Electricity Generation through Exhaust Gases

1. INTRODUCTION
Now-a-days technology is moving at a very faster rate. The conventional sources
of energy are on a verge of extinction. So scientists are merging towards the use of
non- conventional energy resources. But it also requires some kind of energy to
convert it into another form. ur !ro"ect is related in utili#ing the kinetic energy of
exhaust gases of vehicle which is of no use.
1.1 Introduction
$n $.% Engines& during the com'ustion !rocess and the su'sequent ex!ansion
stroke the heat flows from the cylinder gases through the cylinder walls and cylinder
head into the water "acket or cooling fins. Some heat enters the !iston head and flows
through the !iston rings into the cylinder walls or is carried away 'y the engine
lu'ricating oil which s!lashes on the underside of the !iston.
$nternal com'ustion engines at 'est can transform a'out () to *) !er cent of the
chemical energy in the fuel into mechanical energy. +'out *) !er cent of the heat
generated is lost to the cooling medium& remainder 'eing dissi!ated through exhaust
and lu'ricating oil.
$n our !ro"ect we are not using this wasted heat 'ut we are using kinetic energy of
exhaust gasses.
1.2 Necessity
The exhaust gases of the engine are having high velocity and !ressure. So 'y
utili#ing the velocity of exhaust gases a small generator can 'e run which would 'e
ca!a'le to charge a cell !hone. So& we are designing a set u! which uses the high
velocity of exhaust gases to run a small gas tur'ine which in turn runs a small
generator which would 'e ca!a'le enough to generate !ower so that a cell !hone can
'e charged.
GECA Page 1
Electricity Generation through Exhaust Gases
1.3 Objective
+'out *, to -, !er cent heat is dissi!ated through exhaust gases. The heat lost
'y exhaust gases has a very high velocity and !ressure. So our main o'"ective is to
utili#e the kinetic energy of the exhaust gases which are 'eing wasted. By utili#ing the
velocity of exhaust gases a small generator can 'e run which would 'e ca!a'le to
generate the voltage or current which can 'e used for different !ur!ose.
This set u! also can 'e used.-
/. To o!erate the various vehicles accessories such as head and tail lam!s& side
indicators& horn& $0 sensors etc
(. +'ove certain s!eed of engine the generator gives large out!ut than required.
So this extra out!ut can 'e stored using a 'attery and can 'e used at times when the
s!eed of the engine is low and the out!ut required is less.
1.4 Organization
The re!ort consists of re!ort on !ro"ect 1Electricity Generation through
Exhaust Gases2. 3irst cha!ter consist of introduction !art which contain 'asic review
of su'"ect& while second cha!ter consists of literature survey. Third cha!ter contains
main to!ics consisting ty!es of 4arts& construction and working along with design
analysis. $t is followed 'y !erformance analysis containing a!!lications and
com!arison with other materials.
3inally it is followed 'y the conclusion and future sco!e.

GECA Page 2
Electricity Generation through Exhaust Gases
2. IT!R"TUR! #UR$!%
2.1 &istory
3or the design of the !ro!osed model& the following considerations are made.
$. The set u! is so designed that is does not have any effect on the efficiency of
the engine.
$$. $t can 'e easily mounted on the vehicle.
$$$. The exhaust gases can 'e fully utili#ed as !ossi'le.
$5. $t must 'e light in weight.
5. $t is sim!le in construction so as to fa'ricate locally with least availa'le
resources and skills.
5$. $t is of low cost& sim!le in construction and maintenance.
T'e (o))o*ing s+ecia) e,ui+-ents s'ou)d be used in t'e design o(
+ro+osed -ode).
$. +rc welding set with *mm welding rod.
$$. Engineer6s 'ench and vice.
$$$. 7etal sheet cutter and saw.
$5. 7arking com!ass
5. 3iles and general engineering hand tools.
GECA Page 3
Electricity Generation through Exhaust Gases
2.2 Ter-ino)ogy
I. TUR.IN!
+ turbine is a rotary mechanical device that extracts energy from a fluid flow
and converts it into useful work. + tur'ine is a tur'o machine with at least one
moving !art called a rotor assem'ly& which is a shaft or drum with 'lades attached.
7oving fluid acts on the 'lades so that they move and im!art rotational energy to the
rotor.
There& the high velocity and volume of the gas flow from silencer is directed the
over the tur'ine8s 'lades& s!inning the tur'ine and& for so& drives their mechanical
out!ut. The energy given u! to the tur'ine comes from the reduction in the
tem!erature and !ressure of the exhaust gas.
Gas& steam& and water tur'ines usually have a casing around the 'lades that
contains and controls the working fluid. %redit for invention of the steam tur'ine is
given 'oth to the British engineer Sir %harles 4arsons 9/:)-;/<*/=& for invention of
the reaction tur'ine and to Swedish engineer Gustaf de >aval9/:-);/</*=& for
invention of the im!ulse tur'ine. 7odern steam tur'ines frequently em!loy 'oth
reaction and im!ulse in the same unit& ty!ically varying the degree of reaction and
im!ulse from the 'lade root to its !eri!hery.
$m!ulse tur'ines change the direction of flow of a high velocity fluid or gas "et.
The resulting im!ulse s!ins the tur'ine and leaves the fluid flow with diminished
kinetic energy. There is no !ressure change of the fluid or gas in the tur'ine 'lades
9the moving 'lades=& as in the case of a steam or gas tur'ine? the entire !ressure dro!
takes !lace in the stationary 'lades 9the no##les=.
Energy can 'e extracted in the form of shaft !ower& com!ressed air or thrust or
any com'ination of these and used to !ower aircraft& trains& shi!s& generators& or even
tanks. Tur'ine - Extracts the energy from the high-!ressure& high-velocity gas flowing
from the com'ustion cham'er.
GECA Page 4
Electricity Generation through Exhaust Gases
Ty+es
Steam tur'ines are used for the generation of electricity in thermal !ower !lants&
such as !lants using coal& fuel oil or nuclear !ower. They were once used to
directly drive mechanical devices such as shi!s8 !ro!ellers 9for exam!le
the Tur'inia& the first tur'ine-!owered steam launch& 'ut most such a!!lications
now use reduction gears or an intermediat e electri cal ste!& where the
tur'ine is used to generate electricity& which then !owers an electric
motor connected to the mechanical load. Tur'o electric shi! machinery was
!articularly !o!ular in the !eriod immediately 'efore and during @orld @ar $$&
!rimarily due to a lack of sufficient gear-cutting facilities in AS and AB
shi!yards.
Gas tur'ines are sometimes referred to as tur'ine engines. Such engines
usually feature an inlet& fan& com!ressor& com'ustor and no##le 9!ossi'ly other
assem'lies= in addition to one or more tur'ines.
Transonic tur'ine. The gas flow in most tur'ines em!loyed in gas tur'ine
engines remains su'sonic throughout the ex!ansion !rocess. $n a transonic tur'ine
the gas flow 'ecomes su!ersonic as it exits the no##le guide vanes& although the
downstream velocities normally 'ecome su'sonic. Transonic tur'ines o!erate at a
higher !ressure ratio than normal 'ut are usually less efficient and uncommon.
%ontra-rotating tur'ines. @ith axial tur'ines& some efficiency advantage can
'e o'tained if a downstream tur'ine rotates in the o!!osite direction to an
u!stream unit. Cowever& the com!lication can 'e counter-!roductive. + contra-
rotating steam tur'ine& usually known as the >"ungstrDm tur'ine& was originally
invented 'y Swedish Engineer 3redrik >"ungstrDm 9/:E);/<F-= in Stockholm&
and in !artnershi! with his 'rother Birger >"ungstrDm he o'tained a !atent in
/:<-. The design is essentially a multi-stage radial tur'ine 9or !air of 8nested8
tur'ine rotors= offering great efficiency& four times as large heat dro! !er stage as
in the reaction 94arsons= tur'ine& extremely com!act design and the ty!e met
!articular success in 'ack!ressure !ower !lants. Cowever& contrary to other
designs& large steam volumes are handled with difficulty and only a com'ination
with axial flow tur'ines 9GA0EH= admits the tur'ine to 'e 'uilt for !ower greater
than ca ), 7@. $n marine a!!lications only a'out ), tur'o-electric units were
ordered 9of which a considera'le amount were finally sold to land !lants= during
/</E-/<& and during /<(,-(( a few tur'o-mechanic not very successful units were
sold. nly a few tur'o-electric marine !lants were still in use in the late /<F,s 9ss
0agne& ss 0egin= while most land !lants remain in use (,/,.
Statorless tur'ine. 7ulti-stage tur'ines have a set of static 9meaning
stationary= inlet guide vanes that direct the gasflow onto the rotating rotor 'lades.
$n a statorless tur'ine the gasflow exiting an u!stream rotor im!inges onto a
downstream rotor without an intermediate set of stator vanes 9that rearrange the
!ressureIvelocity energy levels of the flow= 'eing encountered.
%eramic tur'ine. %onventional high-!ressure tur'ine 'lades 9and vanes= are
made from nickel 'ased alloys and often utilise intricate internal air-cooling
!assages to !revent the metal from overheating. $n recent years& ex!erimental
ceramic 'lades have 'een manufactured and tested in gas tur'ines& with a view to
increasing rotor inlet tem!eratures andIor& !ossi'ly& eliminating aircooling.
GECA Page 5
Electricity Generation through Exhaust Gases
%eramic 'lades are more 'rittle than their metallic counter!arts& and carry a
greater risk of catastro!hic 'lade failure. This has tended to limit their use in "et
engines and gas tur'ines to the stator 9stationary= 'lades.
Shrouded tur'ine. 7any tur'ine rotor 'lades have shrouding at the to!& which
interlocks with that of ad"acent 'lades& to increase dam!ing and there'y reduce
'lade flutter. $n large land-'ased electricity generation steam tur'ines& the
shrouding is often com!lemented& es!ecially in the long 'lades of a low-!ressure
tur'ine& with lacing wires. These wires !ass through holes drilled in the 'lades at
suita'le distances from the 'lade root and are usually 'ra#ed to the 'lades at the
!oint where they !ass through. >acing wires reduce 'lade flutter in the central
!art of the 'lades. The introduction of lacing wires su'stantially reduces the
instances of 'lade failure in large or low-!ressure tur'ines.
Shroudless tur'ine. 7odern !ractice is& wherever !ossi'le& to eliminate the
rotor shrouding& thus reducing the centrifugal load on the 'lade and the cooling
requirements.
Bladeless tur'ine uses the 'oundary layer effect and not a fluid im!inging
u!on the 'lades as in a conventional tur'ine.
@ater tur'ines
i. 4elton tur'ine& a ty!e of im!ulse water tur'ine.
ii. 3rancis tur'ine& a ty!e of widely used water tur'ine.
iii. Ba!lan tur'ine& a variation of the 3rancis Tur'ine.
iv. Turgo tur'ine& a modified form of the 4elton wheel.
v. %ross-flow tur'ine& also known as Banki-7ichell tur'ine& or ss'erger
tur'ine.
@ind tur'ine. These normally o!erate as a single stage without no##le and
interstage guide vanes. +n exce!tion is the Jolienne BollKe& which has a stator
and a rotor.
5elocity com!ound L%urtisL. %urtis com'ined the de >aval and 4arsons
tur'ine 'y using a set of fixed no##les on the first stage or stator and then a rank
of fixed and rotating 'lade rows& as in the 4arsons or de >aval& ty!ically u! to ten
com!ared with u! to a hundred stages of a 4arsons design. The overall efficiency
of a %urtis design is less than that of either the 4arsons or de >aval designs& 'ut it
can 'e satisfactorily o!erated through a much wider range of s!eeds& including
successful o!eration at low s!eeds and at lower !ressures& which made it ideal for
use in shi!s8 !ower!lant. $n a %urtis arrangement& the entire heat dro! in the steam
takes !lace in the initial no##le row and 'oth the su'sequent moving 'lade rows
and stationary 'lade rows merely change the direction of the steam. Ase of a
small section of a %urtis arrangement& ty!ically one no##le section and two or
three rows of moving 'lades& is usually termed a %urtis 8@heel8 and in this form&
the %urtis found wides!read use at sea as a 8governing stage8 on many reaction
and im!ulse tur'ines and tur'ine sets. This !ractice is still common!lace today in
marine steam !lant.
GECA Page 6
Electricity Generation through Exhaust Gases
4ressure com!ound multistage im!ulse& or L0ateauL. The 0ateau em!loys
sim!le im!ulse rotors se!arated 'y a no##le dia!hragm. The dia!hragm is
essentially a !artition wall in the tur'ine with a series of tunnels cut into it& funnel
sha!ed with the 'road end facing the !revious stage and the narrow the next they
are also angled to direct the steam "ets onto the im!ulse rotor.
Design o( turbine *'ee)
The wheel 9or tur'ine= is a tangential flow im!ulse tur'ine. The exhaust air
strikes the 'ucket along the tangent of the runner. 3igure(./ shows the runner of a
wheel. $t consists of a circular disc on the !eri!hery of which a num'er of 'uckets
evenly s!aced are fixed. The sha!e of the 'ucket is of a cu! or 'owl. The high
velocity air of exhaust gases strikes on the cu! of the runner. The 'uckets are made of
stainless steel s!oons.

/ig. 0i1 Turbine *'ee)
GECA Page 7
Electricity Generation through Exhaust Gases
II. /R"2!
The casing is design as shown in the figure. Two hose cli!s of //Fmm diameter is
taken so that it can 'e mounted easily on the silencer and can 'e tightened as !er the
requirement using nut and 'olt arrangement. 3our rods of Fmm diameter and (-, mm
in length are welded of the !eri!hery of 'oth the hose cli!s so that it can form a rigid
casing for mounting of other accessories.

GECA Page 8
Electricity Generation through Exhaust Gases
/ig. 0ii1 /ra-e
#+eci(ication3 0#4U"R!1
>ength-(,cm
Ceight-)cm
III. #&"/T
+ cylindrical& usually solid metal o'"ect which commonly goes through and
holds other rotating items 9e.g. !ulleys& wheels& gears& 'earings& sleeves= and which
may also transmit rotational forces.
GECA Page 9
Electricity Generation through Exhaust Gases
/ig. 0iii1 #'a(t
Selection of the a!!ro!riate material is an im!ortant consideration in
engineering design? that is& for some a!!lication& choosing a material having a
desira'le or o!timum !ro!erty or com'ination of !ro!erties. Selection of the !ro!er
material can reduce costs and im!rove !erformance. Elements of this materials
selection !rocess involve deciding on the constraints of the !ro'lem and& from these&
esta'lishing criteria that can 'e used in materials selection to maximi#e !erformance.
The com!onent or structural element we have chosen to discuss is a solid cylindrical
shaft that is su'"ected to a torsional stress. Strength of the shaft will
'e considered in detail& and criteria will 'e develo!ed for maximi#ing strength with
res!ect to 'oth minimum material mass and minimum cost. ther !arameters and
!ro!erties that may 'e im!ortant in this selection !rocess are also discussed 'riefly.
3or this !ortion of the design !ro'lem& we will esta'lish a criterion for
selection of light and strong materials for the shaft.
@e will assume that the twisting moment and length of the shaft are s!ecified&
whereas the radius 9or cross-sectional area= may 'e varied.@e develo! an ex!ression
GECA Page 10
Electricity Generation through Exhaust Gases
for the mass of material required in terms of twisting moment& shaft length& and
density and strength of the material.
Asing this ex!ression& it will 'e !ossi'le to evaluate the !erformanceMthat is&
maximi#e the strength of the torsionally stressed shaft with res!ect to mass and& in
addition& relative to material cost.
#+eci(ication3
>ength - /</ mm
Giameter - < mm
7aterial - Card 7S

I$. Circu)ar disc
$t is a metal circular !late on the !eri!hery of which vanes 9s!oon as a vane= is
mounted. By using forging o!eration F vanes 9s!oons= is mounted on the circular
GECA Page 11
Electricity Generation through Exhaust Gases
!late 'y means of the forging o!eration. $n this o!eration for welding !owder is used.
with this !owder welding we can easily "oint the two materials like or different metals
like mild steel and stainless steel. This is most easiest way of welding.
/ig. 0iv1 Circu)ar Disc
@e use here mild steel !late 'ecause the weight of the mild steel 9circular
!late= is more as com!are to !lastic !late 9disk=.
Gue to the use of mild steel disk the mis'alancing of circular disk while the
exhaust gas 'om'arded on the vanes should 'e minimi#ed.
GECA Page 12
Electricity Generation through Exhaust Gases
#+eci(ications
7aterial - 7ild Steel
Giameter - ), mm
Cole - < mm
Slot- - ) mm H F
Thickness - / mm
Thickness of Gisc - /.) mm
$. #U55ORTIN6 COU2N
These are two wooden 'locks of dimension //) N*)N(, mm as shown in the
figure. Grooves are cut on 'oth sides of the column so that it can 'e easily mounted
GECA Page 13
Electricity Generation through Exhaust Gases
on the casing and are fixed with the hel! of araldite. The column is made such that&
the 'earings and the motor can 'e easily mounted on it.
/ig. 0v1 #u++orting Co)u-n
GECA Page 14
Electricity Generation through Exhaust Gases
$I. 6!"R#
Gears are machine elements that transmit motion 'y means of successively
engaging teeth. The gear teeth act like small levers.
Gears are toothed wheels used for transmitting motion and !ower from one
shaft to another shaft.
S!ur gears or straight-cut gears are the sim!lest ty!e of gear. They consist
of a cylinder or disk with the teeth !ro"ecting radially& and although they are not
straight-sided in form& the edge of each tooth is straight and aligned !arallel to the
axis of rotation. These gears can 'e meshed together correctly only if they are
fitted to !arallel shafts.
Gears of velocity ratio *.-./ are directly !urchase from the market. The
velocity ratio of the gears is calculated as follows.
NO. O/ T!!T& ON DRI$IN6 6!"R
$!OCIT% R"TIO 7
NO. O/ T!!T& ON DRI$!N 6!"R
T2 89
7 7
T1 22

7 3.1:
GECA Page 15
Electricity Generation through Exhaust Gases
The gear ratio should 'e more as !ossi'le as so that more r!m can 'e
achieved& out!ut can 'e increased
0i16ears
Ter-ino)ogy (or #+ur 6ears
5itc' sur(ace . The surface of the imaginary rolling cylinder 9cone& etc.=
that the toothed gear may 'e considered to re!lace.
GECA Page 16
Electricity Generation through Exhaust Gases
5itc' circ)e. + right section of the !itch surface.
"ddendu- circ)e. + circle 'ounding the ends of the teeth& in a right
section of the gear.
Root 0or dedendu-1 circ)e. The circle 'ounding the s!aces 'etween the
teeth& in a right section of the gear.
"ddendu-. The radial distance 'etween the !itch circle and the addendum
circle.
Dedendu-. The radial distance 'etween the !itch circle and the root circle.
C)earance. The difference 'etween the dedendum of one gear and the
addendum of the mating gear.
/ace o( a toot'. That !art of the tooth surface lying outside the !itch
surface.
/)an; o( a toot'. The !art of the tooth surface lying inside the !itch
surface.
Circu)ar t'ic;ness 9also called the toot' t'ic;ness= . The thickness of the
tooth measured on the !itch circle. $t is the length of an arc and not the length
of a straight line.
Toot' s+ace. The distance 'etween ad"acent teeth measured on the !itch
circle.
.ac;)as'. The difference 'etween the circle thickness of one gear and the
tooth s!ace of the mating gear.
Circu)ar +itc' !. The width of a tooth and a s!ace& measured on the !itch
circle.
Dia-etra) +itc' 4. The num'er of teeth of a gear !er inch of its !itch
diameter. + toothed gear must have an integral num'er of teeth. The circular
!itch& therefore& equals the !itch circumference divided 'y the num'er of
teeth. The diametral !itch is& 'y definition& the num'er of teeth divided 'y
the !itch diameter.
That is&
GECA Page 17
Electricity Generation through Exhaust Gases
$II. D.C 6!N!R"TOR
$n electricity generation& an e)ectric generator is a device that
converts mechanical energy to electrical energy. + generator forces electric current
to flow through an external circuit. The source of mechanical energy may 'e a
reci!rocating or tur'ine steam engine& water falling through a tur'ine or waterwheel&
an internal com'ustion engine& a wind tur'ine& a hand crank& com!ressed air& or any
other source of mechanical energy. Generators !rovide nearly all of the !ower
for electric !ower grids.
The reverse conversion of electrical energy into mechanical energy is done 'y
an electric motor& and motors and generators have many similarities. 7any motors
can 'e mechanically driven to generate electricity and frequently make acce!ta'le
generators.
5rinci+)e<
GECA Page 18
Electricity Generation through Exhaust Gases
$t is 'ased on the !rinci!le of !roduction of dynamically 9or motional= induced
e.m.f 9Electromotive 3orce=. @henever a conductor cuts magnetic flux& dynamically
induced e.m.f. is !roduced in it according to 3araday8s >aws of Electromagnetic
$nduction. This e.m.f. causes a current to flow if the conductor circuit is closed.
Cence& the 'asic essential !arts of an electric generator are.
" -agnetic (ie)d and
" conductor or conductors *'ic' can so -ove as to cut t'e ()u=
+ G.% Generator of * volts ca!acity is directly !urchased from the market.
Dynamo
+ dynamo is an electrical generator that !roduces direct current with the use of
a commutator. Gynamos were the first electrical generators ca!a'le of delivering
!ower for industry& and the foundation u!on which many other later electric-!ower
conversion devices were 'ased& including the electric motor& the alternating-
current alternator& and the rotary converter.
GECA Page 19
Electricity Generation through Exhaust Gases
0ii1 D.C. 6enerator
#+eci(ication3
This low s!eed G% electric motor rotates at a'out /,,, r!m at /.) volts and
/-,, r!m at *., volts.
7otor diameter. *(mm
7otor casing height. (,mm
7otor shaft diameter. (mm.
Today& the sim!ler alternator dominates large scale !ower generation& for
efficiency& relia'ility and cost reasons. + dynamo has the disadvantages of a
mechanical commutator. +lso& converting alternating to direct current using !ower
rectification devices 9vacuum tu'e or more recently solid state= is effective and
usually economic.
GECA Page 20
Electricity Generation through Exhaust Gases
$III. .!"RIN6#
+ bearing is a machine element that constrains relative motion
'etween moving !arts to only the desired motion. The design of the 'earing may& for
exam!le& !rovide for free linear movement of the moving !art or for free rotation
around a fixed axis? or& it may prevent a motion 'y controlling the vectors of normal
forces that 'ear on the moving !arts. Bearings are classified 'roadly according to the
ty!e of o!eration& the motions allowed& or to the directions of the loads 9forces=
a!!lied to the !arts.
Bearings may 'e classified 'roadly according to the motions they allow and
according to their !rinci!le of o!eration as well as 'y the directions of a!!lied loads
they can handle.
GECA Page 21
Electricity Generation through Exhaust Gases
5rinci+)es o( o+eration
There are at least six common !rinci!les of o!eration.
!lain 'earing& also known 'y the s!ecific styles. 'ushings& "ournal 'earings&
sleeve 'earings& rifle 'earings
rolling-element 'earings such as 'all 'earings and roller 'earings
"ewel 'earings& in which the load is carried 'y rolling the axle slightly off-
center
fluid 'earings& in which the load is carried 'y a gas or liquid
magnetic 'earings& in which the load is carried 'y a magnetic field
3lexure 'earings& in which the motion is su!!orted 'y a load element which
'ends.
Bearings of standard dimension of no. O:(g are directly !urchased from the
market. No. f 'earings required are two as the tur'ine is mounted 'etween
the 'earings so as to rotate freely without friction.
5rinci+)e o( o+eration
There are at least six common !rinci!les of o!eration.
!lain 'earing& also known 'y the s!ecific styles. 'ushings& "ournal 'earings&
sleeve 'earings& rifle 'earings
rolling-element 'earings such as 'all 'earings and roller 'earings
"ewel 'earings& in which the load is carried 'y rolling the axle slightly off-
center
fluid 'earings& in which the load is carried 'y a gas or liquid
magnetic 'earings& in which the load is carried 'y a magnetic field
flexure 'earings& in which the motion is su!!orted 'y a load element which
'ends
GECA Page 22
Electricity Generation through Exhaust Gases

0iii1 .earing
2.3 2ountings
i. 2ounting o( #u++orting Co)u-n3
@e are using two su!!orting columns of wooden 'lock are mounted on the
casing as shown in the figure and are fixed on the rods with the hel! of araldite.
ii. 2ounting o( .earing
GECA Page 23
Electricity Generation through Exhaust Gases

Two 'earings of standard dimension are mounted eccentrically on the
su!!orting column with the hel! of stri!s and nails.
iii. 2ounting o( Turbine

The tur'ine is mounted 'etween the two 'earings with the hel! of a hollow
circular shaft.

iv. 2ounting o( DC 6enerator
The G.% Generator is mounted on one of the su!!orting column in such a way
that gear mounted on generator shaft can easily meshed with the !inion which is fitted
on tur'ine shaft.


GECA Page 24
Electricity Generation through Exhaust Gases

0iv1"ctua) +roject +icture
GECA Page 25
Electricity Generation through Exhaust Gases
0v1 2ounting o( t'e e,ui+-ent on t'e t*o *'ee)er
GECA Page 26
Electricity Generation through Exhaust Gases
3.9 #%#T!2 D!$!O52!NT
3.1 !)ectricity 6eneration t'roug' !='aust 6ases 3
+s discussed a'ove out!ut of this device is G.% current. $t consists of
frame made u! of mild steel. The tur'ine is mounted on the shaft. +t the 'oth end of
shaft& 'earing is attached. Gue to these 'earings the vi'ration of the shaft is reduced
at very great extent and out!ut in terms of shaft rotation is o'tained accurately.
Bearing is fixed 'etween wooden !late 'y using !ress fitting method.
@ooden !lates are fitted to frame 'y using nut and 'olt. n shaft gear with E, teeth
is mounted& and gear with (( teeth is in mesh with it which is mounted on G.%
generator. 3rom G.% generator two out!ut wires are taken out.
The whole assem'ly is mounted on the silencer of the vehicle at the end
of muffler so as it will not affect the efficiency of the engine. The frame is made 'y
taking accurate dimension of silencer and maintaining some tolerance.

@hen the vehicle starts& Exhaust gas come out from the silencer at very
high !ressure and im!inge on the tur'ine. Gue to high !ressure& tur'ine also rotates at
very s!eed with shaft. Gue to rotation of shaft gear with E, teeth rotation of gear with
(( teeth which is in mesh with it is also rotated& which is mounted on G.%. generator.
Gue to rotation of G.%. generator Girect current is !roduced. The out!ut of the
generator at various 047 of the engine can 'e calculated.
GECA Page 27
Electricity Generation through Exhaust Gases
3.2 Design Ca)cu)ations
>'en ve'ic)e running at 29;-?'r@
h
w P
*.(cm
@e know that&
g hg Pw hw&
h
g
P 9/,,,Q,.,*(=R/.() P ().F
$e)ocity o( ()o*@
5
f
P 9(gh
g
=
,.)
P
9(Q<.:/Q().F=
,.)
P((.-/ mIsec
/)o* o( e='aust gases@
7
f
P 5el of exhaust gasses Q area at the exhaust&
P ((.-/Q 9SR-= Q 9,.,(=
(

P E.,-Q/,
-*
kgIm
*
5ressure -easure-ent@
4g P g g hg

P

/.()Q <.:/Q().F
P */*.<(NIm
(
/orce -easure-ent&
3
g
P 4ressure Q +rea of exhaust
P */*.<(Q *./- Q /,
--
P ,.,<:)EN.
Tor,ue -easure-ent@
GECA Page 28
Electricity Generation through Exhaust Gases
TP 3orce Q Gistance 'etween gases striking !oint and axis of shaft
P ,.,<:)E Q, .,)
P -.<(Q /,
-*
Nm
5o*er -easure-ent&
4 P (SNTIF,
P 9(SQ(*,Q-.<( Q /,
-*=
IF,
P ,.//:F@
>'en ve'ic)e running at 49;-?'r@
h
w P
Fcm
@e know that&

g
h
g
P
w
h
w&
h
g
P 9/,,,Q,.,F=R/.() P -:
$e)ocity o( ()o*@
5
f
P 9(gh
g
=
,.)

P 9(Q<.:/Q-:=
,.)

P *,.F< mIsec
/)o* o( e='aust gases@
7
f
P 5el of exhaust gasses Q area at the exhaust&
P *,.F<Q 9SR-= Q 9,.,(=
(

P <.F-Q/,
-*
kgIm
*
5ressure -easure-ent@
4
g
P
g
g h
g
P

/.()Q <.:/Q-:
P )::.F NIm
(
GECA Page 29
Electricity Generation through Exhaust Gases
/orce -easure-ent&
3
g
P 4ressure Q +rea of exhaust
P )::.F Q *./- Q /,
--
P ,./:-: N.
Tor,ue -easure-ent@
T P 3orce Q Gistance 'etween gases striking !oint and axis of shaft
P ,./:-: Q .,)
P <.(-Q /,
-*
Nm
5o*er -easure-ent&
4 P (SNTIF,
P (SQ-),Q<.(- Q /,
-*
IF,
P ,.-*)- @
>'en ve'ic)e running at A9;-?'r&
h
w P
:.*cm
@e know that&
g
h
g
P
w
h
w&
h
g
P 9/,,,Q.,:*=R/.() P FF.-
$e)ocity o( ()o*@
5
f
P 9(gh
g
=
,.)

P

9(Q<.:/QFF.-=
,.)

P *F.,< mIsec
/)o* o( e='aust gases@
7
f
P vel of exhaust gasses Q area at the exhaust&
*F.,<Q9SR-=Q9,.,(=
(

P //./-Q/,
-*
kgIm
*
5ressure -easure-ent@
4g Pg g hg
P

/.()Q <.:/QFF.-
P :-/.(* NIm
(
GECA Page 30
Electricity Generation through Exhaust Gases
/orce -easure-ent&
3
g
P 4ressure Q +rea of exhaust
P :-/.(* Q *./- Q /,
--
P ,.())FE N.
Tor,ue -easure-ent@
TP 3orce Q Gistance 'etween gases striking !oint and axis of shaft
P ,.())FE Q .,)
P /(./(Q /,
-*
Nm
4ower measurement&
4 P (SNTIF,
P (SQE(,Q/(./( Q /,
-*
IF,
P ,.<F)- @
>'en ve'ic)e running at 89;-?'r&
h
w P
<.Ecm
@e know that&

g
h
g
P
w
h
w&
C
g
P 9/,,,Q.,.,<E=R/.() P EE.F
$e)ocity o( ()o*@
5
f
P 9(gh
g
=
,.)

P 9(Q<.:/QEE.F=
,.)
P *<.,( mIsec
/)o* o( e='aust gases@
7
f
P vel of exhaust gasses Q area at the exhaust&
P *<.,(Q 9SR-= Q 9,.,(=
(

P /(./*Q/,
-*
kgIm
*
GECA Page 31
Electricity Generation through Exhaust Gases
5ressure -easure-ent@
4
g
P h
g
g h
g

P

/.()Q <.:/QEE.F
P <)/.)E NIm
(
/orce -easure-ent&
3
g
P 4ressure Q +rea of exhaust
P <)/.)E Q *./- Q /,
--
P ,.(<:E N.
Tor,ue -easure-ent@
TP 3orce Q Gistance 'etween gases striking !oint and axis of shaft
P ,.(<:EQ .,)
P /-.<-Q /,
-*
Nm
5o*er -easure-ent@
4 P (SNTIF,
P (SQ<-,Q/-<- Q /,
-*
IF,
P /.-E)- @
>'en ve'ic)e running at B9;-?'r&
h
w P
//.<cm
@e know that&
g hg P w hw&
h
g
P 9/,,,Q.,.,<E=R/.()
P <).)
$e)ocity o( ()o*@
5
f
P 9(gh
g
=
,.)

P 9(Q<.:/Q<).(=
,.)

GECA Page 32
Electricity Generation through Exhaust Gases
P -*.(( mIsec
/)o* o( e='aust gases@
7
f
P vel of exhaust gasses Q area at the exhaust&
P -*.((Q9SR-=Q9,.,(=
(

P /*.):Q/,
-*
kgIm
*
5ressure -easure-ent@
4g P g g hg
P

/.()Q <.:/Q<).)
P /((,./( NIm
(
/orce -easure-ent&
3
g
P 4ressure Q +rea of exhaust
P /((,./( Q *./- Q /,


P ,.*:*/( N.
Tor,ue -easure-ent@
T P 3orce Q Gistance 'etween gases striking !oint and axis of shaft
P ,.*:*/(Q .,)
P/<.(,Q /,
-*
Nm
5o*er -easure-ent&
4 P (SNTIF,
P (SQ/(*,Q/<.(, Q /,
-*
IF,
P (.-E @
Ca)cu)ation tab)e3
5articu)ars?s+eed 29 49 A9 89 B9
'
*
0 c-1 *.( F :.* <.E //.<
'
g
0 -1 ().F -: FF.- EE.F <).)
GECA Page 33
Electricity Generation through Exhaust Gases
$
(
0 -?s1 ((.-/ *,.F< *F.,< *<.,( -*.((
2
(
0

;g?-
31
E.,-Q /,
-*
<.F-Q /,
-*
//./-Q /,
-*
/(./(Q /,
-*
/*./:Q /,
-*
5
g
0

N?-
21
*/*.<( )::.F :-/.(* <)/.)E /((,./(
T 0 N-1 -.<(Q /,
-*
<.(-Q /,
-*
/(./(Q /,
-*
/-.<-Q /,
-*
/<.(,Q /,
-*
5 0 >1 ,.//:F ,.-*)- ,.<F)- /.-E)- (.-E
Tab)e 0i1 Ca)cu)ation Tab)e
GECA Page 34
Electricity Generation through Exhaust Gases
3.3 Testing o( 5ro+osed 2ode)3
Gifferent readings at different 047 of the engine are noted as shown 'elow in
the ta'le.
#R.NO #5!!D
In
;-?'r
OUT5UT O/
6!N!R"TOR
in $o)ts
CURR!NT
in "-+ere
5O>!R
D!$!O5!D
0$ CI1 in >
/ (, (./E ,.,F ,./*,(
( *, *.E) ,./, ,.*E)
* -, -.<: ,./< ,.<-F(
- ), F.(: ,.(F /.F*(:
) F, E.-F ,.*, (.(*:
F E, :./F ,.*- (.EE)
Tab)e 0ii1 Testing o( 5ro+osed 2ode)
O?5 tab)e
+s shown in the ta'le when the r!m increases the electricity generation or energy
generation also increases. The energy out!ut of vehicle is directly !ro!orational to the
r!m of the vehicle.
Gifferent vehicles have different exhaust gas velocity so the reading may vary
from vehicle to vehicle. +s the r!m of vehicle increases the out!ut !ower of dc
generator increases. +nd it is directly !ro!ortional to the cc of the vehicle as the cc of
the engine increases the energy out!ut is also increases.
GECA Page 35
Electricity Generation through Exhaust Gases

/ig 0vi1 #+eed vs Tor,ue 6ra+'
The a'ove figure shows the S!eed and Torque Gra!h. $t shows that the S!eed
of 4elton @heel increases& the Torque of Generator decreases and vice versa.

GECA Page 36
Electricity Generation through Exhaust Gases
3.4 Cost !sti-ation3
+= %74NENT %+N BE ASEG
#R. NO. CO25ON!NT 4U"NTIT% 5RIC! TOT"
/ GEN0+T0S / E, E,
( CSE %>+74 ( F, /(,I-
* S4A0 GE+0S ( /,, (,,I-
- BE+0$NGS ( F, /(,I-
) S4NS F /( E(I-
F %$0%A>+0 G$S% / () ()I-
E @$0E9/)ft= / *, *,I-
TOT" AD8?3
Tab)e 0iii1 Co-+onents Used
GECA Page 37
Electricity Generation through Exhaust Gases
B= %74NENTS 3+B0$%+TEG
/= 7+TE0$+> %ST
#R. NO. CO25ON!NT 4U"NTIT% R"T! TOT"
CO#T
/ 7.S 0ANG B+0
F77 G$+.
- /) F,I-
( @GEN 4>+TE ( ), /,,
TOT" R#. 1A9?3
Tab)e 0iv1 2ateria) Cost
(= >+BA0 %ST
#R. NO. O5!R"TION
5!R/OR2!D
5RIC!
/ @E>G$NG /),I-
TOT" R#. 1D9?3
Tab)e 0v1 abour Cost
GECA Page 38
Electricity Generation through Exhaust Gases
31 OT&!R !E5!N#!#
#R. NO. 5"RTICU"R# 5RIC!
/ +0+>G$TE -,I-
( 3E5$-TA$%B ()I-
* 4ET0> ),,I-
- N+$>S ()I-
) @$0E /) 3T. *,I-
TOT"
R#. A29?3
Tab)e 0vi1 Ot'er !=+enses
TOT" CO#T O/ 2OD! 7 %ST 3 %74NENT 4A0%C+SEG U
%ST 3 %74NENT 3+B0$%+TEG
7 F)E U 9/), U /F, U F(,=
7 R#. 1D:8?3
3.D "ction 5)an
+ctivities com!leted till date are
/. 4ro'lem identification.
(. >iterature survey.
GECA Page 39
Electricity Generation through Exhaust Gases
Ta'le 9vii= +ction 4lan
GECA Page 40
"CTION 5"N /OR .""NC! "CTI$ITI!#
#R.
NO
.
"CTI$ITI!# F"NU"R%
2913
/!.U"R%
2913
2"RC&
2913
"5RI
2913
>ee; 1 >ee;
132
>ee
; 334
>ee;
132
>ee
; 334
>ee;
132
>ee; 334
1. "dditiona)
data
co))ection to
identi(y any
ot'er
+rob)e-s.
2. /ina)ize )ist o(
+rob)e-s and
"na)yze t'e
+rob)e-s
3. Designing o(
turbine@
(ra-e. gear
ratio etc.
4. 5)anning o(
asse-b)y and
correct
-ounting o(
eac'
co-+onent
D #tudy t'e
-ec'anis-s
invo)ved and
decide
corrective
actions a(ter
eac'
+rob)e-.
A. Co))ecting
co-+onents
*'ic'
avai)ab)e in
-ar;et
8. Re+ort
*riting.
Electricity Generation through Exhaust Gases

4. 5!R/OR2"NC! "N"%#I#
4.1 "dvantages3
/. $t requires no external !ower to drive the generator.
(. $ncreased efficiency of the engine with the same in!ut.
*. $ts weight does not have any effect on the efficiency of the engine.
-. %an 'e easily carried along with the vehicle.
). $t is sim!le in construction so as to fa'ricate locally with least availa'le
resources and skills.
F. $t is of low cost and low maintenance.
E. $t does not give 'ack !ressure on engine.
:. $t does not affect the !erformance of engine.
<. %a!ital cost is low.
/,. There is no maintenance due to there is no friction availa'le 'etween
moving !arts.
4.2 Dra*bac;s3
/. This 7odel is restricted for Two wheeler only.
(. %onstruction is not %om!act.
GECA Page 41
Electricity Generation through Exhaust Gases
4.3 "++)ication
$t is 'asically designed to generate electricity this electricity we can 'e use it
/. To charge cell !hone.
(. To o!erate the vehicles various accessories such as head and tail lam!s& side
indicators& horn $0 sensors etc.
*. +'ove certain s!eed of engine the generator gives large out!ut than required. So
this extra out!ut can 'e stored using a 'attery and can 'e used at times when the s!eed
of the engine is low and the out!ut required is less.
-. $t can also 'e use to charge digital cameras& $-4od etc.


GECA Page 42
Electricity Generation through Exhaust Gases
4.4 Co-+arison
#r.No 5ara-eters Our Device .attery
1. #u++)y No Su!!ly needed %harging is required
2. 2aintainance No 7ore
3. $o)t /F 5 for /,, cc Bike
9changes with s!eed=
: 5 for /,, cc Bike
4. 5o))utant $t uses !ollutant $t creates 4ollutant
D. i(e 7ore >ife >ess >ife
A. Cost >ow %ost Cigh %ost
8. Ot'er No +cid 0equired +cid 0equired
:. Use $t can 'e connected to
4ower !roducing
Gevice.
$t can 'e connected to
4ower consuming Gevice.
:. "++)ication %an also 'e used in
0emote +reas.
+utomo'ile
GECA Page 43
Electricity Generation through Exhaust Gases
D.9 CONCU#ION#
D.1 Conc)usion3
This 4ro"ect is very advantageous and uses the 4rinci!le of
%onservation of energy i.e ne form of energy is converted to another
useful form. The Exhaust which is of no use& is used to !roduce
Electricity which may 'e used for lighting Ceadlam!& Tail-lam!&etc.
The Engine 4erformance is not affected 'y this device.
7oreover the efficiency of the Engine is increased as exhaust which is
of no use& is used to generate Electricity.
$t requires no external !ower to drive the generator.
The weight of this Gevice does not have any effect on the efficiency of
the engine.
$ncreased efficiency of the engine with the same in!ut.
This is a very economical Gevice and can 'e used in all Two @heelers
'y making some changes in the 3rame.
GECA Page 44
Electricity Generation through Exhaust Gases
D.2 /uture #co+e3
By further modification& of this set u! can 'e also 'e used for various !ur!oses as
follows.
To o!erate the vehicles various accessories such as head and tail lam!s& side
indicators& horn etc.
+'ove certain s!eed of engine the generator gives large out!ut than required.
So this extra out!ut can 'e stored using a 'attery and can 'e used at times
when the s!eed of the engine is low and the out!ut required is less.
This set u! also can used at chimney sugar industry& thermal !ower !lant& in
'athrooms at ta! etc out!ut can 'e used for various !ur!oses.
The Gesign of this Gevice can 'e made %om!act.

GECA Page 45
Electricity Generation through Exhaust Gases
R!/!R!NC!#

9i= Gesign of machine elements Second edition Tata 7agraw Cill.
9ii= $.% Engines By 5. Ganeshan
9iii= 7achine Gesign By Bhurmi and Gu!ta
9iv= htt!.IIen.wiki!edia.orgIwikiIGasVtur'ine
9v= htt!.IIen.wiki!edia.orgIwikiIBearingV9mechanical=
9vi= htt!.IIen.wiki!edia.orgIwikiIelectric G.%. generator.
GECA Page 46