Bio-Diesel

Format of presentation

•• Relevance of
Relevance of Biodiesel
Biodiesel
•• Preparation Method
Preparation Method
•• Properties
Properties
•• Emissions
Emissions
•• Testing at
Testing at RDSO
RDSO
•• Indian Scenario
Indian Scenario
Alternate Fuels

• “The use of vegetable

oils for engine fuels
may seem insignificant
today. But such oils
may become in course
of time as important as
petroleum and the
coal tar products of
the present time."
DR RUDOLF DIESEL
(1858 – 1913) 1912
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’ CH2OH R'COOR

| Catalyst | +
CHCOOR” 3 ROH CHOH R''COOR
| +
|
CH2COOR”’ R'''COOR
CH2OH

60 Kg 13.6 Kg 0.60Kg 6.5 Kg 58 Kg

Oil Alcohol NaOH Glycerin 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 85
hydrocarbons(PAH)
CO2 100
NOX +/-2--6
SO2 80-100
NOx Emissions
Notch Regular Bio Diesel Blends with regular diesel
Diesel B10 B20 B50 B100
8th 1422 1266 1480 1553 1491
7th 1511 1337 1590 1658 1647
6th 1669 1522 1769 1826 1804
5th 1891 1711 1980 2015 1970
4th 2166 1931 2201 2215 2127
3rd 2133 1900 2148 2173 2043
2nd 1521 1295 1537 1511 1376
1st 1056 904 1007 1001 870
Idle 789 683 726 791 627
PETRO-DIESEL CO2 CYCLE
13 pounds of fossil CO2 released per gallon burned

Fossil CO2
Release to Atmosphere

Refining

Use in Cars and Trucks

Extraction
BIODIESEL CO2 CYCLE
No fossil CO2 Released

Renewable CO2

Oil Crops Use in Cars and Trucks

Biodiesel Production
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

Regular Bio Diesel Blends with Regular Diesel

Diesel
5% 10% 20%
SFC 150.59 152.12 152.47 154.83
(gms./bhp-
hr)
Firing 1990 1940 1930 1895
Pressures
(psi)
HorsePower 3064 3070 3071 3068
(HP)

Exhaust Gas 472 473 480 477

Temp. in ºC
Performance data-RDSO

Notch Regular Bio Diesel Blends with regular diesel

Diesel B10 B20 B50 B100
Horse 3140 3116 3156 3153 3128
Power
(HP)
SFC 153.68 155.37 156.11 162.15 173.6
(gms/bhp-
hr)
Exhaust 517 511 - 483 486
gas
temp.(0C)
Firing 1648 1650 1644 1631 1655
pressure
(psi)
 FUEL CONSUMPTION

Data from Indian Oil

• 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 “
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
Regular Bio Diesel Blends with regular diesel
Diesel B10 B20 B50 B100

K.Viscosity 3.026 3.07 3.25 3.44 4.05

HP line 927 93 949 971 1015
Pressure

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
Receipts
Seed meal, 1125 tons @ Rs 2000/t Rs 22.5 lakhs
Glycerine, 37.5 tons @ Rs 4000/t Rs 15.0 lakhs
NET COST Rs 78 lakhs
Cost 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 Departure Arrival Type of Fuel HSD
NO. 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

CNG
• Natural Gas
LNG
Methyl
• Alcohol Ethyl
 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
Dev. of LNG 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.
• 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