Performance evaluation of a diesel engine fuelled with waste plastic pyrolysis oil, 1-butanol, and CeO2 additives under varying injection pressures K. Sunil Kumar, Sumathy Muniamuthu, T.M. Yunus Khan, Abdul Razak Case Studies in Thermal Engineering, 2025 This research examines the effects of various injection strategies using a fuel composition of 90% diesel, 7% waste plastic oil, 3% 1-butanol, and 25 ppm of CeO 2 nanoparticles. The novelty in this work includes the addition of limited percentages of cerium oxide with limited percentages of 1-butanol to achieve better performance, combustion, and emission characteristics. A detailed statistical investigation is carried out using Response Surface Methodology, followed by optimization using powerful desirability optimization techniques. Furthermore, advanced Machine Learning (ML) techniques are employed for modeling, enabling precise prediction and analysis of engine behavior under varying operating conditions.The injection pressure tested include 180 bar (low pressure), 200 bar (standard pressure), 220 bar (high pressure), and 240 bar (very high pressure). The findings reveal that the machine learning model outperformed RSM, with predicted R 2 values consistently ranging from 0.9 to 0.999 across all tests evaluating engine performance and emissions. Notably, at an injection pressure of 220 bar, there were significant improvements in key combustion metrics, including a 5.32% increase in cylinder pressure, a 5.11% increase in heat release rate, and a 3.42% increase in cumulative heat release rate, indicating enhanced combustion efficiency and superior atomization. Moreover, a maximum brake thermal efficiency of 35.6% was achieved, along with a reduced brake-specific energy consumption of 10.12 MJ/kWh at this pressure level. The 220-bar injection pressure also effectively lowered harmful emissions of CO, HC, and smoke by 7.23%, 18.72%, and 5.08%, respectively, although it resulted in a slight increase in CO 2 and NOx emissions by 3.91% and 3.94%. These outcomes are attributed to improved spray penetration and more efficient fuel-air mixing, yielding an optimal mean fuel droplet size. Overall, the 220-bar injection pressure demonstrated superior performance compared to the standard 200-bar, higher 240-bar, and lower 180-bar injection pressures, particularly when using a 10% waste plastic pyrolysis oil blend.
In-situ analysis on drop in thermal performance of wind turbine gearbox system: global challenges and sustainable ideas K Sunil Kumar, Sumathy Muniamuthu, Sachin Salunkhe, Robert Cep, Emad Abouel Nasr Engineering Research Express, 2025 The key thrust of this research work is to in-situ Analysis of the drop in Thermal Performance of wind turbine gearbox systems and global challenges and sustainable ideas detection of several failures that occur in the wind turbine gearbox with the help of the latest emerging sensors, and the source of the slave gearbox is a significant input for the master gearbox setup running at 1100 to 1150 rpm at generator side from Jan 2020 to Dec 2020. From the Experimental results, it is clearly understood that the majority of failures occurred due to irregular velocities ranging from 9 to 10 m s−1 at average velocities, and the kinematic viscosities of the oil exceed 400 μ resulting in heavy vibrations resulting in higher maintenance costs. The Master gearbox gives more Predominant results than the Slave gearbox; oil sump temperatures exceeding 85 °C result in poor active power generation falling below 100 Kw, and slave Gearbox oil sump temperatures are achieved at 100 °C; the Maximum temperature attained from the IMS Drive end-stage rate of 85 °C to 90 °C at lower speeds for master gearbox; Whereas slave gearbox temperatures are attained at 110 °C. The average temperature attained from the HSS stage of the Gearbox coupled with the generator is 90 °C, causing heavy vibration frequencies ranging from decibels causing tooth pitting failures for the master gearbox and for the slave gearbox. Average temperatures were attained by 120 °C.
Extraction of Pyrolysis Oil from Mixed Waste Plastics Derived from Energy Efficient Pyrolysis Reactor and Red Mud as Catalyst K. Sunil Kumar, Sumathy Muniamuthu International Journal of Renewable Energy Research, 2025 Although various techniques are implemented towards the synthesis of oil from various alternative sources such as seeds, stem layers of trees, and chicken wastes, the yielding percentage of oil was limited. The yielding of oil from these conventional techniques by mechanical expeller, Where the mechanical expeller rotates at 25 to 35 rpm to convert the seeds into oil, Solvent techniques essentially require a solvent as hexane as an absorbing agent to change the seeds into oil. The thermocracking method is the generation of oil from seeds with the help of a reactor working with temperatures of 400°C-500°C. This paper uses an energy efficient waste plastic Reactor to focus on oil extraction from mixed waste plastic. The experimental setup consists of an inner tank of 20CR80S-75µm YSZ (20% Chromium 80% Steel and 75 microns Yttria-stabilized zirconia) coated material that can withstand temperatures up to 1000°C. Experiments were carried out with 6 kgs of MWP (Mixed Waste Plastics) plastics kept inside the reactor in red mud as a catalyst for better yielding. The results observed that 450 ml of oil was yielded from 6 kgs of MWP at the reaction temperature range of 300-500°C with a reaction time of 1.5 to 2 hours for red mud catalyst. The condenser effectiveness was achieved up to 0.88 due to increased copper windings from 8 to 16, along with the implementation of two-stage condenser setups.
Investigation on Delonix regina biodiesel blends on diesel engine with 1-butanol-diesel blends to test engine performance, combustion and emission characteristics Sumathy MUNIAMUTHU Journal of Thermal Engineering, 2025 The need for automobiles is rapidly increasing all over the world. The biofuel requirement has also increased due to the need to avoid the nonpolluted atmosphere and improve performance. This work, with its innovative use of nonedible Delonox regina blends with limited proportions of butanol alcohols has practical implications for the automotive industry. The novelty of this research lies in the investigation of 1-butanol additives on Delox regina blends with the lowest proportions followed by 5%,12%, and 14% as a best-boosting ignitor. This limited butanol proportions proved that the engine’s thermodynamic performance was better when fuelled with Delonox regina blends and subjected to different loads. The results obtained from the Delonox regina blends and diesel in terms of performance, owing to combustion and owing to emissions for every stage, are compared with diesel. Higher thermal efficiency is obtained for the blend D90DR05B05, and the least BSFC is also attained for the blend D90DR05B05 than diesel, But the emissions are very low for the blend DR 100 followed by CO emissions, which is 34.5% superior to diesel. CO 2 emissions are 14.5% decreased for the blend D70DR16B14 than diesel, HC emissions for blend DR100 are less than 42.5%, and NOx emissions for blend DR100 are less than 23.53% compared to diesel. Cite this article as: Muniamuthu S, Kumar KS, Deepa S, Elangovan M, Verma A, Sonekar MM. Investigation on Delonix regina biodiesel blends on diesel engine with 1-butanol-die-sel blends to test engine
Emerging trends and global challenges to predict drop in thermal performance of WTG gearbox K. Sunil KUMAR Journal of Thermal Engineering, 2024 The assessment of performance is the key role factor for the gearboxes in the field of wind turbine industry. The thermal performance depends upon the viscous forces of the oil; bearing with stand capacity of the gearboxes and unnecessary irrotational forces or movements caused during the rotation of the gears at intermediate stage and high speed stage. The generation of the power starts from 15 m/s to 25 m/s with the starting rpm of 15 rpm to 1150 rpm; from initial stage to high speed stage of the gearbox. Hence the reduction of torque at higher rev-olutions may tends to complete reduction in power; owing to the thermal performance drop occurred due to the reduction of oil viscosities; improper maintenance during the high load conditions. This may lead to cause higher maintenance costs for the investors who is coming in front to invest huge amount of money. This present experimental work deals with latest sensors utilization to analyse the data from master gear box to slave gear box. From the results it is observed that the implementation of latest technology sensors tends to improves the main-tanence costs by 20% as compared to conventional sensors. Hence it is adviced to implement the latest technology sensors which is capable to measure the wind speed loads of 20 m/s to 45 m/s. This gives range of resolution for downloading the past data and predicting the futurized data for evaluating the thermal performance drop; leads to save the maintanence costs 20% as compared to conventional methods.
Assessment of performance, combustion, and emission characteristics of single cylinder diesel engine fuelled by pyrolysis oil + CeO2 nanoparticles and 1-butanol blends K. Sunil Kumar, Sumathy Muniamuthu International Journal of Ambient Energy, 2024 This experimental work focused on trials on diesel engines using Pyrolysis blends. The novelty in this work is the addition of cerium oxide additives with 1-butanol as an ignitor. The blends used were D100, 90D7WPO3B + 25 ppm CeO2, 85D10WPO5B + 50 ppm CeO2, 80D13WPO7 + 75 ppm CeO2 and 100WPO + 100 ppm CeO2. The results were outstanding as BTE is good for the fuel 90D7WPO3B + 25 ppm CeO2 by 36.2%, which is 12.25% greater than diesel, BSFC is better for the blend 90D7WPO3B + 25 ppm CeO2 by 0.22 kg/kWh, and maximum in-cylinder pressure obtained for 90D7WPO3B + 25 ppm CeO2 blend rated as 66.45bar; and maximum HRR is obtained for 85D10WPO5B + 50 ppm CeO2 blends by 84 J/ deg CA, BSEC of 85D10WPO5B + 50 ppm CeO2 blend is lower next only to diesel by 12.5 KJ/kWh, NOX emission minimum for 100WPO + 100 ppm CeO2 blends rate of 12 g/kWh, 14.2% lower than diesel, and lowest CO is attained for blend 80D13WPO7 + 75 ppm CeO2 blends at a rate of 0.8 g/kWh, 27.7% less than diesel, CO2 is minimum for blend 80D13WPO7 + 75 ppm CeO2 rate of 5 g/kWh; 18.03% less than diesel and HC is minimum for blend 100WPO + 100 ppm CeO2 blend rate of 0.18 kg/kWh; Which is 40% lower than diesel.
Review on electric vehicles Sumathy Muniamuthu et al., Sumathy Muniamuthu et al., and International Journal of Mechanical and Production Engineering Research and Development, 2018
Review on one manned aircraft International Journal of Mechanical Engineering and Technology, 2017
Experimental analysis of noise and vibration reduction in windmill gear box for 5mw wind turbine International Journal of Mechanical Engineering and Technology, 2016
Investigation on mechanical properties of Al 7075-Al2O3 metal matrix composite International Journal of Mechanical Engineering and Technology, 2016
Performance and emission characteristics of biodiesel-butanol blended fuel in Ci engine International Journal of Applied Engineering Research, 2015
Influence of video display terminal user’s qualification on the level of musculoskeletal disorder prevalence International Journal of Applied Engineering Research, 2014
The influence of psychosocial factors on the occurrence of musculoskeletal disorders regarding VDT users European Journal of Scientific Research, 2010
RECENT SCHOLAR PUBLICATIONS
Computational Fluid Dynamics R Kannan, KS Kumar, S Muniamuthu Innovation and Sustainability for Automation, Aerospace, and Robotics … , 2026 2026 Citations: 1
Extraction of Pyrolysis Oil from Mixed Waste Plastics Derived from Energy Efficient Pyrolysis Reactor and Red Mud as Catalyst KS Kumar, S Muniamuthu International Journal of Renewable Energy Research (IJRER) 15 (4), 708-724 , 2025 2025
Modeling Heat Transfer in Multi-Plate Heat Exchangers Using Phase Change MK Kumar, RM Reddy, LB Abhang, S Muniamuthu, HP Bhavsar, ... Proceedings of International Conference on Artificial Intelligence and … , 2025 2025
Performance evaluation of a diesel engine fuelled with waste plastic pyrolysis oil, 1-butanol, and CeO2 additives under varying injection pressures KS Kumar, S Muniamuthu, TMY Khan, A Razak Case Studies in Thermal Engineering 72, 106284 , 2025 2025 Citations: 5
TransGlass: A Transformer-Based Glass-Box AI Framework for Interpretable Predictions in Critical Domains S Aarathi, CHN Santhosh Kumar, S Muniamuthu, D Anil, Preethi, C Jain World Conference on Artificial Intelligence: Advances and Applications, 192-201 , 2025 2025
In-situ analysis on drop in thermal performance of wind turbine gearbox system: global challenges and sustainable ideas K Sunil Kumar, S Muniamuthu, S Salunkhe, R Cep, E Abouel Nasr Engineering Research Express 7 (1), 015556 , 2025 2025 Citations: 1
Investigation on Delonix regina biodiesel blends on diesel engine with 1-butanol-diesel blends to test engine performance, combustion and emission characteristics S Muniamuthu, KS Kumar, S Deepa, M Elangovan, A Verma, MM Sonekar Journal of Thermal Engineering 11 (1), 170-180 , 2025 2025 Citations: 4
Assessment of performance, combustion, and emission characteristics of single cylinder diesel engine fuelled by pyrolysis oil + CeO 2 nanoparticles and 1 … KS Kumar, S Muniamuthu International Journal of Ambient Energy 45 (1), 2344568 , 2024 2024 Citations: 21
Design and fabrication of nickel-chromium reinforced 2-stage energy efficient pyrolysis reactor for waste plastics applications KS Kumar, S Muniamuthu International Journal of Ambient Energy 45 (1), 2288148 , 2024 2024 Citations: 19
Assesment of Flow Dynamics in a Modified Exhaust Gas Calorimeter for Four-Stroke Diesel Engines Utilizing Computational Fluid Dynamics R Kannan, K Sunil Kumar, S Muniamuthu International Conference on Sustainable Technologies and Advances in … , 2024 2024
Processing and investigation on microstructure and characterization of advanced metal composites S Magbul, K Krishnasamy, R Velumayil, UP Jayavelu, S Muniamuthu, ... AIP Conference Proceedings 3192 (1), 020054 , 2024 2024
Productivity enhancement and comparative analysis of water as a heat storage medium with Paraffin wax for a solar desalination system B Ellappan, VR Madhavan, R Velumayil, K Krishnasamy, S Muniamuthu, ... AIP Conference Proceedings 3192 (1), 020076 , 2024 2024
Modeling Heat Transfer in Multi-Plate Heat Exchangers Using Phase Change Materials MK Kumar, RM Reddy, LB Abhang, S Muniamuthu, HP Bhavsar, ... International Conference on Artificial Intelligence and Networking, 331-340 , 2024 2024
Design of K-Type Propeller Optimized with Lightweight Aluminum Material and Its CFD Analysis for Marine-Based KS Kumar, V Kamalakar, S Palani, S Muniamuthu, CM Belinda Recent Trends in Thermal and Fluid Sciences: Select Proceedings of INCOME … , 2024 2024 Citations: 1
Design of K-Type Propeller Optimized with Lightweight Aluminum Material and Its CFD Analysis for Marine-Based Applications K Sunil Kumar, V Kamalakar, S Palani, S Muniamuthu, CM Belinda International Conference on Mechanical Engineering, 375-390 , 2023 2023 Citations: 6
Investigation of mechanical properties of metal matrix composites S Muniamuthu, JU Prakash, SJ Juliyana, CS Rubi Materials Today: Proceedings , 2023 2023 Citations: 6
Scope of waste plastic to reuse in India–A review J Sundaram, S Muniamuthu, C Rajkumar, JU Prakash, VSH Kumar, ... Materials Today: Proceedings , 2023 2023 Citations: 7
Measurement of temperature flow analysis by condition monitoring system for WTG gear box to evaluate the thermal performance associated with plant load factor KS Kumar, S Munıamuthu, KR Mohan Journal of Thermal Engineering 9 (4), 979-987 , 2023 2023 Citations: 15
Fabrication and mechanical characterization of venturi duct using fused deposition modelling through finite element approach J Sundaram, C Rajkumar, S Salunkhe, AS Praveen, S Muniamuthu, ... Materials Today: Proceedings , 2023 2023
Effect of dielectric medium on electro-discharge machining of aluminium metal matrix composites S Muniamuthu, C Rathinasuriyan Materials Today: Proceedings 92, 61-65 , 2023 2023 Citations: 3
MOST CITED SCHOLAR PUBLICATIONS
Effect of Charging and Discharging Process of PCM with Paraffin and Additive Subjected to Three Point Temperature Locations SK Kumar, S Muniamuthu, A Mohan, P Amirthalingam, M Anbu Muthuraja Journal of Ecological Engineering 23 (2), 34-42 , 2022 2022 Citations: 38
Experimental analysis of noise and vibration reduction in windmill gear box for 5MW wind turbine KS Kumar, S Arun, A Mohan, S Muniamuthu Int J Mech Eng Technol (IJMET) 7 (6), 76-85 , 2016 2016 Citations: 31
Investigation of heat generation during submerged friction stir welding on 6061-T6 aluminum alloy C Rathinasuriyan, S Muniamuthu, A Mystica, VSS Kumar Materials Today: Proceedings 46, 8320-8324 , 2021 2021 Citations: 29
An investigation to estimate the maximum yielding capability of power for mini venturi wind turbine K Sunil Kumar, S Muniamuthu, BT Tharanisrisakthi Ecological Engineering & Environmental Technology 23 , 2022 2022 Citations: 23
Assessment of performance, combustion, and emission characteristics of single cylinder diesel engine fuelled by pyrolysis oil + CeO 2 nanoparticles and 1 … KS Kumar, S Muniamuthu International Journal of Ambient Energy 45 (1), 2344568 , 2024 2024 Citations: 21
Dynamic characterization of hybrid composite based on flax/E-glass epoxy composite plates S Muniamuthu, KS Kumar, K Raja, PL Rupesh Materials Today: Proceedings 59, 1786-1791 , 2022 2022 Citations: 21
Investigation on mechanical properties of Al 7075-Al2O3 metal matrix composite S Muniamuthu, NL Raju, S Sathishkumar, KS Kumar Int J Mech Eng Technol 7 (6) , 2016 2016 Citations: 20
The influence of psychosocial factors on the occurrence of musculoskeletal disorders regarding VDT users S Muniamuthu, R Raju European J Sci Res 43 (2), 290-6 , 2010 2010 Citations: 20
Design and fabrication of nickel-chromium reinforced 2-stage energy efficient pyrolysis reactor for waste plastics applications KS Kumar, S Muniamuthu International Journal of Ambient Energy 45 (1), 2288148 , 2024 2024 Citations: 19
Measurement of temperature flow analysis by condition monitoring system for WTG gear box to evaluate the thermal performance associated with plant load factor KS Kumar, S Munıamuthu, KR Mohan Journal of Thermal Engineering 9 (4), 979-987 , 2023 2023 Citations: 15
Experimental analysis of CI engine running with mango seed biodiesel at optimum fuel injection pressure P Yogesh, B Murali, S Muniamuthu Materials Today: Proceedings 62, 1889-1893 , 2022 2022 Citations: 9
Scope of waste plastic to reuse in India–A review J Sundaram, S Muniamuthu, C Rajkumar, JU Prakash, VSH Kumar, ... Materials Today: Proceedings , 2023 2023 Citations: 7
Design of K-Type Propeller Optimized with Lightweight Aluminum Material and Its CFD Analysis for Marine-Based Applications K Sunil Kumar, V Kamalakar, S Palani, S Muniamuthu, CM Belinda International Conference on Mechanical Engineering, 375-390 , 2023 2023 Citations: 6
Investigation of mechanical properties of metal matrix composites S Muniamuthu, JU Prakash, SJ Juliyana, CS Rubi Materials Today: Proceedings , 2023 2023 Citations: 6
Performance evaluation of a diesel engine fuelled with waste plastic pyrolysis oil, 1-butanol, and CeO2 additives under varying injection pressures KS Kumar, S Muniamuthu, TMY Khan, A Razak Case Studies in Thermal Engineering 72, 106284 , 2025 2025 Citations: 5
Emerging trends and global challenges to predict drop in thermal performance of WTG gearbox KS Kumar, R Surakasi, A Mohan, BT Tharanisrisakthi, S Muniamuthu, ... Journal of Thermal Engineering 10 (3), 657-669 , 2021 2021 Citations: 5
Investigation on Delonix regina biodiesel blends on diesel engine with 1-butanol-diesel blends to test engine performance, combustion and emission characteristics S Muniamuthu, KS Kumar, S Deepa, M Elangovan, A Verma, MM Sonekar Journal of Thermal Engineering 11 (1), 170-180 , 2025 2025 Citations: 4
Study on TIG welding parameters for joining different kind of aluminium tube with a tube plate J Chandran, S Muniamuthu, G Padmanaban, A Kishore kumar, ... Journal of Physics: Conference Series 2272 (1), 012018 , 2022 2022 Citations: 4
Effect of dielectric medium on electro-discharge machining of aluminium metal matrix composites S Muniamuthu, C Rathinasuriyan Materials Today: Proceedings 92, 61-65 , 2023 2023 Citations: 3
Dr. Naga Lingeswara Raju, S. Sathishkumar and K. Sunil Kumar, Investigation on Mechanical Properties of Al 7075-Al2O3 Metal Matrix Composite DS Muniamuthu International Journal of Mechanical Engineering and Technology 7 (6) , 2016 2016 Citations: 3