Bio-Diesel

Format of presentation

• Relevance of Biodiesel

• Preparation Method

• Properties

• Emissions

• Testing at RDSO

• Indian Scenario

• Relevance of Biodiesel

• Preparation Method

• Properties

• Emissions

• Testing at RDSO

• Indian Scenario

Alternate Fuels

• ““The use of vegetable The use of vegetable oils for engine fuels oils for engine fuels may seem insignificant may seem insignificant today. But such oils today. But such oils may become in course may become in course of time as important as of time as important as petroleum and the petroleum and the coal tar products of coal tar products of the present time.the present time."" 

(1858 – 1913) 1912

DR RUDOLF DIESEL

What Is Bio-Diesel• Diesel fuel substitute produced from

renewable sources• It is manufactured from animal or

vegetable fats and has physical properties very similar to petroleum diesel fuel.

• Defined as mono alkyl ester of long chain fatty acids derived from renewable lipid sources

RELEVANCE OF BIODIESEL

• Oil demand to touch 274 MT by 2005.

• 40% of India’s consumption of 120 MT is diesel.• • 48 Million Tonnes of Diesel is consumed in India every year.

• 70 % of the above is imported.

• Expected to increase to 85% by 2020

• 75 million tonnes of fuel imported in 02-03.

• Import Bill in 04-05 Rs 1,20,000/ Cr expected to increase to 1,80,000 Cr in 05-06.

RELEVANCE OF BIODIESEL

• IR Has a fleet of 4800 diesel locomotives.

• Diesel Fuel .. 2000 million liters of diesel fuel consumed every year.

• Lubricating oil .. 26 million liters of lubricating oil consumed every year

• IR spends over Rs. 5000 crores on purchase of Diesel oil which is 17 % of expenditure.

RELEVANCE OF BIODIESEL

• Sale of Carbon credits(CERs) to developed countries under Kyoto Protocol can add to revenue.

• The Kyoto Protocol, that came into force on February 16, 2005, makes it obligatory for 37 developed countries to reduce their emissions of six harmful GHGs, including carbon dioxide. They can do this through a combination of direct domestic action and by investing in developing countries that reduce these emission levels.

• CER stands for one tonne equivalent of carbon dioxide reduced and can be traded globally.

BASIC REACTION

CH2COOR’

|

CHCOOR”

|

CH2COOR”’

3 ROH

Catalyst

CH2OH

|

CHOH

|

CH2OH

R'COOR

+

R''COOR

+

R'''COOR

60 Kg

Oil

13.6 Kg

Alcohol

0.60Kg

NaOH

6.5 Kg

Glycerin

58 Kg

Biodiesel

.

BENEFITS OF BIODIESEL

• Renewable fuel.• Import Substitute• Environment friendly & Clean burning• No engine modification• Superior Lubricity.• Helps clean injectors, fuel pumps and

fuel lines.• Higher Cetane No. helps reduce

knocking and contributes to smooth running engine.

Environment Friendly Fuel

• The vegetable oil esters are free of sulphur.

• The oxygen content of pure biodiesel is about 11% contributing to cut soot emissions up to 50 %

• Biodiesel is virtually CO2 neutral as the plants producing the seeds capture the carbon dioxide from the air, returning it through the emissions by the engines. So, biodiesel produces no increase of CO2 in the air.

• When burned Bio-diesel replaces exhaust odour of petroleum diesel with pleasant smell of popcorn or French fries.

• Free of carcinogenic benzene

Environmental Concerns

Emission Reduction (%)

CO 67

Hydrocarbon 30

Particulate Matter 68

SOOT 50

Polycyclic aromatic hydrocarbons(PAH)

85

CO2 100

NOX +/-2--6

SO2 80-100

NOx Emissions

Bio Diesel Blends with regular dieselNotch RegularDiesel B10 B20 B50 B100

8th 1422 1266 1480 1553 14917th 1511 1337 1590 1658 16476th 1669 1522 1769 1826 18045th 1891 1711 1980 2015 19704th 2166 1931 2201 2215 21273rd 2133 1900 2148 2173 20432nd 1521 1295 1537 1511 13761st 1056 904 1007 1001 870

Idle 789 683 726 791 627

Extraction

Refining

Use in Cars and Trucks

Fossil CO2

Release to Atmosphere

PETRO-DIESEL CO2 CYCLE13 pounds of fossil CO2 released per gallon burned

BIODIESEL CO2 CYCLENo fossil CO2 Released

Biodiesel Production

Use in Cars and TrucksOil Crops

Renewable CO2

CAN BIODIESEL WORK IN INDIA?

• India with just 2.4% of global area supports more than 16% of the human population and 17% of the cattle population

• India is one of the largest importers of edible oil

• Where do we find the oil for biodiesel?

• A sustainable source of vegetable oil is to be found before we can think of biodiesel

VEGETABLE OIL PRODUCTION

COUNTRY PRODUCTION YIELD (TONS/Ha)

(MILLION TONS)

EU-15 15.30 3.1

USA 15.41 2.62

CHINA 12.08 1.83

MALAYSIA 10.82 --

INDIA 7.5 0.87 (World average 2.13)

JATROPHA THE ANSWER?

•Oil extracted from seeds of Karanj tree in Karnataka and seeds of Jatropha bush grown in Gujarat when filtered & refined produce fuel•Jatropha (Jatropha curcas, Ratanjyot, wild castor) thrives on any type of soil

Needs minimal inputs

Can survive long periods of drought

Rapid growth; forms a thick live hedge after only 9 months of planting

Yield from the 3rd year onwards and continues for 25-30 years

Yield from established plantations in Brazil, 1.5 to 2.3 tons per

Hectare

The meal after extraction an excellent organic manure (38% protein, N:P:K ratio 2.7:1.2:1)

JATROPHA THE ANSWER?

•Jatropha plant is suitable for preventing soil erosion.

•Can be used for fencing

• Jetropha oil burns without emitting smoke.

•Latex of Jatropha contains Jatrophine which has anti-cancerous properties and is also used as an external application for skin disease and for sores on domestic live stock.

JATROPHA PLANT

Testing at RDSO

• Testing done with 120 liters of Bio diesel• Testing done at 7th & 8th Notches• Testing done with 5%, 10% & 20% blends of Bio diesel

Performance data-RDSO

Bio Diesel Blends with Regular DieselRegularDiesel

5% 10% 20%

SFC(gms./bhp-

hr)

150.59 152.12 152.47 154.83

FiringPressures

(psi)

1990 1940 1930 1895

HorsePower(HP)

3064 3070 3071 3068

Exhaust GasTemp. in ºC

472 473 480 477

Performance data-RDSO

Bio Diesel Blends with regular dieselNotch RegularDiesel B10 B20 B50 B100

HorsePower(HP)

3140 3116 3156 3153 3128

SFC(gms/bhp-

hr)

153.68 155.37 156.11 162.15 173.6

Exhaustgas

temp.(0C)

517 511 - 483 486

Firingpressure

(psi)

1648 1650 1644 1631 1655

FUEL CONSUMPTION

• Slight increase in the apparent fuel consumption rate– 2% for B20 blend; 14% for B100 (Cummins engine)

• Brake-specific fuel consumption figures – Petrodiesel 0.43 lb/HP-hr– B20 0.44 “– B100 0.50 “

Data from Indian Oil

Problem Areas

• Biodiesel has strong solvent properties– Natural rubber and soft plastics especially vulnerable– Problem substantially reduced for the B20 blend– The only hose and gasket material that is truly resistant to

biodiesel is Viton

• Biodiesel Blends > 30%– Free fatty acids formed during combustion can harm the fuel

injection pumps

• Low temperature performance can be a problem– the pour point of the ester is higher

• Emission of N0x may be higher– Because of the higher oxygen content in bio diesel

Problem Areas

• Viscosity of bio-diesel is higher than petro diesel

Bio Diesel Blends with regular dieselRegularDiesel B10 B20 B50 B100

K.Viscosity 3.026 3.07 3.25 3.44 4.05HP linePressure

927 93 949 971 1015

Injection pressure in HP tube increases significantly with viscosity. It is therefore essential to control the viscosity limit while producing bio-diesel.

THE INDIAN SCENE

WHAT NEEDS TO BE DONE :

• National programme & policy• Thorough research on plant type• Genetic manipulations for best breed• Large scale plantation• Establish supply – consumption chain• Downstream technologies• Tax benefits

BIODIESEL FROM JATROPHA

• India has 175 m hectare of wastelands• IF

– 10 MILLION HECATRES OF WASTE LAND IS BROUGHT UNDER JATROPHA CULTIVATION

– Can yield 15 million tons of seed (@1.5 Tons / Hectare )– 4.0 million tons of oil– An equivalent amount of biodiesel, almost one tenth

requirement of diesel in the country– Enormous employment generation potential in rural areas

• If only 1 person/family is employed per 5 hectares for jatropha cultivation, additional 2 million new jobs

• 200 new extraction units of 250 tpd capacity to crush the seeds

– 12 Million tons of excellent organic manure– 0.4 million tons of technical grade glycerol

COMMUNITY LEVEL BIODIESEL FACILITY

For a facility producing 1 ton of biodiesel per day:

Land required 1000 hectares

Seed yield 1500 tons

Oil yield 375 tons

Biodiesel yield 375 tons

Cost

Seeds @ Rs 4000/t Rs 60 lakhs

Processing cost @Rs 3000/t Rs 45 lakhs

Overheads @10% Rs 10.5 lakhs

Total Rs 115.5 lakhs

ReceiptsSeed meal, 1125 tons @ Rs 2000/t Rs 22.5 lakhsGlycerine, 37.5 tons @ Rs 4000/t Rs 15.0 lakhs

NET COST Rs 78 lakhsCost of fuel per kg = Rs 20.00 per litre = Rs 17.50

GLOBAL INITIATIVES

• EU has set a goal of using 2 % of vehicle fuel from bio fuels by 2005 and 6% by 2010.

• This would mean 4 lac tonnes of extra vegetable oil production.

• Argentina has increased production of soya oil by 12 MT for meeting fuel requirements.

• 60 Cars in Thailand were running on Coconut oil.• EU had set up capacity to produce 2 MT of bio-diesel

in 2002.• France is largest producer of Bio-diesel in Europe

due to total tax exemption granted by govt.

GLOBAL INITIATIVES

• Bio-diesel used in USA has grown from 50000 gallons in 1999 to more than 20 million gallons in 2003.

• US plans to replace 10% of petroleum best fuels by 2006 and increase their use to 30 % by 2020.

• Brazil is already using 15% bio-diesel for fuel

BIO-DIESEL INITIATIVES

• Residents of Kagganahalli village near Bangalore in Karnataka get regular power & water supplied by generators run on bio-diesel.

• P.Janardan Reddy of Hyderabad runs his Jeep for last few years on BioDiesel

• DaimlerChrysler has test driven a Mercedes C Class luxury sedan across India to promote bio-diesel.

• In villages around Ahemadabad large scale plantation of Jatropha has been done the plants will grow to5-6ft in two years.

BIO-DIESEL INITIATIVES

• Forest Department of UP has decided to undertake massive plantation of high yielding Jetropha species on 99000 Hectares in forest land.

• Government of Tamil Nadu is planning to spend over 17000 crores for planting Jetropha in 5 million hectares of waste land and producing bio-diesel.

• A national bio-fuel board (NBB) is proposed to be set up to promote bio-fuel.

• Chhatisgarh , Orissa and Gujurat Govts. Are actively promoting Jatropha plantation.

BIO-DIESEL INITIATIVES

• The national oil seeds and vegetable oil development board has prepared Re.1430 Cr. Project for bio-diesel production from Jatropha seeds.

• The project involves plantation of Jatropha in 50, 000 ha. In each of the 8 states - AP, Karnataka, Gujrat, Rajsthan, MP, MH , Chhatisgarh and UP.

BIO-DIESEL INITIATIVES

• Ministry of Petroleum is roping in Panchayats for mass cultivation of Jatropha as it provides a source of income to farmers and will reduce dependence on imports.

• RIL life sciences has taken up planting of Jatropha on 200 acres of land near Kakinada . This will be expanded after successful trials.

IR’s Initiative

• Railways are inviting parties to plant Jatropha on Rly land.

• An MOU has been signed with IOC for a pilot project. • Rly will offer 500 hectare land on token lease and IOC

will take up plantation,extraction, transestrification,blending and testing

• IOC has selected 81 hectares land for Jatropha carcus plantation at Surendra Nagar district in Gujrat under Rajkot division.

• IOC has set up a pilot plant with 200 litre per day capacity for production of bio-diesel at Gurgaon.

IR’s Initiative

• First train was run succeesfully on Dec’30,2002 with 5% biodisel mix.

• It has been decided to run locos with 5% bio diesel to start with and go upto 20% with field experience.

• Perambur loco workshop has set up a pilot plant for producing Bio-diesel

• Three road vehicles are regularly being run on bio-diesel.

JATROPHA PLANT

JATROPHA PLANTATION IN RLY.

IR’s Initiative

• Sourthern Railway has started using bio-diesel blend of 5% in one MG shunting loco with oil supplied by Perambur Worskhop.

• Detailed testing and evaluation of bio-diesel has been conducted in May 04 at RDSO viz. 10% , 20%,50% and 100% bio-diesel on 3100 HP Engine on test bed.

• Follow up service field trails were conducted in May 04 on Lucknow-Allahabad Janshatabdi with B-10 bio-diesel blend in three round trips.

Field Trial Summary Date Train

NO.Departure Arrival Type of Fuel HSD

in Litre

14/05/04 2054 LKO-0600 ALD-1020 10% bio 750

14/05/04 2053 ALD-1520 LKO-1930 10% bio 770

15/05/04 2054 LKO-0600 ALD-1020 10%BIO 700

15/05/04 2053 ALD-1520 LKO-1930 10%BIO 700

2054 LKO-0600 ALD-1020 10% BIO 700

17/05/04 2053 ALD-1520 LKO-1930 10%BIO 700

22/05/04 2053 ALD-1520 LKO-1930 Normal HSD 700

CONCLUSIONS

• Technically bio-diesel can be used in medium speed diesel engines without engine modification and can attain full operating power.

• Use of bio-diesel reduces amount of harmful emissions released from fuel consumed by locomotives. The benefit would be directly proportional to the amount of petro diesel replaced.

• A blend of B-20 appears most suitable for IR which amongst to nearly 400 million litres of bio-diesel consumption on railways.

CONCLUSIONS

• Only pilot plants are available in the country. Commercial size plants are needed to meet the requirement.

• This would require government concessions by way of tax benefits to producers of bio-diesel so that it remains price competitive.

CONCLUSIONS

• It can benefit our domestic economy. Spending on foreign imports of petroleum takes dollars away from our economy. Bio-diesel can help us shift this spending to domestically produced energy, and offers new energy-related markets to farmers.

• Commuter rail services and shunting operations can be the starting points for introducing bio-diesel.

THANKS

OTHER OPTIONS

• Natural Gas

• AlcoholMethyl

Ethyl

CNG

LNG

LNG vs. CNG

•LNG is 5 times more dense than CNG

•LNG has to be stored in a special Tender Car

•Temperature maintained at –260 F• Heat exchanger convert the liquid to gaseous form•Gas flows to the loco through a flexible hose connection

Natural Gas Locomotives

• The BN 7149, one of two natural gas locomotives developed for the Burlington Northern by Energy Conversions Inc. The locomotives operated on a commercial coal haul between Wyoming and Wisconsin from 1991-1996.

Dev. of LNG Locomotives

• ECI's natural gas technology applied to the Burlington Northern locomotive 7890.Shown with LNG tender car.

CONVERSION KITS

• Electronically controlled gas injectors

• Specially designed pistons and cylinder heads

• Electronic engine control and monitoring system

Conversion Kits

• Dual fuel conversions systems have been designed for EMD 645 and 710 engines

• ECI retrofit system converts GM EMD engines to dual fuel operation