Experiences of conversion of Diesel Engine To 100% Biogas Engine

Transcription

POWER GENERATION BY BIOGAS
Kit to convert Diesel/ Petrol engine to Gaseous
Fuel engine
Prof. (Dr.) G.P. Govil
Director
Northern India Engineering College
New Delhi
E-mail: [email protected]
M: 9811345179
CONTENTS

Introduction
Conversion of Diesel Engine to 100 % Gaseous
Fuel CNG/Biogas/Producer Gas (S.I Mode)
Conversion of Diesel Engine to Dual Fuel
engine CNG/Biogas/Producer Gas
Conversion of Petrol Engine to 100% Biogas
engine
Conclusions
Modes to Convert Diesel Engine into
Gaseous fuel Engine

Operation on gas alone with spark ignition

Dual fuel operation with ignition by pilot fuel
injection.
Conversion of Diesel engine
to
Spark Ignition Mode
Concept for Domestic Power
Supply in Rural Area
Balloon Biogas Digester
Biogas Storage Balloon
INVERTER
Biogas Generator
Govil Energy Solutions
Requirement of conversion

Petrol Engine conversion
Gas carburetor
Governing Mechanism
Diesel Engine Conversion
Ignition Mechanism/ignition advance
Gas carburetor
Governing Mechanism
Conversion of Diesel Engine to Gaseous
Engine

Gas –Air Mixing
Compression Ratio
LPG, Natural Gas
CR=11
Alcohol (jet enlarged)
CR=12
Petrol
CR=7.7-9.5
Biogas
CR =10-12
Ignition Advance
More Wear & Tear because of less lubrication
Air Filter
BIO – GAS
DIGESTER
Air Gas Mixture
Spark Plug
Butterfly
Venturi
Exhaust
ENGINE
Electronic
ignition
Mechanis
m on cam
shaft
Distributor
Governor
Control
Unit
Flywheel
Speed Pick
up sensor
Diaphragm
operated Biogas
Valve
Biogas
MANUAL GAS CONTROL VALVE
Fig.1 : Schematic Diagram for Conversion of Diesel engine to 100% Biogas
Engine
Modifications of the Engine

Removal of fuel injection pump, fuel lines
and injector,
Reduction of compression ratio,
Modification in cylinder head for
installation of spark plug in the injector
hole,
Mounting of an ignition system with
contact breaker assembly, ignition coil,
spark plug,
Installation of Gas carburetor
Installation of Governing Mechanism
Reduction of Compression Ratio

Exchanging the piston for one that effects a
lower compression ratio,
Machining off material from the piston top,
Machining off material from the combustion
chamber in the cylinder head,
Exchanging the standard cylinder head for a
special low compression head,
Using a thicker cylinder gasket, and
Using shims below the cylinder block.
Flow Diagram
Existing Diesel Engine
Disassemble engine, Remove piston, Remove fuel Pump, Remove Injector
Change compression Ratio
Enlarge injector hole dia to adapt spark plug
Install the ignition mechanism on cam shaft/
Crank shaft .
Install gas carburetor.
Advance the ignition mechanism
Diesel engine converted to 100% Biogas
Engine/Producer gas
Modified &Original Piston
Disassembled Diesel Engine
Tapping the injector hole for spark plug
Tapped Cylinder Head & Spark Plug
Cylinder Head
GAS CARBURETTOR/AIR-GAS
MIXING
Manual control
Gas Valve
Gas Carburettor
Diaphragm
control Gas Valve
Vacuum operated Biogas Diaphragm Valve
ELECTRONIC GOVERNING MECHANISM
ACTUATOR
GOVERNING
BUTTERFLY OF
CARBURETTOR
Actuator
ECU UNIT
Speed Sensor on Flywheel
Speed Sensor
SPARK IGNITION MECHANISM
Spark plug in
head of the engine
H.T COIL
Electronic Distributor
mounted on camshaft
Spark Plug
Distributor
H.T. Coil
GOVERNING MECHANISM
ELECTRONIC IGNITION
MECHANISM
Generator-12 KW at IIT-Delhi
Engine
3KVA (Single cylinder),7.5 KVA (Double cylinder)
CONVERSION OF PETROL
ENGINE
TO
GASEOUS FUEL ENGINE
Actuator Governing the Butterfly of Gas
Carburetor
Petrol engine converted to 100% BioGas Engine
BIO – GAS
DIGESTER
DIESEL
DIESEL
INJECTOR
VENTURI
AIR
FILTER
ENGINE
FUEL PUMP
GOVERNOR
GAS
CONTROL
VALVE
FUEL FILTER
MANUAL GAS CONTROL VALVE
Schematic Diagram for Conversion to Bio fuel Engine in
Dual Fuel Mode using Diesel and Biogas
Dual fuel Biogas Generator
MGIRI
3KVA Sulabh International
5KVA MNIT Jaipur
7.5 KVA VIJAY SOLAR
4 KVA AARVADK U.K
Flexible Modes of engine operation

100% Biogas
Dual Fuel Mode
Diesel Mode
Biogas Generator at IDEAL Institute of
Technology Ghaziabad
Diesel Engine Converted To gaseous
engine Installed In Scotland
5 Kw Dual Fuel generator at DRDO
complex New Delhi
Biogas Plant,Balloon,Compressor ,
Biogas Generator at Bhatinda
Power Generation at Gram
Panchyat Behal (Bhiwani)
Biogas Generator at Aardvark Em. Ltd.
U.K (4 KVA)
Generator-15KVA at IIT-Delhi
Two 7 KW Biogas generator installed in
Scotland
Power Generation at Sulabh
International Academy New Delhi
Two 7 KW Biogas generator installed in
Scotland
CONT…
Cont…
Power Generation at Mullahai Khera (Lucknow)
Power generation in Scotland U.K
Other Products…
Flow Meter
Biogas Analyzer
Biogas Balloon
Biogas Purification System (PSA)
Performance of the Engine
Power v/s Exhaust Temp
Power v/s Efficiency
700
25
600
Exhaust Temp (deg C)
20
A
15
10
500
B
400
300
200
5
100
0
0
0
1
2
Power (kW)
3
4
Diesel
Biogas
Figure1 : comparison of power V/s
efficiency in Diesel mode and 100%
Biogas mode.
0
1
2
Power (kW)
3
4
5
Diesel
Biogas
Figure - 2: Power v/s Exhaust Temperature Diesel
mode and 100% Biogas mode.
Technical Details

Gas Consumption
3
25kg of dung is required to generate 1 m of
the gas
3
The consumption of the gas is 0.8 -1.0 m /
KW-hr .

Power of the Engine
Diesel engines converted to Biogas engine
will get derated.
Power generated by the converted biogas
engine will be approximately 50%-55% in
comparison to original diesel engine
Conclusions

The conversion of the diesel engine to a
Biogas/producer gas operation to spark ignition
mode of operation is quite satisfactory
The developed gas carburetor’s performance is
quite satisfactory
Conversion of the engine is easy
Continued...

The engine suffered a power deration of
approximately 40-45%Biogas/ producer gas
mode of operation.
Brake Thermal Efficiencies of 18 to 22% on
Biogas/producer gas mode are satisfactory.
Power output is quite sensitive to the air to fuel
ratio during gas operation.
Continued...

Engine performance with respect to brake power
and brake thermal efficiency has been found to be
better for compression ratios 11.5:1.
The exhaust emissions of carbon monoxide and
hydrocarbons were less for the converted engine as
compared to conventional Diesel engines
The spark timing was found to be having significant
effect on both cylinder peak pressure and rate of
pressure rise
Continued...

Biogas/Producer Gas can be used effectively as
an alternative fuel in a thus achieving complete
independence from petroleum based fuels.
Places where Engines have been
installed

Aardvark EM. Ltd
JEON Tech. Company
Sulabh International, Palam Gaon
Rajasthan Gosewa sangh
CIAE
G.B. Pant. Agriculture University
Punjab Agricultural Univ.
MERADO
TNAU
IIT
MGIRI
MPUAT
MNIT
Vijay Solar industries
U.K
KOREA
New Delhi.
Jaipur
Bhopal
Pantnagar
Ludhiana
Ludhiana
Coimbtore
New Delhi
Wardha
Udaipur
Jaipur
Karnatka
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