Use of biodiesel as a Traction fuel for Indian Railways

– A Case Study

A.K.Kathpal
Government of India – Ministry of Railways

1st Workshop on Railways and Biofuel at UIC, Paris

 Introduction
Approx. two billion litres of diesel
fuel is consumed annually by nearly
4,000 freight and passenger
locomotives in the Indian Railway
fleet.

The annual expenditure of Indian

Railways on diesel fuel is approx.
US $1.3 Billion.

1st Workshop on Railways and Biofuel at UIC, Paris

 Diesel Loco fleet of IR
• Indian Railways operate around 4000
Diesel Locomotives.
LOCO HORSE POWER NO. OF LOCOS
4000 57
3300 12
3100 885
2600 2304
Below 2600 694

• Around 100-120 locos are added to the fleet

every year

1st Workshop on Railways and Biofuel at UIC, Paris

Policy Map

1st Workshop on Railways and Biofuel at UIC, Paris

Government of India policies for Bio-Diesel

Financial and fiscal incentives

Tax and duties structure
Subsidies
Knowledge banks
Financial assistance
Micro-credit
National Bio-fuels Development Board
Core groups on Technology development

1st Workshop on Railways and Ministry

Biofuel at
ofUIC,
Railways
Paris
R&D areas in focus by Govt. of India
Plantation methods
Generative Propagation
Vegetative Propagation
High yield plants of Genus Jatropha – 160 types
Heterogeneous transesterification – 2nd generation
conversion method
Quality Control
Engine Studies/ Optimisation
Engine Development Experiments
Field trial
New Raw Materials
Algae, Fungi etc.
Biomass

1st Workshop on Railways and Biofuel at UIC, Paris

Testing in RDSO, R&D Wing of IR
Preliminary testing of Bio diesel blend was first carried
out on the test bed at Engine Development Directorate
of RDSO in Nov. 2002.
The above was followed by detailed testing and
evaluation of biodiesel on the test bed in April 2004 .

16-Cyl. ALCO engine under test at RDSO

1st Workshop on Railways and Biofuel at UIC, Paris

Engine configuration on the Test Bed
Engine 16 cylinder ALCO DLW 251

Rating (kW) 2315

Engine Speed (RPM) 400-1050
Manifold Stream lined – 3 entry
Cam shaft 140 degree valve overlap
Fuel injection pump 17 mm plunger diameter, 157-
degree nozzle spray angle having
0.350 mm dia. holes.
Bore/ Stroke 228.60 mm/ 266.90 mm
Turbocharger Turbocharged, ABB, GE

1st Workshop on Railways and Biofuel at UIC, Paris

 Experimental setup
FEM A (For PT-100,
High Speed Thermocouple, mA input )
Data Display LOAD SPEED
FEM P (For Pressure)
Data Acquisition Terminal DISPLAY DISPLAY
FEM CNT (For Counter)
System FEM D (For Digital O/P)

Water
EMCON Control
Valve
WINDOWS NT Starting
Base Data Motor RPM
N L A
Acquisition DYNAMO
And Control ENGINE METER
Starting System
Manual, Actuator
Auto control LOAD CELL

Fuel Rack
Control (FVG)
On Line Fuel Dynamometer
Measuring Amplifier
System Valve Control
System

1st Workshop on Railways and Biofuel at UIC, Paris

Load & Speed combinations used

Notch RPM Load(N)

th
8 1050 21600
th
7 950 19082
th
6 850 16018
th
5 750 13826
th
4 650 10616
rd
3 550 8138
nd
2 450 5471
st
1 350 2984
Idle 350 2131

1st Workshop on Railways and Biofuel at UIC, Paris

Test results of Bio-diesel

1st Workshop on Railways RDSO, Lucknow,

and Biofuel INDIA
at UIC, Paris
 Engine Power
2360
2355
En gine Pow e r k W 2350
2345
2340
2335
2330
2325
2320
2315
2310
2305
B0 B10 B20 B50 B100
Biodiesel blends

• Maximum engine power with Bio-Diesel blends remains within 1% of

Petro-diesel.

1st Workshop on Railways and Biofuel at UIC, Paris

 Brake Specific Fuel Consumption (BSFC)

280
B0

260 B 10
b s f c ( g m /b h p - h r )

B 20
240
B 50

220 B 100

200

180

160

140
8th 7th 6th 5th 4th 3rd 2nd 1st Idle
Notch

• Bsfc highest with B100, followed by B50. Lowest bsfc with Petro-diesel.
• With B10 and B20 blends, negligible penalty in terms of volumetric fuel
consumption.

1st Workshop on Railways and Biofuel at UIC, Paris

 Thermal Efficiency
39.0
Thermal Efficiency 37.0
35.0
33.0
31.0
B0
29.0
B 10
27.0 B 20
25.0 B 50
B 100
23.0
8th 7th 6th 5th 4th 3rd 2nd 1st Idle
Notch

B0 blend gives the lowest thermal efficiency, thereby concluding

that biodiesel has improved combustion efficiency.

1st Workshop on Railways and Biofuel at UIC, Paris

 Exhaust Temperatures & Boost air pressure
520
1.84
515

510
1.82
Exhaust temperature °C

505 1.8

BAPbar
500
1.78
495

490
1.76
485 1.74
480
1.72
475
D100 B10 B20 B50 B100
470
D100 B10 B50 B100
Diesel Blend
Diesel Blend

• Exhaust gas temperatures show a downward trend with higher

percentage of biodiesel.
• Boost air pressure (Pressure at the exit of compressor) reduces due
to reduced energy content of the exhaust gases.

1st Workshop on Railways and Biofuel at UIC, Paris

 Fuel Injection pressure
4.5 K.Vis c o s ity (c S t) 1040
4 HP line pre s s ure 1020

Fuel Injection pressure

K.Viscosity (cSt) 3.5 1000
3
980
2.5
960
2
940
1.5
1 920

0.5 900
0 880
B0 B10 B20 B50 B100
Biodiesel blends

• Good correlation between kinematic viscosity and fuel injection

pressures.
• Higher injection pressures suitable for improved fuel atomization.

1st Workshop on Railways and Biofuel at UIC, Paris

 NOx Emissions
2300 B0
2100 B10
B2 0
1900 B50
B10 0
1700
NOx

1500

1300
1100
900
700
500
8th 7th 6th 5th 4th 3rd 2nd 1st Idle
Notch

• NOx emissions increase upto 4th Notch and decrease thereafter.

• Lowest NOx emissions with B10 and highest with B50.

1st Workshop on Railways and Biofuel at UIC, Paris

 Gaseous HC Emissions
20.00
B10 0
18.00
B50
16.00 B20

14.00
G HC g m /h r

B10
B0
12.00
10.00
8.00
6.00
4.00
2.00
0.00
8th 7th 6th 5th 4th 3rd 2nd 1st Idle
Notch

• GHC show a generally downward trend from B0 to B100.

• GHC is lowest with B100 and highest with B0.
• Indicates improved combustion characteristics of biodiesel.

1st Workshop on Railways and Biofuel at UIC, Paris

 CO Emissions
1.80
B100
1.60 B50

1.40 B20
B10
C O g m /h r

1.20
B0
1.00
0.80
0.60
0.40
0.20
0.00
8th 7th 6th 5th 4th 3rd 2nd 1st Idle
Notch

• CO emissions are comparable and less than 0.2 gm/hr.

• For B100, CO emissions at 8th notch are significantly higher.

1st Workshop on Railways and Biofuel at UIC, Paris

p-θ & lN- θ diagram for B0

1st Workshop on Railways and Biofuel at UIC, Paris

p-θ & lN- θ diagram for B20

1st Workshop on Railways and Biofuel at UIC, Paris

p-θ & lN- θ diagram for B100

1st Workshop on Railways and Biofuel at UIC, Paris

 Combustion Analysis
• With Petro-diesel, the peak firing pressure is 130 bar,
with B20 and B100, the pressures are less than 110 bar.
• This is due to poor volatility of biodiesel.
• Combustion starts early with biodiesel blends, at 17° CA
BTDC as compared to 10° CA BTDC for Petrodiesel
suggesting lower ignition delay for biodiesel.
• For Petro-diesel, the Needle lift is less than 0.2 mm
whereas with the Biodiesel blends, it is more than 0.6
mm.
• Duration of fuel injection is more in the biodiesel blends
as compared to petro-diesel.
• Difference is due to lower calorific value and higher
viscosity of biodiesel.

1st Workshop on Railways and Biofuel at UIC, Paris

Shatabdi Express Trial
• Indian Railways tried a 5%
blend of bio diesel on ALCO
locomotive to haul their
prestigious Shatabdi express
on 31st Dec, 2002.
• Hauling Capacity: No adverse
effect was observed during
the run in terms of haulage
capacity etc.
• Filters: No unusual deposits
were noticed on the filter
surface.
• Fuel Injection System: The
fuel injection pumps and
injector nozzles were also
found in satisfactory
condition.

1st Workshop on Railways and Biofuel at UIC, Paris

 Field Trials - II
• Subsequently, in May 2004, the locomotive
hauling the
• Jan-Shatabadi Exp. from Lucknow to Allahabad has
been fuelled with B10 and performance monitored for
5 days.
• No adverse effect has been observed with B10
also in terms of
• haulage capacity,
• lube oil consumption,
• abnormal engine performance etc.
• No unusual deposits have been noticed in the
fuel filters in this trials also.
• Fuel injection pumps and injector nozzles
• found in satisfactory condition and
• free from any gum or resinous deposits.

1st Workshop on Railways and Biofuel at UIC, Paris

 Present Status
Indian Railways have signed an MOU with Indian Oil
Corporation to plant Jatropha saplings on land to be
provided by Indian Railways.
This pilot project is aimed at generating base-line scientific data
on growth of plants, seedlings, yield of the oil seeds, oil from
seeds etc.
All the Railways have grown Jatropha plants on their surplus
land.
Indian Railways have advertised seeking Expression of
Interest for Jatropha plantation in Railway land of about
43,000 Hectares.
Railway Board has issued instructions to all Zonal Railways
to set up their transesterification plants.
RDSO plans to set up state of the art hetrogenous catalyst
based transesterification plant to try out Bio-diesels
produced from different plants.

1st Workshop on Railways and Biofuel at UIC, Paris

 Present Status (Contd.)
Southern Railway has got their own transesterification
plant and are running two Diesel Multiple units on B5
blend.
Northern Railway has recently set up transesterification
plants at their Shakurbasti and Tughlakabad Diesel
sheds.
South Eastern and Northeast Frontier Railways are also
running trains with B10 diesel.
Northern Railways will start field trials with 3000 KL of
B-10 blend in their Alambagh Diesel shed based
locomotives.
Railway Board has advertised seeking Expression of
Interest for supply of 50,000 KL of Bio-Diesel to Indian
Railways.

1st Workshop on Railways and Biofuel at UIC, Paris

MoU with IOC - Salient features
Signed in February 2003 for a period of 15
years.
Railways has offered about 500 hectare land
to IOC for plantation of Jatropha curcas.
IOC will take up plantation, extraction,
transesterification.
81 hectares have already been planted and
normal yield expected from 2008.
IR will use bio diesel supplied by IOC.
Starting with 1-5% bio diesel, Indian Railways
will go upto 20 % depending on field
experience.

1st Workshop on Railways and Biofuel at UIC, Paris

 Future Plan of RDSO
Well to wheel project for biodiesel at RDSO.
Setting up of pilot biodiesel plant with
heterogeneous catalyst technology.
Transesterification with multiple stocks.
Engine studies and optimisation with multi-stock
biodiesel, Jatropha, Karanja, etc.
Finalise the specifications for Biodiesel plants in
Zonal Railways.
Development of Industry for production of
biodiesel.
Monitoring of B10/B20 blended biodiesel on
whole fleet of diesel locomotives.

1st Workshop on Railways and Biofuel at UIC, Paris

Multiple feed stocks planned by RDSO

Non-edible oils
Jatropha Curcas, Pongamia Pinata,
Shorea Robusta, Mahua, Neem,
Rubber, Tree Seed etc.
Waste vegetable oils
Lard/ Other waste animal fats
Surplus edible oils
Biomass to Liquid - BTL

1st Workshop on Railways and Biofuel at UIC, Paris

Future Engine Studies on RDSO Test bed

Modify fuel injection timings.

Increasing compression ratio.
Increase / decrease fuel injection pressure
and injection rate.
Optimisation of Intake manifold air
temperature.
Improve turbocharger match and air boost.
Improve and optimise individual notch and
duty-cycle operations.
Toxicological Studies.

1st Workshop on Railways and Biofuel at UIC, Paris

 Quality Assurance
Standards
Problems IS 15607:2005
Long term stability ASTM D 6751
Compatibility with
EN 14214
natural rubber, plastics
Purity is process Test Laboratories
dependent IOC(R&D)
Pour point is high RDSO
Special equipments for IIP
certain parameters
IICT
Private Sector

1st Workshop on Railways and Biofuel at UIC, Paris

 Savings of HSD with use of Biodiesel

Annual consumption Savings in HSD (in million litres)

of HSD by blending Bio-diesel
(in million litres) 5% 10% 20%

2000 100 200 400

Thus if B10 blend is used by IR, then 200 million
litres of diesel shall be saved annually.

1st Workshop on Railways and Biofuel at UIC, Paris

 Land requirement
For 200 million litres/year requirement
Per Hectare Oil yield Conversion Biodiesel Biodiesel Total
tonnage in % efficiency production production in Hectarge
in tons Litres/Hectare required

5 30 90 1.4 1588.2 125,926

10 33 95 3.1 3688.2 54,226
12 40 97 4.7 5477.6 36,512

• Land availability with Indian Railways – 44,000 ha

• Ministry of Rural development plans for 11Million
ha of wastelands
• Land availability through Intercropping

1st Workshop on Railways and Biofuel at UIC, Paris

 Contract Management
Public Private Partnership
Vendor selection procedures
ISO TS 16949
Juran’s 16-step vendor development
procedure, etc.
Market friendly contract conditions
Reduction of delay points
In synchronisation with International
practices

1st Workshop on Railways and Biofuel at UIC, Paris

 Conclusion

• Initial engine test bed and field trials

have shown promising results in use of
biodiesel as alternative fuel for Diesel
traction on Indian Railways.
• Optimisation of the engine parameters
are required for widespread use of
Biodiesel on diesel locomotives.

1st Workshop on Railways and Biofuel at UIC, Paris

Eco-Friendly Locomotives of IR

Not only travelling along greener pastures

but using Bio-fuels as well

1st Workshop on Railways and Biofuel at UIC, Paris

Thank You

1st Workshop on Railways and Biofuel at UIC, Paris