Chapter 1-Introduction

LPG fitted bike runs on both petrol as well as on LPG .With the increasing prices of petrol so

as to give relief to the common people from the high cost of petrol the use of LPG in a bike is

beneficial one. To get the system working, we assembled the LPG cylinder to a stand, which

had been welded to the grill placed in front side of the bike. The LPG converter was fixed to

the rear seat hand grip, and the inlet pipe connected to inlet of the carburettor, and finally a

vacuum pipe to the inlet manifold. Later on we test rode the bike for about 5 KMs during

which we found hardly any difference in the performance and handling with that of a petrol

bike. Meanwhile, he also told me that the bike can give mileage of up to 135 KM per kg of

LPG. In case LPG gets over, we can switch over to petrol. Since LPG costs Rs 65 per KG, the

KM cost of this bike is 25 paisa per KM. Assuming a mileage of 60 KMPL and petrol cost of

rs 70, the equivalent cost for petrol is Rs 1.20. This means that the LPG running cost of this

bike is a whopping 80% cheaper than with petrol. LPG on two-wheelers will be a great

development for the world. As the two-wheeler runs quite smoothly in LPG and in fact as

good as petrol, this seems like a very good invention. Except the starting problems, this is

technology is perfectly usable. The LPG means Liquefied Petroleum Gas. It is also called as

bottled gas (or) Refinery gas. It is obtained as a by product during cracking of heavy crude

oils or from directly obtained natural gas. The LPG obtained either from cracking or from

CNG (Compressed Natural Gas) is dehydrated, desulphurised and traces of organic sulphide

(Mercaptans) are added to give warning of gas leak. It is then filled in cylinders and added to

give warning of gas leak. It is then filled in cylinders and compressed to that extend the fuel

gas in liquid state and supplied under the trade name like INDANE-BURSHANE, and many other

such suppliers. The calorific value is 27.800 Kael/map proximately.

Natural gas technology I.C engines beats the current emission standards for hydro carbons

(HC) and nitrous oxide (NO) by more than two thirds and level for carbon dioxide (CO) by

more half. LPG consists of Hydrocarbons of such volatility that they can exist as gas under

atmospheric pressure but can be readily liquefied under pressure. Air pollution is fast

becoming a serious urban as w ell as global problem with the increasing population and its

subsequent demand. Finding an alternative to conventional fuels would help to reduced it.

Vehicles running on cleaner fuels produce few er harmful emissions, and can offer some

savings on fuel costs, compared with petrol or diesel. In addition to cleaner, low sulphur

versions of the conventional vehicle fuels petrol and diesel, the main alternatives are

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currently road fuel gases LPG and CNG bio-fuels and, more distantly, hydrogen fuels,

including methanol; fuel cells, and electric vehicles. LPG as a fuel for spark ignition engines,

it has many of the same advantages as natural gas with the additional advantage of being

easier to carry aboard the vehicle. Its major disadvantage is the limited supply, which rules

out any large-scale conversion to LPG fuel. LPG is typically a mixture of several gases in

varying proportions. Major constituent gases are propane (C3H8) and butane (C4H10), w ith

minor quantities of propane (C3H6), various butanes (C4H8), iso-butane, and small amounts

of ethane (C2H6). The composition of commercial LPG is quite variable. Most LPG vehicles

can operate on both LPG and petrol. Conversion to LPG usually involves fitting an additional

fuel tank, fuel lines and associated components.

Figure 1

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1.1 Goals and objectives

The main objective of this design project is to develop and build an economic and efficient

LPG fitted bike that is capable of delivering over 100 km per litre of fuel (kmpl). The bar has

been set at 100 kmpl due to our limited budget, also considering the build time and time

needed to order parts within a period of three and a half months. We plan to set certain

parameters such as, accomplishing the said km per litre, a maximum velocity of 100 kmph.

The overall objective of the project is to fit LPG on a bike and made all those changes

essential for the completion of the project.

1.1.1 Motivation

The idea of this project struck us because of the increasing fuel rates day by day. Before

selecting a project topic, a criterion was developed to judge the different project proposals

available. This project matched the criterion more than any other project. First off all we

decide to make an CNG fitted bike as we thought that using CNG in case of LPG would be

an easy one and would be much more economical but we were wrong in that sense we make

the change and started working on making LPG fitted bike.The topic of environmentally

friendly technology is one of crucial importance nowadays. Being able to develop a vehicle

and contribute to the development of a future environmentally friendly vehicle was by far the

greatest motivation to undertake this project.

1.1.2 Method

After selected the project the team started working on the project,We started doing market

survey,we search for the bike,while doing this project certain question arises such as:-

1.Will this project will be success or not?

2.Two wheeler LPG kit would be available in market or not?

3.Would we be able to overcome all problems that comes our way or not?

4.would we be able to complete our project in time or not?

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After discussing all these questions and all we started working we purchased a four stokr bike

and all those which were required for the bike to run on LPG.

1.2 Overview of technical area

We started working on the project but we had to make a certain changes in bike.We had to

make a kit for the fitment of the lpg cylinder,we purchased LPG cylinder,pipes and and done

the changes in both rees valve and in carburettor for the proper functioning of the LPG fitted

bike which work both on LPG and as well as on Petrol,which may be called as a dual fuel

technology for the automobile.

1.3 Overview of the report

This report tells all the steps that had been undertaken during the project undertaken.The

steps may be such as:-

Purchasing of the bike,

Modification on the bike,

Various test done,

Changes and modifications

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Figure 2

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Figure 3

Chapter 2.Literature survey

The term ‘LPG’ covers a range of mixtures of propane and butane stored as liquidsunder

pressure, but it is propane that is mostly used to fuel vehicles.LPG and petrol have many

similar properties and the good practices appropriate for work on petrol vehicles apply

equally to LPG vehicles.The main difference is that LPG vaporises more rapidly than petrol,

so, as LPG is stored in the fuel tank and associated fuel lines at elevated pressure (up to10 bar

g), any leakage will immediately vaporise and disperse. LPG vapour is highly flammable and

mixtures in air of between 2% and 10% will easily ignite and explode.The rapid expansion

resulting from the conversion of liquid propane into a vapour causes severe cooling of the

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gas.Anyone exposed to a vapour cloud or in contact with metal surfaces may receive cold

burns.

Most LPG vehicles can operate on both LPG and petrol. Conversion to LPG usually involves

fitting an additional fuel tank, fuel lines and associated components.New vehicles can be

converted by the original manufacturer, but as with used vehicles, this must be done by

somebody with the necessary skills and knowledge to carry out the work safely, such as a

There is no such thing as a ‘standard conversion’, which is why competence when carrying

out this work is so important.

Engine modifications required

Many propane vehicles are converted gasoline vehicles the relatively inexpensive conversion

kits include a regulator/vaporizer that change liquid propane to a gaseous form and an air/fuel

mixer that meters and mixes the fuel with filtered intake air before the mixture is drawn into

the engine’s combustion chambers. Also included in conversion kits is closed-loop feedback

circuitry that continually monitors the oxygen content of the exhaust and adjusts the air/fuel

ratio as necessary.LPG vehicles additionally require a special fuel tank that is strong enough

to withstand the LPG storage pressure of about 130 pounds per square inch.

Engine technology for LPG vechiles

As the LPG is stored in liquid form under high pressure,it is need to convert it into vaporized

form before drawn into the combustion chamber. As engine technology for LPG vehicles is

similar to that for natural gas vehicles, with the exception that LPG is not commonly used in

dual-fuel diesel applications due to its relatively poor knock resistance. For Spark ignition

engine there are two types of LPG engines are primarily studied :-

1. LPG which is stored in composite vessel at high pressure approximately at 10-20

bar,supply to the engine is controlled by a regulator or vaporizer, which converts the LPG to

a vapour. The vapour is fed to a mixer located near the intake manifold, where it is metered

and mixed with filtered air before being drawn into the combustion chamber where it is

burned to produce power, just like gasoline.

2. LPG fueled direct injection SI engine, especially in order to improve the exhaust emission

quality while maintaining high thermal efficiency comparable to a conventional engine. In-

cylinder direct injection engines developed recently worldwide utilizes the stratified charge

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formation technique.duration both declined. The dog dish cavity achieved the lowest thermal

efficiency, whereas the bathtub cavity showed the highest value. Although the nebula cavity

showed improved combustion characteristics, had the highest NOx emissions than produced

with dogdish cavity. The nebula cavity showed a better thermal efficiency than the bathtub

cavity, since the nebula cavity could achieve leaner combustion. High swirl improved

combustion stability and thermal efficiency, and enabled engine operation at low NOx levels.

2.1 Survey

In the above figure we see that the maximum pollution is due to the two wheelers which are

running on gasoline,by using LPG in bikes we can reduce pollution level of the bike to upto

50%.The flame propagation speed of the fuel is increased with the decrease of initial pressure

and the increase of initial temperature in the constant volume chamber. The results also show

that the equivalence ratio has a great effect on the flame speed, combustion pressure and the

combustion duration of the fuel-air mixture.carried out to quantify the combustion and

emissions characteristics of LPG fuelled SI engine with minor modification in original SI

engine to run on LPG fuel with varying volume percentage of LPG at 5%,10%,20% with the

help of PLC controller. Engine speed maintained at 4000rpm,the relative air-fuel ratio varies

from 0.8 to 1.3.The exhaust gas constituents (CO2,CO,uHC and NOx) were measured using

the 5-gas analyzer. Percentage of LPG in gasoline means that the combustion shifted towards

complete phase and ‘greener’ exhaust products were subsequently released to the atmosphere.

For each proportion of LPG in gasoline investigated, it was also observed that the CO2

emissions peaked at around λ=1 and exhibits lower percentages at rich and lean mixtures.

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Figure 4

. An increasing proportion of LPG in gasoline promotes faster burning velocity of mixture

and hence reduce the combustion duration and subsequently the in-cylinder peak temperature

increases. At high relative air-fuel ratio, the amount of NOx measured was much higher, uHC

also shows marked reduction as the relative air-fuel ratio exceeds Stochiometric. Later, a

number of parameters in determining the noise developments were investigated which

include the first and the second derivative of cylinder pressure . These methods were effective

in revealing the relationship between engine combustion and noise. Some of them still play

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an important role in identifying the source of engine noise.Although there are a number of

engine noise sources, one of the most fundamental is the combustion-induced noise. It occurs

toward the end compression stroke and subsequent expansion stroke. The rapid pressure

change due to the combustion transmits through engine structures and forms a part of the

airborne noise . This pressure change also causes the vibration of the engine components such

as the cylinder head, pistons, connecting rods and engine body.Because of its superior knock-

resistance, propane is preferred to butane as an automotive fuel.The lean combustion limit of

propane-gasoline mixtures is considerably leaner than for gasoline, allowing the use of lean-

burn calibrations, which provides more resistant to knocking and permit the use of still higher

compression ratios.LPG has many of the same emission characteristics as natural

gas.Emissions comparison study between Gasoline, LPG and CNG.Switching from gasoline

to LPG and CNG results in a substantial reduction in the CO emission. CNG also reduced HC

and NOX emissions. From the above literature review showed the improved combustion

characteristics, performance and emissions characteristics with LPG as alternative fuel to

gasoline at various condition such as changing the piston cavities, air fuel ratio, speed

etc.Further research has to be carried out by changing compression ratio/ignition timing to

compare the performance and emissions characteristics.

The study of engine noise has been carried out since the early stages of engine development.

In 1931, Ricardo first found a descriptive relationship between the combustion pressure rise

and the noise produced . Later, a number of parameters in determining the noise

developments were investigated which include the first and the second derivative of cylinder

pressure . These methods were effective in revealing the relationship between engine

combustion and noise. Some of them still play an important role in identifying the source of

engine noise.Although there are a number of engine noise sources, one of the most

fundamental is the combustion-induced noise. It occurs toward the end compression stroke

and subsequent expansion stroke. The rapid pressure change due to the combustion transmits

through engine structures and forms a part of the airborne noise . This pressure change also

causes the vibration of the engine components such as the cylinder head, pistons, connecting

rods and engine body.Because of its superior knock-resistance, propane is preferred to butane

as an automotive fuel.The lean combustion limit of propane-gasoline mixtures is considerably

leaner than for gasoline, allowing the use of lean-burn calibrations, which provides more

resistant to knocking and permit the use of still higher compression ratios.LPG has many of

the same emission characteristics as natural gas. Graph shows IANGV emissions comparison

study between Gasoline, LPG and CNG.Switching from gasoline to LPG and CNG results in

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a substantial reduction in the CO emission. CNG also reduced HC and NOX

emissions.Emissions like (1,3-butadiene,benzene,formaldehyde and methanol of all the

alternative fuel) of LPG give vehicles are generally less than formaldehyde levels for

gasoline fuels. Graph shows Three-way catalyst technology is efficient in removing not only

regulated emission components but also harmful unregulated components. On gasoline, the

TWC reduces 1,3-butadiene, benzene and formaldehyde emissions by a factor of more than

10. For these three components, LPG and CNG give lower emissions than gasoline.TNO data

on acetaldehyde emissions from non-catalyst vehicle Switching from gasoline to gaseous

fuels reduces PAH emissions by a factor of 10. However, one could estimate that the total

toxic effects going from gasoline to natural gas in non-catalyst vehicles will be reduced

substantially.

Rules and Regulations

■■ Provide safe locations for parking and working on LPG vehicles. As with petrol fuelled

vehicles, they should be parked away from sources of heat, open flames or other sources of

ignition. They should also be parked away from openings in the ground like drains and pits.

■■ Clearly identify each LPG vehicle, eg with suitably positioned signs, as a reminder to

people working on the vehicle, and anyone in the vicinity, especially those who may be

carrying out ‘hot work’.

■■ Provide plant and equipment that is suitable for its intended use.

■■ Don’t take vehicles with leaking LPG systems inside a workshop or other building, as

dangerous concentrations of vapour could accumulate.For any work that may have the

potential to affect the LPG system, and where it is possible to do so, the shut-off valve (where

provided) on the fuel tank(s) should be closed and the LPG fuel in the service line exhausted.

When doing so, take the following precautions.

■■ Wear suitable personal protective equipment (PPE) to prevent cold burns, eye

damage and the discharge of static electricity.

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■■ Only carry out work which involves breaking into, or removing components from, the

LPG system in a safe place and in the open air; before doing so, disconnect the vehicle

battery, and display warning signs, eg ‘No smoking’ around the area.

■■ Empty LPG fuel lines from the tank to the engine by isolating the fuel tank and running

the engine until it stops (this procedure will not remove LPG from the line between the filling

point and tank). If this is not possible, and provided the fuel tank is isolated, disconnect fuel

lines in the open air, where LPG should disperse.

■■ Release LPG slowly into the atmosphere where appropriate and give it time to

disperse.

Comparison b/w gasoline and LPG

Properties/fuel Gasoline LPG

Chemical structure C7H17/C4 to C12 C3H8

Energy density 109,000-125000 84,000

Octane number 86-94 105+

Lower heating value(MJ/KG) 43.44 46.67

High heating value(MJ/KG) 46.53 50.15

Stoichimetric air/fuel ratio 14.7 15.5

Density at 15 degree Celsius 737 1.85/505

Figure 5

On an energy basis LPG has a lower carbon content than gasoline or diesel fuel. When used

in spark-ignition engines, LPG produces near-zero particulate emissions, very little CO and

moderate HC emissions. Variations in the concentration of different hydrocarbons in LPG

can affect the species composition and reactivity of HC exhaust emissions. As olefin (such as

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propene and butane) are much more reactive in contributing to ozone formation than

paraffin’s (such as propane and the butanes), an increase in the olefin content of LPG is likely

to result in increased ozone-forming potential of exhaust emissions. Due to the gas-tight seals

required on the fuel system, evaporative emissions are negligible.Exhaust NMHC and CO

emissions are lower with LPG than gasoline. CO2 emissions typically are also somewhat

lower than those for gasoline due to the lower carbon-energy ratio and the higher octane

quality of LPG. NOx emissions are similar to those from gasoline vehicles, and can be

effectively controlled using three-way catalysts. Overall, LPG provides less air quality

benefits than CNG mainly because the hydrocarbon emissions are photochemically more

reactive and emissions of CO are higher. Amongs the spark ignition and the compression

ignition engines, diesel engines tend to be more energy efficient than Gasoline engines,

provide higher torque output and operate over limited engine speeds; however, such engines

typically do not provide the throttle response and flexibility desired for lighter weight

vehicles. The parameters of particular interest are engine torque, power and specific fuel

economy. Engines are basically air pumps,ability of an engine to pump air is called

Volumetric efficiency (VE), which if reduced; the maximum power output will be reduced.

As the gaseous fuel requires 4 to 15 percent of more intake passage volume than liquid fuels

which reduces the VE and hence maximum power output will also be reduced(by 4%). SI

engines burn a premixed air-fuel mixture followed by compression before a spark ignites the

mixture. Octane rating of a fuel indicates how slowly the fuel will burn and how well the fuel

will resist pre-ignition before the spark plug fires. Higher octane fuels can be burned at high

compression ratios (CR). The higher CR of an engine, the more efficient is the engine and

more is the power generated with given amount of the fuel. LPG has high octane rating 110+

that allows CR to be high up to 15:1, which is in the range of 8:1 to 9.5:1 for gasoline

engines.

SR.NO. Emissions and fuel Gasoline LPG

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consumption

1 CO(g/km) 0.87 0.72

2 HC(g/km) 0.14 0.12

3 Nox(g/km) 0.12 0.16

4 Fuel

consumption(1/100k

m)

8.7 11.3

5 Energy

consumption(MJ/KM)

2.8 2.7

Figure 6

The gaseous nature of the fuel/air mixture in an LPG vehicle’s combustion chambers

eliminates the cold-start problems associated with liquid fuels. LPG defuses in air fuel mixing

at lower inlet temperature than is possible with either gasoline or diesel. This leads to easier

starting, more reliable idling, smoother acceleration and more complete and efficient burning

with less unburned hydrocarbons present in the exhaust. In contrast to gasoline engines,

which produce high emission levels while running cold, LPG engine emissions remain

similar whether the engine is cold or hot. Also, because LPG enters an engine’s combustion

chambers as a vapour, it does not strip oil from cylinder walls or dilute the oil when the

engine is cold. This helps to have a longer service life and reduced maintenance costs of

engine. Also helping in this regard is the fuel’s high hydrogen-to-carbon ratio (C3H8), which

enables propane-powered vehicles to have less carbon build-up than gasoline and diesel-

powered vehicles. LPG delivers roughly the same power, acceleration, and cruising speed

characteristics as gasoline. Its high octane rating means engine’s power output and fuel

efficiency can be increased beyond what would be possible with a gasoline engine without

causing Destructive Knocking. Such fine-tuning can help compensate for the fuel’s lower

energy density. The higher ignition temperature of gas compared with petroleum based fuel

leads to reduced auto ignition delays,less hazardous than any other petroleum based fuel and

expected to produce less CO, NOx emissions and may cause less ozone formation than

gasoline and diesel engines. LPG has a relatively high energy content per unit of mass, but its

energy content per unit volume is low. Thus, LPG tanks have more space and weight than

petrol or diesel fuel tanks, but the range of LPG vehicles is equivalent to that of petrol

vehicles. Bi-fuel LPG tests show around a 15% reduction in greenhouse gas emissions (per

unit of distance) compared to petrol operation. The best quality LPG bi-fuel engines produce

fewer NOx emissions and virtually zero particulate emissions if compared to petrol.

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2.2 Conclusion

Based on the reviewed paper for the emissions and performance, its concluded that the LPG

represents a good fuel alternative for gasoline in bikes and therefore must be taken into

consideration in the future for transport purpose. Apart from the fuel storage and delivery

mechanism, LPG engines similar to petrol engines, and deliver nearly similar performance

and good in combustion characteristics than Gasoline. In the short term, LPG as a alternative

fuels reviewed could displace 10 per cent of current usage of oil, or bring significant

reductions in CO, CO2 emissions and help to reduce harmful greenhouse gas emissions. In

the next five to ten years, LPG will be more widely available and gaining market share across

vehicle ranges.

Chapter 3. Problem definition

We had faced several problems while we were doing in the project as:-

Firstly we were a bit confused about placing of the cylinder. Secondly it was bit confusing about making a hole in the reed valve. We had make a slight change in the carburator. Adjusting of the air pressure and gas pressure to give the correct supply in the

combustion chamber was also a bit difficult task.

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Figure 7

3.1 Specification

- Maximun 1.5 kg gas can be stored at a time into the cylinder.

-Pressure reducer

3.2 Requirements

Klockner gas technology is a amalgamation of a seven new principles and technologies, which we have discovered first time in the world and applied for successfully running of all types of 2 wheelers on LPG Fuel. It is not the all, bike fitted with Klockner gas kit system beats petrol run original Models in terms of power developed, cold starting, fuel efficiency, pick up, pollution, maintenance and engine life. 

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cylinder

Regulator

Pressure reducer

EMR Single kick starting technology:- This system ensures first kick-start of engine without touching the Accelerator. In this starting technique Air& Fuel are pre mixed in explosive ratio & fed directly to intake manifold facilitating instant starting.

Figure 8

This supersaver Reed Valve Operated device specially developed to work in tandem with the gassifire does not allow any fuel wastage by the kit and enhances the power output of the engine, for example:- if an engine has a top speed of 100 Km./hour on petrol then on klockner gas system with this device, ensures that the engine will give a top speed of 105 Km/hour. All klockner gas system works on low-pressure systems i.e., Gas cylinder by design, supplies gas fuel at a pressure as low as 0.5 PSI.

KLOCKNER Gassifire is a single stage suction based, twin diaphragm operated precision gas to gas control valve, specially designed to run air cooled single cylinder engines 50 cc to 375 cc 4 stroke as well 2 stroke.

Chapter 4. Testind deployment

4.1 Validation

Our motive was to run a bike on an LPG to get a validation is not in our hands but we saw by the results it is following all the norms that are made by the central government for petrol vechiles.

We conclude from the down figure that it is following all standards of pollution norms.

We saw that co level increases a bit but it is following all the standards.

We saw that the HC level goes down.

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Figure 9

In comparison to petrol it has certain benefits,Government should look at this and think about this to validate the use of LPG in bikes.As it is very much beneficial in increasing efficiency and it is much eco-friendly too. LPG as Auto fuel is gaining popularity day by day. LPG dispensing Units/ Pumps are opening up in all major cities of the country in another 2 years time another additional 20new cities will be having LPG Pumps.LPG system is coming in four wheelers and by this new innovation we expect we would be able to see bike with LPG to rule the market in coming days.

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