxygen concentration sensor (14) is placed behind the combustion chamber, showing the air/fuel ratio AFR. This ratio is regulated by means of a centrifugal fan regulator (11). To reduce the exhaust gas temperature, a water heat exchanger of the spiral type (15) made of stainless steel is used. This heat exchanger cools the exhaust gases by heat transfer between the heated (gases) and cold (water) media. Recirculation of water from tank (21) through the heat exchanger is carried out using a circulation pump (22) with a maximum volume flow of 2.5 m3/h. After cooling, the exhaust gases are released into the atmosphere through pipe (19). However, when the EGR system needs to be operated, throttle valve (18) opens. To determine the component composition of the gas combustion products, a gas analyzer (20) and a probe (16) installed in the heat exchanger casing (15) are utilized. The location of the probe is determined depending on the exhaust gas flow velocity; for the most reliable measurement, the location with the lowest flow velocity is required. Therefore, the most suitable location of the probe is the heat exchanger casing, namely, behind the heat exchanger relative to the motion direction of exhaust gases. Magnetic stirrer (27) with a heating option is employed to maintain a constant and homogeneous fuel temperature in the storage tank (8) at a level of 20°C ± 1°C.
2.4. Biodiesel atomization characterization
To study fuel atomization with and without a gas-liquid flow swirl, a series of three experiments is performed at injection pressures (P) of 0.6 MPa and 1.2 MPa. At the same time, the air flow velocity varies in the range from 11 m/s to 13 m/s. The spray process is recorded by shadow video recording at a distance of 7 cm from the nozzle orifice in the central part of the viewing window of the combustion chamber. Video recording is carried out using a high-speed video camera (scale factor 0.0248 mm/px, sample rate 25,000 fps, resolution 384\(\times\)288 px) with a lens (focal length 200 mm, aperture 11), a LED spotlight and a PC with software for processing and post-processing the captured video material. Post-processing of the resulting image is performed in the Matlab software package using the in-house code that implements the Kalman filtering method [44]. This filter allows tracking individual droplets in the flow, while determining their number, size, trajectory, and velocity according to the DIN SPEC 91325 [45]. The Kalman filter also allows predicting the future location of a droplet based on the equation of motion. To perform post-processing using the Kalman filter, the original video recording consisting of 500 frames is uploaded to Matlab. In each video frame, droplets are detected and assigned an individual track number, which allows tracking the detected droplets on subsequent video frames. For each detected droplet, the area S in pixels is calculated, and then the droplet diameter is calculated using the following formula: \(d=\sqrt {{{4S} \mathord{\left/ {\vphantom {{4S} \pi }} \right. \kern-0pt} \pi }}\), where S is the area of a spherical droplet. Multiplying by a scale factor, the diameter is converted from a pixel value to a millimeter value. Calculating the droplet diameters on all video frames enables the determination of the arithmetic mean diameter (d10), Sauter mean diameter (d32), and droplet velocity magnitude (U) estimated as \(U=\sqrt {U_{x}^{2}+U_{y}^{2}}\), where Ux and Uy are the droplet velocities along the X-axis and Y-axis, respectively. Diameter d10 is calculated as: \({d_{10}}={{\sum d } \mathord{\left/ {\vphantom {{\sum d } N}} \right. \kern-0pt} N}\), where d is the droplet diameter, N – total number of droplets. The diameter d32 is the one of a droplet that has the same volume-to-surface ratio as the total volume (V) of all droplets relative to their total surface (A), and is calculated as: \({d_{32}}={{d_{{\text{V}}}^{3}} \mathord{\left/ {\vphantom {{d_{{\text{V}}}^{3}} {d_{{\text{S}}}^{{\text{2}}}}}} \right. \kern-0pt} {d_{{\text{S}}}^{{\text{2}}}}}\) where dS is the surface diameter of droplet set, dV – volume diameter of droplet set. The values of dS and dV are determined as: \({d_{\text{V}}}={\left( {{{6V} \mathord{\left/ {\vphantom {{6V} \pi }} \right. \kern-0pt} \pi }} \right)^{{1 \mathord{\left/ {\vphantom {1 3}} \right. \kern-0pt} 3}}}\) and \({d_{\text{S}}}=\sqrt {{A \mathord{\left/ {\vphantom {A \pi }} \right. \kern-0pt} \pi }}\). Averaged droplet velocity fields and droplet trajectories are also constructed using a Kalman filter based on video fragments consisting of 10 consecutive frames. Figure 2a depicts a region of the atomized flow and the averaged velocity field. The size of the analyzed region for the averaged velocity field is 2.232\(\times\)2.248 mm.
2.5. Biodiesel combustion characterization
Measurement of the flame temperature in the combustion chamber T when EGR is on and off, as well as visualization of the flame (no EGR) of diesel and biodiesel fuel with and without a swirl of the gas-liquid flow are carried out at P = 0.6 MPa and P = 1.2 MPa; the air flow velocity ranges from 11 m/s to 13 m/s. The temperature T is measured in the combustion chamber using a multifunctional thermometer (error ± 1.5%, operating conditions 0–40°C, temperature range 250-1,767°C) and a type-K temperature probe (temperature range 200-1,372°C). Before each measurement, the combustion chamber is cooled to room temperature. The flame structure is recorded at a distance of 7 cm from the nozzle orifice in the central part of the viewing window of the chamber using a high-speed color video camera (sample rate 4,200 fps, resolution 1,280\(\times\)800 px) with a lens (focal length 200 mm, aperture 11) and a PC with software for processing and post-processing of video data.
The delay time of gas-phase ignition (tdelay) refers to the time interval from the beginning of the thermal effect on the sample to the implementation of the flame combustion of the vapor-gas shell around the fuel droplet. The values of tdelay is carried out on an auxiliary experimental setup, which consists of the following elements: a tubular muffle furnace (maximum heating temperature up to 1,100°C, muffle pipe inner diameter 30 mm), a high-speed monochrome video camera (sample rate 2,500 fps, resolution 1,280\(\times\)800 px) with a lens (focal length 50 mm, aperture 2.8), and a robotic linear displacement device. A fuel droplet with a diameter of 2 ± 0.2 mm is moved by the device in a muffle furnace, and a high-speed camera records the fuel ignition process from the opposite side. For more information, see Ref. [46].
To determine the stoichiometric mixture in the combustion chamber, at which λ = 1, the mass flow rates of fuel Qm and air QV are measured. Figure 3 provides the mass flow rates at λ = 1 and ALR = 14.5.
2.6. Analysis of exhaust gases
Tests on fuel combustion product analysis are carried out on a test rig (Fig. 1) with the EGR system turned on and off in the presence of a gas-liquid flow swirl. The injection pressure P is 0.6 MPa and 1.2 MPa. The EGR system is a device that allows returning some of the exhaust gases to the combustion chamber for mixing with air and fuel. As a result, concentrations of nitrogen oxides (NOx) are reduced, which helps to reduce their emissions into the atmosphere [30, 32, 47]. The role of the EGR system is played by a throttle valve and a recirculation path. When the throttle valve is opened, some of the exhaust gases are fed through the path to the combustion chamber for reuse. The gas analyzer used has the following characteristics: a measurement accuracy of ± 5% and a sensor response time of 5–15 s. It is equipped with the following sensors: electrochemical for O2 (± 0.2 vol%, 0–25%), NO (0–2000 ppm, ± 5%), and NO2 (0–500 ppm, ± 7%), as well as optical ones for CO2 (0–30%, ± 2%) and CO (0–50%, ± 5%). During measurements, the gas analyzer plots real-time curves of exhaust gas concentrations. A universal broad-band lambda probe (Bosch, accuracy 0.1 ALR) with a diameter of 52 mm and a measuring range of 11–17 is employed to determine an ALR. It is located at the exit of the combustion chamber to monitor a proper stoichiometric ratio. During the tests, the ALR is maintained at a constant value of about 14.5. This ratio ensures complete combustion of diesel fuel according to the findings from Ref. [48].