A comparative analysis of mixing methods for real time emulsion fuel supply systems for common-rail fuel injection diesel engine

•Two types of water in diesel emulsification methods were compared in terms of engine performance and exhaust emissions.•Rotary Blade mixing method resulted in negligible fuel pressure difference compared to static mixing method.•Performance of rotary blade mixing method resulted in 10.62% increase in fuel efficiency compared to diesel.•Overall, the emulsion fuel resulted in reduced NOx levels and smoke opacity. This study compares the effects of two Real Time Emulsion Fuel Supply System (RTES) types, static mixer RTES (SM) and rotary blade RTES (RB), on engine performance and exhaust emissions in a common-rail fuel injection diesel engine using water in diesel (W/D) emulsion. RB system uses a novel mixing system design upgraded from SM design, with an elimination of mixing conduit component. The comparison involves pressure checking during RTES installation in the test vehicle, followed by on-road and idling emission testing to assess fuel consumption and exhaust emissions from both RTES types. Results indicate that the RB design excludes the need for an extra pump, unlike the SM, but still showcases a 10.62% improvement in fuel efficiency compared to diesel. While the W/D shows slightly increased CO emissions compared to baseline diesel, emulsion fuel consistently lowers NOx levels across different engine speeds. Notably, RB’s emulsion fuel exhibits significantly reduced smoke opacity compared to SM across various engine speeds.