PRESENTATION ON

BIOBIO-DIESEL.

By ARVIND LAL, M.Sc.( Chemistry) IRIMEE,JAMALPUR.

29 June 2011

E-MAIL:- lalarvind2@gmail.com 1

ADVANTAGE. MANUFACTURE ENVIRONMENT

SOCIAL FACTOR.

PROPERTIES. Engine performance. BIO-DIESEL

RAILWAY PLANNER.

What is

WHY ?

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FOR ANY DEVELOPED COUNTRY IT MUST BE REQUIRED TO FOLLOW OR TO ACHIEVE ITS 4-E goals.

Energy Security. Environment protection Energy conservation. Employment

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TO ACHIVE 4-E goals & IMPROVE THE WORLD ECONOMY.

BIO-DIESEL MAY BE THE HOPE FOR TODAY & TOMORROW

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TWO STRATEGIES FOR VEGETABLE OIL HAVE BEEN PERFORMED AND EVALUATED.

1. ADAPTATION OF ENGINE TO THE FUEL.

2. ADAPTATION OF THE FUEL TO THE ENGINE. ( Much work has been done in this area)

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Alternate Alternate Fuels

Fuels

DR RUDOLF DIESEL

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." time."
1912
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(1858 1913)
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CUMMINS ENGINES ON BIO-DIESEL

WE APPRECIATED THE BIO-DIESEL INITIATIVE TAKEN BY IR, MEASURE COUNSUMER OF HSD OIL. CUMMINS IS PROUD TO BE ASSOCIATED WITH IRS JOURNEY TOWARDS ECONOMICAL OPERATION USING RENEWABLE ENERGY SOURCE SUCH AS BIODIESEL. EVALUATE THE BIODIESEL ON DEMU ON 27.05.05.

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FUEL DOES GROW ON TREES

DIESEL GROWS ON TREES.

TIMES OF INDIA . 1ST JULY,2005.

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WHAT IS BIO-DIESEL ?
is a domestically produced, Biodiesel renewable fuel that can be manufactured from vegetable oils, animal fats, or recycled restaurant greases. Biodiesel is safe, biodegradable, and reduces serious air pollutants such as particulates, carbon monoxide, hydrocarbons, and air toxics.

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ADVANTAGES OF BIO-DIESEL
RENEWABLE ENERGY SOURCE. RURAL EMPLOYMENT. SAVE FOREIGN EXCHANGE. DECENTRALIZED AND INTEGRATED POWER GENERATION. BIO DEGRADABLE AND NON-TOXIC. REDUCTION OF GREEN LAYER GASES AND POLLUTION. TECHNICAL FESSIBILITY. VALUABLE BY PRODUCT.
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IMPACT OF BIO-DIESEL ON ENVIRONMENT

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India will become third biggest CO2 emitter by 2015

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An unconvenient truth : global warming

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Our Competitors

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Where is the truth? Rail and energy

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Attention on exhaust gas NOx emissions from the transport sector, emission EU25, 1990-2001:

Rails share of emissions comparably small (1-3 %), but Increasing attention on air quality from public and authorities

Source: European Environment Agency, TERM 2003 03 EEA31

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Road performance improvement

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Benefits
According to the National Biodiesel Board, using a B20 biodiesel fuel blend can reduce vehicle emissions: oUnburned hydrocarbons - 20% reduction oCarbon monoxide - 12% reduction oParticulate matter - 12% reduction

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CO2 Cycle
Petro Diesel BIODIESEL Potential CO2 Neutral Technology
Fossil CO2 Release to Atmosphere

Oil Crops

Exploration Refining 29 June 2011

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ENVIRONMENTAL CONCERNS Environmental Concerns

Emission CO Hydrocarbon Particulate Matter SOOT Polycyclic aromatic hydrocarbons(PAH) CO2 NOX SO2

Reduction (%) 67 30 68 50 85 100 +/-2--6 80-100

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Advantages of Biodiesel PM,HC,CO reduction

EPA analysis: data from many studies engine models through 1997 NOx No change for B5 2% up for B20 10% up for B100 PM 5% down for B5 12% down for B20 48% down for B100
Analysis fr
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PA420-P-02-001, O t b r 2002
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Biodiesel is domestically produced, so its use helps reduce the nation's dependence on imported oil and can help boost the agricultural sector of the economy.

Biodiesel is a renewable fuel made from domestically grown crops like soybeans and mustard seed. Biodiesel can also be produced from recycled cooking grease.

* When using biodiesel, lubricity is improved over conventional diesel fuel.

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IMPACT OF AIR POLLUTION.

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PONGAMMIA TREE

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PONGAMMIA TREE WITH FRUITS

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PONGAMIA PINNATA KARANJIA / HONGE TREE

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JETROPHA CURCAS PLANT

JATROPHA CURCAS AS ENERGY PLANT

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JATROPHA THE ANSWER?

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)
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Manufacture of Bio-diesel:
Conversion of the of long chain fatty acids of the oil in to mono alkyl ester is called trans-esterification, which forms the basis for the production of Bio-diesel. Many technologies are currently available and used in the industrial production of Bio-diesel. Fatty acids available in the oil reacts with Methanol in presence of a catalyst acid or base to yield Glycerine and Methyl esters.

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BASIC BASIC REACTION

CHEMICAL REACTION.
CH2OH Catalyst | CHOH | CH2OH NaOH/ KOH Glycerin R'COOR + R''COOR + R'''COOR
R, R and R indicates the fatty acids chain associated with oils.

CH2COOR | 3 ROH CHCOOR | CH2COOR Oil Alcohol

BIODIESEL

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PROCESS VARIABLES IN TRANS-ESTERIFICATION. Conditioning of vegetable oils  Oil temperature.  Reaction temperature.  Ratio to alcohal to oil  Types of catalyst and concentration  Intensity of mixing  Purity of reactants.  Glycerin neutralization.  Methyl ester wash.  Removal of water.

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BIO-DIESEL in IR
Some trains & Road vehicle are already run on blended Bio-diesel in IR. Supported of Bio-diesel.

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Jatropha Plantation in LW/PER

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Jatropha plantation at Diesel Loco shed Tondiarpet.

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Jatropha plantation on track side Bodinayakkanur. S.Rly

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Jatropha plantation at Bangalore Railway premises

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BioBio-diesel production
Loco works, S.Rly, Perambur, Chennai took the lead for Indian Railways in succeeding to produce biodiesel as under
In a 150 litre capacity pilot plant with in house

technology and efforts and Presently in a production plant of 300 litres capacity

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Work done in diesel shed shakurbasti

Plant has been tested successfully and can produce 200 lt of bio-desel from the waste vegetable oil obtained free of coast from star hotel

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BIO-DIESEL PLANT SET UP AT IRIMEE.

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Fuel Properties
The fuel properties of raw karanja, bio-diesel obtained from karanja oil and their blends with varying proportion from 20% to 80% by volume (B20, B40, B60, B80) were determined as per the test code prescribed by the various ASTM standards.  The measured properties are presented in table . The kinematic viscosity of karanja oil was found to be 10.7 times more than that of diesel when determined at 40rC. After esterification, the kinematic viscosity reduced to 2.1 times only. It further reduced with increase in diesel amount in the blend. Similar reduction in specific gravity was also observed.
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Fuel Properties
The calorific value of karanja was found to be 36.12 MJ/kg and is less than the calorific value of diesel (42.2 MJ/kg) but greater than that of pure oil. As the percentage of bio-diesel in the blends increased, the calorific value decreased.  Flash point of karanja and its bio-diesel were found to be greater than 100r C which is safe for storage and handling.

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FUEL PROPERTIES OF KARANJA OIL, ITS BIO-DIESEL AND BLENDS WITH DIESEL
Fuel properties Karanja oil 0.912 27.84 34.0 205 6 0.5 1.5 2.10 Karanja bio-diesel B100 0.876 9.6 36.12 187 4 0.05 0.2 0.45 B80 B60 B40 B20 Diesel Bio-diesel standards ASTM 1.9-6.0 Sp. Gravity Kinematic viscosity, cst Calorific value MJ/kg Flash point rC Pour point rC Water content % Carbon residue % Acid value 0.869 6.56 36.47 92 2.5 Traces 0.864 5.42 37.25 84 1.1 0.856 4.63 37.85 81 0.5 0.848 3.39 38.28 79 0 0.842 2.601 42.21 52 -4 <0.03 Traces <0.8 >130

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Problem Areas

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

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Problem Areas

PROBLEM AREAS

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

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Engine Performance
The bio-diesel (B100) and its blends (B20, B40, B60 & B80) were used to test in a single cylinder, 4-stroke, DI, water cooled diesel engine having a rated output of 7.5 KW at 3000 rpm with a compression ratio of 16:1. The engine was coupled to an electric dynamometer to apply different loads. Engine tests were done according to BIS:5994_II. After the engine reached the stabilized working condition, various parameters such as speed of operation, fuel consumption and torque were measured at different engine loads (10, 25, 50, 75% of the load corresponding to load at maxm power) at an average engine speed of 2000 rpm from which brake power, Brake specific fuel consumption and brake thermal efficiency were computed.
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Torque and Brake Power

The variation of Torque and brake power output of the engine with load for different fuels are presented. Both torque and brake power increased with increase in load.  This was due to increase in fuel consumption with increase in load. The torque and brake power produced in case of B20 and B40 were higher than that of diesel due to complete combustion of fuels due to presence extra oxygen in bio-diesel as compared to diesel due to decrease in calorific value of fuel with increase in biodiesel percentage in blends.


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TORQUE AND BRAKE POWER.

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Brake Specific Fuel Consumption

The variation of brake fuel consumption with load for different fuels is presented in Fig. For all the fuels tested, brake specific fuel consumption decreased with increase in load. The explanation for this reduction is due to higher percentage of increase in brake power with load as compared to fuel consumption. For an average speed of 2000 rpm, the brake specific fuel consumption for B20 & B40 was lower than diesel. This reverse trend was observed due to lower calorific value with increase in bio-diesel percentage in the blends.
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Brake Specific Fuel Consumption

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Brake Specific Fuel Consumption

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Brake Thermal Efficiency

The variation of brake thermal efficiency with load for different fuels is shown in Fig. In all cases it increased with increase in percent load. This was due to increase of power with increase in load. The maxm brake thermal efficiency was obtained to be 20.8 and 19.8 for B20 and B40 respectively which were higher than that of diesel. The maxm brake thermal efficiency obtained for B60, B80 & B100 were 18.2, 17.6 & 16.9%. This lower brake thermal efficiency obtained for B60 to B100 is due to reduction in calorific value and increase in fuel consumption as compared to B20.
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Exhaust Temperature
The variation of exhaust temperature with load for different fuels tested is compared with diesel in Fig. 6. For B20 to B100, the exhaust temperature was varied between 260 and 336 as compared to 262 and 335rC for diesel indicating not much variation in exhaust temperature.  This could be due to nearly same quantity of fuel being consumed per hour for both diesel and bio-diesel blends in each load setting of the engine.

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BIO-DIESEL INITIATIVES BIO-DIESEL INITIATIVES

Residents of Kagganahalli village near Bangalore in Karnataka get regular power & water supplied by generators run on biodiesel. 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. 29 June 2011 58

BIO-DIESEL INITIATIVES 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. 29 June 2011 59

BIO-DIESEL INITIATIVES 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.
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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.
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IRs Initiative
  

IRS 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. Set up IROAF, to promote RE.
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IRs Initiative
    

IRS INITIATIVE

First train was run succeesfully on Dec30,2002 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 IRIMEE also has set up a pilot plant for the trainees of IR officers & supervisors. Three road vehicles are regularly being run on biodiesel.

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WHY for IR ?
 Indian Railways operate around 4000 Diesel Locomotives.  Approx two billion litres of diesel fuel are consumed annually. The annual expenditure on diesel fuel is approx Rs. 4400 crores.

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Anticipated Savings of HSD after blending with Bio diesel

Annual consumption of HSD in million liters 2000

Savings in HSD (in million liters) as a result of blending bio diesel 5% 100 10% 200 20% 400

Thus if B20 blend is used by IR, then 400 million liters of diesel shall be saved.

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Indian Railways runs Shatabdi on biodiesel blend

Shatabdi run from Delhi to Amritsar on 31st December 2002. Fuel used 5% blend of bio diesel Parameters monitoredFilters SFC Fuel Injection Equipment

Results No loss of hp, acceleration or any other problem observed during run. No unusual deposits observed on fuel filters.
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Tata Sumo running on 100% Bio Diesel from May 2004

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MAHINDRA VOYAGER RUNNING ON 20% BIO DIESEL FROM MAY 2004

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JATROPHA PLANT

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FRONT END LOADER WORKING WITH B-20

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DEMU RUNNING ON 5% BLEND BIO DIESEL FROM MARCH 2005

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BG Locomotive on 5% blend

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DEMU RUNNING ON 5% BLEND BIO DIESEL FROM MARCH 2005

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Meter gauge Locomotive running on 5% blend Bio Diesel from July 2004

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PERFORMANCE EVALUATION BASED ON BIO-DIESEL

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Technical Tasks Ahead

Detailed study including sensitivity analysis. Optimization of combustion process and minimization of NOx emissions. Sustained field trials to ascertain the long term impact of the fuel on: Fuel injection system Filters Deposits on pistons, valves, cylinder head
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Condition of Engine components

All fuel injection equipment, engine power pack components were stripped & to our excitement found that all these components were in normal condition. None of the components has shown abnormal wear & tear. No abnormal soot was observed in the fuel injectors.
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Experience of GOC Diesel shed

Regular HSD oil B5 Bio-diesel oil

Horse power (hp) SFC (gms / bhp-hr)

1294

1325

171

170.72

Exhaust gas temp in F

1100

1080

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Condition of filters
The Bio-Diesel Locos never had fuel oil filter blockage or fuel oil pressure dropping. Bio-diesel Locos had not experienced fuel starvation problems even once.

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Experience of GOC Diesel shed

Reduction in Lube oil consumption after use of Bio-diesel
1.2 1 0.8 0.52 0.6 0.4 0.2 0 Lube to Fuel percentage Lube to 100 EKM 0.42 Before the use of Bio-Diesel oil After use of Bio-Diesel oil 1.17 0.98

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Emission Results
Testing at RDSO April 2004
Emission results obtained are as follows:

Bio Diesel Blends with Regular Regular Diesel

Diesel 1422 13 12.2 0.01 6.2

B10 1266 12 12.3 0.01 5.9

B20 1480 9 12.2 0.01 5.8

B50 1553 11 12.1 0.01 6.0

B100 1491 6 12.2 0.00 6.1

NOx at 8th notch (in ppm) Hydro carbons (HC Hexane) in ppm Residual oxygen (% Vol) CO (% Vol) CO2 (% Vol)

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Conclusions of GOC experience

The study conducted with B5 blend Bio-diesel at GOC shed reveals that:
Bio-diesel can be easily adopted for Diesel Locos with out any modification. Bio-diesel is capable of developing full horsepower on the ALCO/DLW engines. The exhaust gas temperature showed decreasing trend. The lubricity property of the bio-diesel oil reduces wear and tear of the engine components and enhances the life of fuel injection equipments. Use of Bio-diesel oil reduces lube oil consumption considerably. Hence, it is clear that Bio-diesel oil has got tremendous potential as alternate fuel for Diesel Locos. The experience of June 2011 very 29 Golden rock Diesel Loco shed with the Bio-diesel is 84 much encouraging.

Mileage with Bio-diesel

Vehicle Mileage (KMs/litre) Bio-diesel Jeep (B20) Tata Sumo (B100)
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Diesel 5.9 10.1

5.9 10.1

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Performance of Bio-diesel
YDM4 Locos 6225 / 6275
SFC during load box test with Bio-diesel 170.72 gms per BHP.Hr. SFC during load box test for conventional HSD 171.00 gms per BHP.Hr. SFC of 1000 GTKM with Bio-diesel (June 2005 Fig.) 5.57 ltr / 1000 GTKM SFC of 1000 GTKM with Conventional oil 5.57 ltr / 1000 GTKM

1 WDM2 loco No.16867 is running on 10% Biodiesel from 7.7.2006 and is used as a shunting loco. The performance is 29 June 2011 86 satisfactory.

Performance of Bio-diesel
Loco WDM2 11008 was in use during 200506 with 5% Bio-diesel in TNP DSL. Shed. No abnormalities noticed either in Fuel Injection Equipment or in Primary, Secondary filters. There was no case of premature change of filters. Carbon deposits seems to be less. Consumption of fuel could not be assessed since the Loco was used for both shunting & passenger trains. 10% blending of Bio-diesel was effected from April 2006 & performance is being monitored.
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Performance of Bio-diesel
4 DPCs Nos.14011 & 14012 (700 hp) and 14030 & 14031 (1400 hp) were working on 5% Bio-diesel for more than 1 year & from 30.9.2006 are working on 10% in TPJ division. Engine service performance at all notches was found Normal. No adverse effect or maintenance problem was reported so far. Lube oil collected from the DPCs were sent to M/s CIL, Pune on number of occasions, but no report received so far. It is understood that the results will be advised only in case of any adverse remark. Engine check was conducted by Cummins Diesel on 31.12.2005 for DPC 14030 & 14031 & nothing was found

abnormal.
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IRs Initiative


IRS 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.

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Field Trial Summary

ate 14/05/04 14/05/04 15/05/04 15/05/04 Train O. 2054 2053 2054 2053 2054 17/05/04 22/05/04 2053 2053 eparture O-0600 -1520 O-0600 -1520 O-0600 -1520 -1520

FIELD TRIAL SUMMARY

rrival -1020 O-1930 -1020 O-1930 -1020 O-1930 O-1930 Type o Fuel 10 10 10 10 10 10 bio bio IO IO IO IO S in itre 750 770 700 700 700 700 700

ormal S

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FollowFollow-Up Field Trials

Field Trial done on LucknowAllahabad Jan Shatabdi (2054/2053). 3 round trips of the train made using B10 blend. Field trial successful in terms of haulage and other performance characteristics.

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Condition of Engine components

All fuel injection equipment, engine power pack components were stripped & to our excitement found that all these components were in normal condition. None of the components has shown abnormal wear & tear. No abnormal soot was observed in the fuel injectors.
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Problems to be resolved
 Optimization of trans-esterification process to enable the bio-diesel out put to meet the BIS, ASTM and EN standards  Effective disposal of by-products, viz. Crude Glycerin etc. so as to minimize the production cost.  Procurement of suitable raw oil at reasonable rate  Obtain explosive license for storage of methanol  Setting up of an effective effluent treatment plant  R&D efforts for better catalyst to improve the yield of biodiesel.

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CONCLUSIONS CONCLUSIONS


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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 amounts to saving nearly 400 million litres of bio-diesel consumption on railways.

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Conclusions
Based on the results of this study, the following specific conclusions were drawn: After esterification, the kinematic viscosity & specific gravity of karanja oil were reduced to 9.6m2/sec and 0.876 from 27.84m2/sec and 0.912 respectively. The calorific value of esterified karanja oil is 36.12 MJ/kg which is 5.86% higher than unprocessed karanja oil but 14.42% lower than diesel.
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Conclusions
While running the engine with esterified karanja oil and its blends emissions such as CO, smoke density and NOx were reduced on an average by 86, 50 and +/2 to 6% as compared to diesel.

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Conclusions
Bio-diesel blends B20 B40 produced an average 6% more torque and brake power than diesel due to complete combustion of fuel. However, a reduction in brake power output and torque was observed with increase in bio-diesel percentage in the blends due to reduction in the calorific value of the fuel.

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Conclusions
For all fuels tested, the brake thermal efficiency increased with increase in load. Maxm brake thermal efficiency in case of bio-diesel was found to be 26.79% for B20 as compared to 24.62% in case of diesel and it decreased with increase in bio-diesel percentage in the blend.

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CONCLUSIONS

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 biodiesel so that it remains price competitive.

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CONCLUSIONS 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.

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IN CONCLUSION
BioBio-diesel has potential to become the fuel of the future & it will not only provide employment opportunities in rural areas but also energy security, Cleaner air & savings in foreign exchange. exchange.

IN SHORT WE WILL BE MOVING FROM

BLACK GOLD

GREEN GOLD

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Open questions Open questions

1. Technicals: is biofuel use for railways feasible? Which blend? What obstacles? When? is the price right? What measures are needed?

2. Economy:

3. Sustainability: How can we be sure that we are helping the planet and not ruining it instead?

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