Aqua Silencer

CONTENTS

DESCRIPTION PAGE NO.

1. Abstract 2
2. Introduction 3
3. Literature survey 4
4. Exhaust silencer 6
4.1. Silencer selection Factor
4.2. Acoustical performance
4.3. Aerodynamic performance
4.4. Mechanical performance
4.5. Reactive silencer
4.6. Absorptive muffler
5. Design consideration 10
6. Parts/Components 12
7. Construction 15
8. Working 16
9. Effect of Dissolved gases on Lime water 18
10. Merits & Demerits 19
11. Conclusion 20
12. References 21

Cambridge institute of technology, k r puram, bengaluru-560036 Page 1

1. ABSTRACT

Air pollution is most important from the public health of view, because every individual
person breaths approximately 22000 times a day, inhaling about 15 to 22 kg of air daily.
Polluted air causes physical ill effect decides undesirable aesthetic and physiological effects.
Air pollution can be defined as addition to our atmosphere of any material, which will have
a dexterous effect on life upon our planet. The main pollutants contribute by automobile are
carbon monoxide (CO), unburned hydrocarbon (UBHC), oxides of nitrogen (NOx) and
Lead.

Automobiles are not the only sources of air pollution, other sources such as electric power
generating stations, industrial and domestic fuel consumption, refuse burning, industrial
processing etc. also contribute heavily to contamination of our environment so it is
imperative that serious attempts should be made to conserve of our environment from
degradation.

An Aqua Silencer is an attempt, in this direction, it is mainly dealing with control of

emission and noise. An Aqua Silencer is fitted to the exhaust pipe of engine. Sound
produced under water is less hearable than it produced in atmosphere. This mainly because
of small sprockets in water molecules, which lowers its amplitude thus, lowers the sound
level. Because of this property water is used in this silencer and hence its name AQUA
SILENCER. The noise and smoke level is considerable less than the conventional silencer,
it is cheaper, no need of catalytic converter and easy to install. It is imperative that serious
attempts should be made to conserve earth’s environment from degradation. An aqua
silencer is an attempt in this direction; it is mainly dealing with control of emission and
noise.
2. INTRODUCTION

Diesel engines are playing a vital role in Road and sea transport, Agriculture, mining and
many other industries. Considering the available fuel resources and the present
technological development, Diesel fuel is evidently indispensable. In general, the
consumption of fuel is an index for finding out the economic strength of any country.
Inspire, we cannot ignore the harmful effects of the large mass of the burnt gases, which
erodes the purity of our environment every day. It is especially so, in most developed
countries like USA and EUROPE. While, constant research is going on to reduce the toxic
content of diesel exhaust, the diesel power packs find the ever increasing applications and
demand. This project is an attempt to reduce the toxic content of diesel exhaust, before it is
emitted to the atmosphere.

This system can be safely used for diesel power packs which could be used in Inflammable
atmospheres, such as refineries, chemical processing industries, open cast mines and other
confined areas, which demands the need for diesel power packs. For achieving this toxic
gases are to be reduced to acceptable limits before they are emitted out of this atmosphere,
which otherwise will be hazardous and prone to accidents.

The principle involved is by bubbling the exhaust gas through the scrubber tank containing
an alkaline solution, here the temperature of the gases is reduced, while most of the oxides of
nitrogen in the exhaust are rendered non – toxic. The highly dangerous carbon monoxide is
not such a menace in diesel exhaust, as it does not exceed 0.2 percent by volume, whereas in
petrol engines the CO content may be as high as 10 percent. A lime stone container in the
scrubber tank reduces the considerable percentage of sulphur – di – oxide presents in the
exhaust.

The provision of suitable baffles in the scrubber tank aids the turbulence so that, thorough
scrubbing take place. The bell-mouth solution, while reducing the back pressure. For
measuring the contents of the exhaust gas, provisions are made to take samples between
engine outlet and scrubber inlet and after the scrubber outlet before the gases are let out to
the atmosphere.
3. LITERATURE SURVEY

Allen. M. A et al [1]A lot of effort is being made to reduce the air pollution from petrol and
diesel engines and regulations for emission limits are also imposed. Furthermore, developments
in petrol and diesel engines, combined with improvements in the vehicles, will make fuel
consumption reduction of 40% or more in the future cars. One such development is
improvement of the silencer unit of an engine. This is where an Aqua Silencer comes into play.
An Aqua Silencer mainly deals with control of emission and noise in engine exhaust. It
basically consists of a perforated tube which is installed at the exit of the exhaust from the
engine, which may have holes of variable diameters. This is done to divide the gas molecules of
large proportions to form gas molecules of smaller diameter. Theoretically, four or more sets of
holes are made on the perforated tube using drilling. The other end of the perforated tube is
sealed using a plug.

A small coating of activated charcoal is provided all around the perforated tube using an
inner cylinder which holds the charcoal in place and separates the charcoal and lime water
from the water in the Aqua Silencer. This unit is then placed in a container in which water is
filled to a certain level. A small opening is provided on the lid of the inner box which carries
the exhaust from it to the outside using a small diameter pipe. A U-bend of pipe is
constructed at the end of perforated tube which doubles as a nonreturn valve which prevents
the back flow of engine exhaust or lime water back into the engine. After passing over the
charcoal layer, a portion of the gases dissolve into the water and finally the exhaust gases
escape through the opening in to the atmosphere. “Emission” is a term that is used to
describe the totality of undesired gases and particulates which are released into the air or
emitted by numerous sources some of the examples are CO, CO2, NOX, and Hydrocarbon
and the main contribution of air pollution comes from automobiles and industrial engines
releasing gases like carbon dioxide and not burnt.

Maruthi Prasad yadav et. al [2] carried out research for the four stroke multi cylinder diesel
engine with an aqua silencer. In most of application the final selection of an aqua silencer is
based on an arrangement between the predicted acoustical, aerodynamic, mechanical and
structural performance in conjunction with the cost of the resulting system then have
performance and work in the model and get result. They conclude that load increases the
contaminations gradually
by using conventional silencer but by fitting with aqua silencer, the contaminations
decreases. They found comparison of different silencer for sound characteristic of engine. In
conventional silencer is sound level is 83db but in an aqua silencer is 75 db. without any
load. Around 50% load in conventional silencer it gives 84.5db and in an aqua silencer give
76.5 db. load. In the fully loading condition the conventional silencer give 86 db. and in an
aqua silencer is 78 db.

Keval Patel et. al. [3] designs the dimensions of aqua silencer for two stroke petrol engines.
The exhaust pipe connects with shell and inner side of it perforated tube is arranged. The
charcoal layer is pasted over the perforated tube. Bead Activated carbon is used as a charcoal
layer. It is a process by which the carbonized product develops porous structure of molecular
dimensions and extended surface area on heat treatment in the temperature range of 800 –
1000 oC in presence of suitable oxidizing gases such as steam and carbon dioxide (CO2).
Bead activated carbon is made from petroleum pitch and supplied in diameters from
approximately 0.35 to 0.80 mm. It is also noted for its low pressure drop, high mechanical
strength and low dust content, but with a smaller grain size. Its spherical shape makes it
preferred for fluidized applications. According to operational parameter they conclude that
CO is reduced 60-70% compared to ordinary silencer. But it is big in size and more space is
required. It is used in both two-wheeler and four-wheeler.

P. Balashunmugam et. al. [4] carried out the analysis in which the lime stones are originally
intended to reduce the toxic ingredients of the exhaust, gas through chemical reaction.
Because of the introduction of the scrubber, the net length of the exhaust gas flow path is
also increased which is again, against the original intention according to his study they
conclude that water in scrubber tank can itself play an important role in absorbing the
obnoxious products of combustion like the oxides of nitrogen. NO is converted into NO2
after emission which highly toxic is mainly absorbed in the water scrubber.
4. EXHAUST SILENCER
Engine exhaust noise is controlled through the use of silencers and mufflers. Generally
speaking, there is no technical distinction between a silencer and muffler and the terms are
frequently used interchangeably. A silencer has been the traditional name for noise
attenuation devices, while a muffler is smaller, mass-produced device designed to reduce
engine exhaust noise.

4.1 Silencer Selection Factors

The use of an exhaust silencer is prompted by the need to reduce the engine exhaust noise. In
most applications the final selection of an exhaust silencer is based on a compromise between the
predicted acoustical, aerodynamic, mechanical and structural performance in conjunction with
the cost of the resulting system.

4.2 Acoustical performance

The acoustical performance criterion specifies the minimum insertion loss (IL) of the silencer,
and is usually presented in IL values for each octave band as well as an overall expected noise
reduction value. The insertion loss is determined from the freefield sound pressure levels
measured at the same relative locations with respect to the outlet of the unsilenced and silenced
systems. The IL of a silencer is essentially determined by measuring the noise levels of piping
systems before and after the insertion of a silencer in the exhaust stream.

IL data presented by most manufacturers will typically be based upon insertion of the silencer
nto a standard piping system consisting of specified straight runs of piping before and after the
silencer. Exhaust system configurations as well as mechanical design can have a substantial
impact on the performance of and exhaust silencer and should be considered at the time of
specification. Raw exhaust noise levels should be obtained from the engine manufacturer to
determine the necessary noise reduction requirements of the proposed silencer. Specific
installation conditions and exhaust noise levels will aid the manufacturer in determining the
correct silencer to meet the required noise reduction. If a silencer is located outside of the room
or housing in which the engine is installed, one must be cognoscente of the effects of ‘break-out’
noise from either the silencer body or associated piping system. Breakout noise can dominate the
stack radiated noise, particularly for high-performance silencers that greatly reduce the noise
transmitted downstream. A high-performance exhaust silencer may have extremely good IL
performance, but utilization of a thin walled piping system may allow substantial noise to be
radiated from the piping system before entering the silencer body. The effects of sound
transmission through a mass layer are discussed in Chapter 25. One solution avoids potential
breakout from dominating the overall noise levels is to ensure a balance between the exhaust
silencer shell thickness and corresponding piping.

4.3 Aerodynamic performance

The Aerodynamic performance criterion specifies the maximum acceptable pressure drop
through the silencer (backpressure of the silencer). The exhaust flow rate and temperature from
the engine manufacturer are required to accurately predict the backpressure of a silencer and
piping system. Selection of an exhaust silencer based solely on the diameter of the connecting
piping can often lead to improperly selected products that may present installation issues.
Traditional head loss calculations utilizing standardized coefficients for sudden contraction and
expansion of fluids can be used to approximate the pressure drop through a silencer and
combined with the values obtained for the remainder of the piping system. More complex
silencer internal structures should be analysed using Computational Fluid Dynamics (CFD)
where traditional empirical calculations or assumptions may lead to inaccurate results. The
pressure drop through silencers should be obtained from the manufacturer of the product upon
submission of the required flow information.

4.4 Mechanical performance

The Mechanical performance criterion specifies the material properties of the exhaust system
to ensure that it is durable and requires little maintenance when incorporated into service.
Material selection is especially important in cases involving high temperature or corrosive
gases.
Traditional carbon steels will typically be sufficient for the majority of applications using
Diesel fuelled generators. Natural Gas engines will traditionally run at an elevated
temperature above their Diesel counterpart, and may require a graded carbon or stainless
steel that can maintain an element of structural performance at elevated temperatures.
Aluminized steel is available from many silencer manufacturers and is often preferred for
general applications.
Aluminized steel is slightly more heat resistant than carbon steel and offers an increased
resiliency to corrosion and is often selected as an economical alternative to specifying a
stainless steel system. Regular periodic testing of a standby generator will subject the
exhaust system to thermal cycles that can contribute to the premature corrosion of carbon
steel.

4.5 Reactive Silencer

Fig 4.5.1 Reactive muffler

Figure 4.5.1 represent the reactive muffler which generally consist of several pipe segments
that interconnect with a number of larger chambers. The noise reduction mechanism of
reactive silencer is that the area discontinuity provides an impedance mismatch for the
sound wave traveling along the pipe. This impedance mismatch results in a reflection of part
of the sound wave back toward the source or back and forth among the chambers. The
reflective effect of the silencer chambers and piping (typically referred to as resonators)
essentially prevents some sound wave elements from being transmitted past the silencer. The
reactive silencers are more effective at lower frequencies than at high frequencies, and are
most widely used to attenuate the exhaust noise of internal combustion engines. A generic
reactive engine silencer comprised of two proportionally sized chambers with a pair of
interconnecting tubes is shown above.
4.6 Absorptive muffler

The muffler is composed of a tube covered by sound absorbing material. The tube is
perforated so that some part of the sound wave goes through the perforation to the absorbing
material. The absorbing material is usually made of fiberglass or steel wool. The dampening
material is protected from the surrounding by a supplementary coat made of a bend metal
sheet. The advantage of this method is low back pressure with a relatively simple design.
The inconvenience of this method is low sound damping ability compared to the other
techniques, especially at low frequency. The mufflers using the absorption technique are
usually sports vehicle because they increase the performances of the engine because of their
low back pressure. A trick to improve their muffling ability consists of lining up several
"straight" mufflers.

Fig 4.6.1 absorptive muffler

Aqua Silencer

5. DESIGN CONSIDERATION
The exhaust gas contains carbon-dioxide, sulphur-dioxide, carbon monoxide and other
oxides of nitrogen. At full load, the temperature of the exhaust gas will lay anywhere
between 500°c to 700°c. The pressure of the exhaust gas depends upon so many factors
viz.The design of exhaust gas manifold Magnitude of valve overlaps Engine speed Number
of cylinders The length of the exhaust gas flow path etc. The design of exhaust gas manifold
is very important in case of high speed diesel engines. In order to maintain the exhaust gas
pressure within the required limits, the exhaust gas manifold is designed so that, the gases,
which come out of the cylinder flows very smoothly, before it is let out into the atmosphere.

This is absolutely essential in order to maintain the back pressure within safe limits, so that
the engine can be kept at the optimum operating level. The back pressure, if it is allowed to
exceed the pre-determined level, the effort on the part of the piston for scavenge is
considerably increased and so power is lost in performing the above, so, the primary
consideration when introducing any modification in exhaust system does not and shall not
increase the back pressure which drastically affect the performance characteristics of an
engine. To be more precise, the speed of the engine is affected for a given specific fuel
consumption rate and so the combustion characteristics of an engine are all affected. As a net
result of the combustion is not proper and complete which results in the increased impurities
or unburnt gases. This principle against the purpose of introducing any system whose sole
object is reducing the very toxic property of the exhaust gas.

So, it is implied that the introduction of any system reduces the toxic property of the exhaust
gas, shall not result in any effects in the opposite direction. So by introducing any component
in the system the flow path length and the resistance to flow are indirectly increased. So the
increase of back pressure is inevitable unless the increase in magnitude compensated in the
design of the component itself. The exhaust gas has to pass through the water, which is filled
in the scrubber tank. In any case, the outlet from the engine shall be kept below the water
level in the scrubber tank for that the gas will pass through the water. The gas has no to push
the water, in order to bubble through the water.

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Aqua Silencer
The gas has to push the water, in order to bubble through the water in the scrubber tank. This
may create chances to increase the backpressure. The baffles, which are provided to deflect
the exhaust gases, also offer resistance to the flow and in turn increase the back, pressure.
Due to the high temperature, the exhaust gas is let out from the engine, some of the water
particles which come in contact, readily changes its phase from liquid state to gaseous state
i.e., Steam which increases the net mass of the exhaust gas flow per unit time. The resultant
may increase the backpressure.

The lime stone container is used to store the limestone and offers a definite and increased
resistance to flow, which again contributes to the increase of backpressure. The limestones
are originally intended to reduce the toxic ingredients of the exhaust, gas through chemical
reaction. It is evidently affected the flow of resistance and hence the combustion
characteristics of the engine will finally contribute the increased toxic ingredients of the
exhaust gas. Because of the introduction of the scrubber, the net length of the exhaust gas
flow path is also increased which is again against the original intention.

So, all the above factors contribute for the increased backpressure of the system, the system
has to be so designed or constructed to reduce the above increase of pressure to its original
intended value or original designed value of the engine exhaust system. This could be in
principle, accomplished by so many ways. Basically, the elimination of a separate silencer
will have way solve the problem, because the scrubber tank, it will act as a silencer and
hence the resistance offered by a separate silencer, which is eliminated totally. The
introduction of the bell-mouth assembly facilitates the exhaust gas to expand many times by
volume gradually before it is coming in contact with the water in the scrubber tank.

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6. PARTS/COMPONENTS TO BE USED
6.1. Perforated tube

Fig 6.1 Perforated tube

Figure 6.1 represent the perforated tube which consist number of holes of various diameter
mainly there are four sets of holes. It is used to convert the high mass of bubble to low mass
and very important activated charcoal layer is pasted on it.

6.2. Non-return valve

Fig 6.2 Non-return value

Figure 62 represent the non-return value which is an important part uses to avoid back flow
of water and gases. It is placed at the inlet mouth of the aqua silencer.
 6.3. Outer shell

Fig 6.3 Outer shell

Figure 6.3 show the outer shell system which is kept inside it. It is mainly made up of steel
or iron. Water outlet, inlet also the exhaust tube is provided in this shell itself.

6.4. Flange

Fig 6.4 Flange

Figure 6.4 represent the photograph of Flange. It is a connection of pipes, where the connecting
pieces have flanges by which the parts are bolted together. Here flange is used to connect the
silencer to the engine.
 6.5. Charcoal layer

Fig 6.5 Charcoal layer

Figure 6.5 show the charcoal layer and is activated charcoal is a fine black powder made from
bone char, coconut shells, peat, petroleum coke, coal, olive pits or sawdust. The charcoal is
"activated" by processing it at very high temperatures. The high temperatures change its internal
structure, reducing the size of its pores and increasing its surface area. This results in a charcoal
that is more porous than regular charcoal.
7. CONSTRUCTION
An aqua silencer consists of a perforated tube which is installed at the end of the exhaust
pipe. The perforated tube may have holes of different diameters. The very purpose of
providing different diameter hole is to break up gas mass to form smaller gas bubbles the
perforated tube of different diameter .Generally 4 sets of holes are drilled on the perforated
tube. The other end of the perforated tube is closed by plug. Around the circumference of the
perforated tube a layer of activated charcoal is provided and further a metallic mesh covers
it. The whole unit is then placed in a water container. A small opening is provided at the
Top of the container to remove the exhaust gases and a drain plug is provided at the bottom
of the container for periodically cleaning of the container. Also a filler plug is mounted at the
top of the container. At the inlet of the exhaust pipe a non-return valve is provided which
prevents the back flow of gases and water as well.
8. WORKING
As the exhaust gases enter in to the aqua silencer, the perforated tube converts high mass
bubbles in lo low mass bubbles after that they passes through charcoal layer which again
purify the gases. It is highly porous and possess extra free valences so it has high absorption
capacity. After passing over the charcoal layer some of the gases may dissolved into the
water and finally the Exhaust gases escape through the opening in to the atmosphere. Hence
aqua silencer reduces noise and pollution. Following chemical reactions takes place in aqua
silencer:

Fig 8.1

Chemical Reaction 1

The obnoxious product of combustion is NOX – the oxides of Nitrogen. Water will absorb
the oxides of Nitrogen to a larger extent. The following chemical reaction will enhance the
proof, for the above statement.

NO2 + 2H2O 2 HNO2 + 2HNO3 (Diluted)…….Eq.1

Chemical Reaction 2

If a small amount of limewater is added to scrubber tank, further reaction takes place as below.

Ca (OH) 2 + 2HNO2 Ca (NO2)2 + 2H2O

Ca (OH) 2 + 2HNO3 Ca (No3)2 = 2H2O.......Eq.2

Chemical Reaction 3

When the carbon-di-oxide present in the exhaust gas comes in contact with the limewater,
calcium carbonate will precipitate. The calcium carbonate when further exposed to carbon-
dioxide, calcium-bi-carbonate will be precipitated. The following is the chemical reaction,

Ca (OH) + CO2 CaCO3 = H2O

CaCO3 + H2O + CO2 Ca (HCO3)2............Eq.3

Chemical Reaction 4

The sulphur-di-oxide present in the Diesel Exhaust also reacts with the limewater. But the
small trace of sulphur-di-oxide makes it little difficult to measure the magnitude of the
chemical reaction, accurately. The following equation gives the chemical reaction and
calcium sulphite will precipitate.
Ca (OH) 2 + SO2 CaSO3 + H2O..............Eq.4

From calcium carbonate, calcium sulphite will precipitate and CO2 will be by-product.
Because of the small percentage and SO2 presence, the liberation of Carbon dioxide is very
less. But the liberated CO2 will again combine with CaCO3 to form calcium bicarbonate.
9. EFFECTS OF DISSOLVED GASES ON LIME WATER
The lime water is a good absorbing medium. In aqua silencer the gases are passed through
perforated tube which is dipped in lime water. When these gases dissolved in water they
form acids, carbonates, bicarbonates etc,

1. Action of dissolved SO2:- When SOx is mixed in water, it form SO2, SO3, SO4, H2SO4
i.e. sulfur Acid ( H2SO3), it forms Hydrogen Sulphide which causes carious egg smell,
acidify and corrosion of metals.

2. Action of dissolved CO2:- The dissolved carbon dioxide forms bicarbonate at lower PH
and Carbonates at higher PH. Calcium carbonate will precipitate when carbon dioxide
present in exhaust gas and in contact with lime water.

3. Effect of dissolved NOx:- The NOx is abnoxious product of combustion-the oxides

of nitrogen. nitrogen absorbed to a larger exent by water.

9.1 Reactions

 The SO2 gas is removed from the flue gases forming calcium sulphate.

Ca(OH)2+ SO2.......CaSO3+ H2o

 Neutralizes any acid present in water

2HCL + Ca(OH)2..........Cacl2+ 2H2H2SO4+ Ca (OH)2........CaSo4+ 2H20

 Precipitates bicarbonate as calcium

carbonate CO2+ Ca(OH)2 CaCO3+2H2O

 Precipitates bicarbonate as calcium carbonate

Ca(HCO3)2+ 2Ca (OH)2........2CaCO3+

2H20

 Converts bicarbonate ions (Like NaHCO3, KHCO3etc.) into

carbonates. NaHCO3+ Ca(OH)2 CaCO3+ H20 + Na2CO3

10. MERITS AND DEMERITS
10.1 Merits

i. At running of engine, there is no vibration.

ii. Easy starting.
iii. Reduce noise and pollution at greater level.
iv. Carbon is separated
v. Cost is low.
vi. Easy construction and working.
vii. No need of catalytic converter.

10.2 Demerits

i. Lime water should be filled once in a year.

ii. Weight is more compared to conventional silencer.

iii. Space required is more compared to conventional silencer.

Aqua Silencer

11. CONCLUSION
The aqua silencer is more effective in the reduction of emission gases from the engine
exhaust using perforated tube, lime water and charcoal by using perforated tube the back
pressure will remain constant and the sound level is reduced. By using perforated tube the
fuel consumption remains same as conventional system by using water as a medium the
sound can be lowered and also by using activated charcoal in water we can control the
exhaust emission to a greater level. The water contamination is found to be negligible in
aqua silencer. It is smokeless and pollution free emission equivalent to the conventional to
the silencer. It can be also used both for two wheelers and four wheelers and also can be
used in industries.

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Aqua Silencer

12. REFERENCES
[1] Akhil Anil Kumar, Anoop N, “Design and Development of Aqua Silencer”, IJEIT, May
2016.

[2] Alen M.A., Akshay M., “ Fabrication and Testing of Aqua Silencer”, IRJET, Aug-2015.

[3] Rahul. S. Padval, Nitin V. Patil, “Aqua Silencer”, ICETEMR, March 2016.

[4] Prof. H.A. Khande, Karansingh Naglot, “Reduction in Emission and noise using
Aqua Silencer”, IJSDR, May 2016.

[5] Prof. M.M.Kulkarni, “Experimental Investigation and testing of Diesel engine and
Analysis of exhaust gases by using Aqua Silencer” IJERT, June, 2014

[6] Rohit Thakre,Ajit Khushwah “Design and Fabrication of Aqua Silencer For Automobile”

[7] Dr. P.K.Sharma ,Swapnil V. Kasar “Design And Manufacturing of Auqa Silencer for
Two Stroke Petrol engine.

[8] Santosh Kumara,Richard Brinton,”Design and Fabrication of Eco-Friendly Aqua Silencer”

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