Small Biogas Engine conversion kit

Rural Application
(No Petrol, No Diesel )

By Dr.G.P.Govil Director SIYA INSTRUMENTS

gpgovil@gmail.com siya1234@gmail.com, Mobile: 9811345179

CONTENTS
Introduction Conversion of Petrol Engine to gas engine Conversion of Diesel Engine to Dual fuel mode Conversion of Diesel Engine to 100 % Biogas (S.I.Mode) Conclusions

Technology Developed By
Indian Institute of Technology Delhi Under MGIRI Project (Prof.R.R.Gaur)
Mahatma Ghandhi Institute of Rural Industrialisation Wardha

with Dr. G.P.Govil

MOTIVATION
To provide power in each house from renewable source of energy in villages To provide drinking water in villages To create employment in rural areas To have sustainable growth To provide an affordable conversion kit to convert diesel engine to gaseous engine on site

Concept for Domestic Power Supply in Rural Area

Balloon Biogas Digester Biogas Storage Balloon

INVERTER

Biogas Generator

Power Need Village Household requirements Dairy requirement Village cluster requirements 1-10 KW 20-50 KW >100 KW

CONVERSION OF PETROL ENGINE TO GASEOUS FUEL ENGINE

Conversion of Petrol Engine to Gaseous Engine

Gas Air Mixing Compression Ratio LPG, Natural Gas, Biogas, Producer gas CR=10-12 Petrol CR=7.7-9.5 More Wear & Tear because of less lubrication Conversion Leads to DERATING of engine

Reasons for Engine Derating

Lower calorific value of Biogas Lower volumetric efficiency Higher spark advance due to lower burning rate of Biogas

Conversion of Diesel Engine to Gaseous fuel Engine

Modification of Engine-Dual fuel Mode Using Diesel

Gas Carburettor Arrangements for supply of Diesel

Dual fuel operation (Gas+ Diesel) Ignition by pilot fuel injection (Diesel)

DIESEL DIESEL INJECTOR VENTURI

BIO GAS DIGESTER

AIR FILTER ENGINE FUEL PUMP GOVERNOR GAS CONTROL VALVE

FUEL FILTER MANUAL GAS CONTROL VALVE

Schematic Diagram for Conversion to Dual Fuel Mode using Diesel and Biogas

Problems associated with DualFuel Engine

Dual Fuel needs Diesel The Fuel Injector gets over heated when Diesel flow is reduce to 10 to 15 % It is more severe with purified Bio-gas (Methane 95 %) Check for injector nozzle.

Conversion of Diesel engine to 100% Biogas Engine (S.I.Mode)

Biogas Engine Kit

The kit consists of

Gas carburetor for air gas mixing, Ignition Mechanism for generating spark Governing Mechanism

Biogas Engine with conversion kit

Modifications of the Engine

Removal of fuel injection pump, fuel lines and injector, Modification in cylinder head for installation of spark plug in the injector hole, Mounting of an ignition system Installation of Gas carburetor,

BIO GAS DIGESTER Spark Plug

VENTURI

AIR FILTER

Ignition

ENGINE

Mechanism

(Battery ignition / Magneto ignition)

GOVERNOR

SPEED CONTROLLED BY GOVERNOR IN CASE OF OVERSPEED

MANUAL GAS CONTROL VALVE

Schematic Diagram for Conversion to Biogas Engine

Gas Valve & Air Gas Mixing

Modified Cylinder Head & Spark Plug

Ignition System
Battery Ignition System Magneto Ignition System

Battery Ignition System

Battery Ignition System Contact Point Cam Spark Plug

Conversion Kit for Battery Ignition System

Converted Gaseous Engine with Battery Ignition System

Magneto Ignition System

Magneto Ignition System Spark Plug

Engine kit with Magneto Ignition system

Magneto Mounted on Engine

Diesel Engine Converted To 100% Biogas Engine

Flexible Modes of engine operation

100% Biogas Dual Fuel Mode Diesel Mode

Technical Details
Gas Consumption
25kg of dung is required to generate 1 m3 of the gas The consumption of the gas is 0.8 -1.0 m3 / kWhr .

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

Performance of the Engine

Power v/s Efficiency
25

Power v/s Exhaust Temp

700

20

600
Exhaust Temp (deg C)

1 5

500

400

1 0

300

200

5
100

0 0 1 2 Power (kW) 3 Diesel Biogas 4

0 0 1 2 Power (kW) 3 4 Diesel Biogas 5

Figure-1 : comparison of power V/s efficiency in Diesel mode and 100% Biogas mode.

Figure - 2: Power v/s Exhaust Temperature Diesel mode and 100% Biogas mode.

Economics of Conversion Kit

Use of Kit in a 5 hp Diesel Engine Consumption of Diesel =1.0 lts./hr. Use of Diesel Engine =5 hr. Total Diesel consumed =5.0 lts. Cost of Diesel =Rs.35 (approx.) = Expenditure = =Rs.200/= per day Cost of Conversion Kit. Rs.20,000/= Payback period 6 Months. (approx)

Places where Engine has been installed

JEON Tech. Company Sulabh International, Palam Gaon Rajasthan Gosewa sangh CIAE G.B. Pant. Agriculture University Punjab Agricultural Univ. MERADO TNAU IIT MGIRI MPUAT KOREA New Delhi. Jaipur Bhopal Pantnagar Ludhiana Ludhiana Coimbtore New Delhi Wardha Udaipur

Biogas Generator at IDEAL Institute of Technology Ghaziabad

Biogas Engine at Sulabh International

( 7.5kW Air cooled, Double Cylinder, 3 Phase)

Biogas Engine at CIAE Bhopal (4.4 kW, water cooled)

Biogas Engine Exported To Jeon Tech. Co. Ltd Korea

Biogas Generator at MERADO Ludhiana

Contact Person
Dr. G.P.Govil 09811345179 Mr. Vimal Jagatiya 09414156154
SIYA INSTRUMENT S-17 Road No.2, Mewar Industrial Area Udaipur, Rajasthan- 313002 Email-Id : siya1234@gmail.com

Other Products

Biogas Purification

Biogas Analyzer Flow Meter Biogas Balloon

Conclusions
100% Biogas engine can be supplied from 1.25 kVA to 10 kVA An engine can be converted from3 kW to 20 kW on site. There is no need to take it to workshop. Diesel engine whether Single or Double cylinder, Air cooled or Water cooled can be converted on site.

THANK YOU