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Conversion of Diesel/S.I. Engines to Operate on Biogas
Dr. Ram Chandra
Assistant Professor
Centre for Rural Development and Technology
Indian Institute of Technology Delhi
Hauz Khas, New Delhi – 110 016
I.C. Engines
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
Fig.1 : Schematic Diagram for Conversion of Diesel engine to 100% Biogas Engine
Spark Plug
Air Filter
MANUAL GAS CONTROL VALVE
BIO – GASDIGESTER
Electronic ignition Mechanism on cam shaft
ENGINE
Governor Control Unit
VenturiButterfly
Diaphragm operated Biogas Valve
Biogas
Speed Pick up sensor
Flywheel
Exhaust
Air Gas Mixture
Distributor
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
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
Actuator ECU UNIT Speed Sensor on Flywheel Speed Sensor
Electronic Governing Mechanism
ACTUATOR
GOVERNING
BUTTERFLY OF
CARBURETTOR
Spark Plug Distributor
H.T. Coil
Spark Ignition Mechanism
Spark plug in head
of the engine
Electronic Distributor
mounted on camshaft
H.T COIL
Vacuum operated Biogas Diaphragm Valve
Gas Carburetor/Air-gas Mixing
Diaphragm control
Gas Valve
Manual control
Gas Valve
Gas Carburettor
Diesel Engine Converted to 100% Biogas Generator-12 KW at IIT Delhi
Diesel Engine Converted to 100% Biogas Engine 3KVA (Single cylinder),7.5 KVA (Double cylinder)
Schematic Diagram for Conversion to Bio fuel Engine in Dual Fuel Mode using
Diesel and Biogas
VENTURIDIESEL
INJECTOR
DIESEL
FUEL FILTER
AIR
FILTER
MANUAL GAS CONTROL VALVE
BIO – GAS
DIGESTER
GOVERNOR
FUEL PUMP
ENGINE
GAS
CONTROL
VALVE
Dual Fuel Biogas Generator
Petrol Engine Converted to 100% Bio-Gas Engine
16
5.9 kW Diesel Engine Converted to Gas Engine
Brake Power
Engine Speed
Specific gas consumption rate
Brake thermal efficiency
Relative air/fuel ratio of combustion
22
Engine parameter at 12.65 CR Ignition advance (0TDC)
30 35 40
Brake power output (kW) 3.548 (CNG)
3.500 (enriched biogas)
2.581 (biogas)
3.914 (CNG)
3.800 (enriched biogas)
2.661 (biogas)
3.763 (CNG)
3.650 (enriched biogas)
2.661 (biogas)
Engine speed (rpm) 1409–1544 (CNG); 1402–1537 (enriched biogas), 1228–1437 (biogas)
Specific gas consumption (g/kWh) 465–1550 (CNG)
471-1667 (enriched biogas)
651–3524 (biogas)
409–1240 (CNG)
421-1304 (enriched biogas)
625–3550 (biogas)
535–1240 (CNG)
548-1391 (enriched biogas)
626–3674 (biogas)
Maximum brake thermal efficiency, % 18.8 (CNG)
21.8 (enriched biogas)
22.5 (biogas)
22.2 (CNG)
26.2 (enriched biogas)
23.3 (biogas)
19.4 (CNG)
20.9 (enriched biogas)
23.3 (biogas)
Range of relative air/fuel ratio of combustion 1.1–1.5 (CNG)
1.0-1.9 (enriched biogas)
0.5–0.7 (biogas)
0.6–1.1 (CNG)
0.4-1.1 (enriched biogas)
0.5–0.8 (biogas)
0.6–1.8 (CNG)
0.8-1.5 (enriched biogas)
0.5–0.9 (biogas)
Maximum load development, % 59.7 (CNG)
59.2 (enriched biogas)
53.4 (biogas)
68.2 (CNG)
66.6 (enriched biogas)
53.5 (biogas)
67.9 (CNG)
66.2 (enriched biogas)
51.9 (biogas)
Performance results: stationary engine
Chandra et al., 2011. Applied Energy, 88;3969–3977.
Thank You