Experience in Use of By-Products in India

with Focus on Rural Electrification

Jai Uppal, Sr. consultant Sr. Advisor, Center for Alternate Energy Research

Gen Secretary - SVSjaiuppal @ yahoo.com

(M) +919811171121

International Consultation on Pro-Poor Jatropha Development

IFAD, Rome, April 2008

Agenda

• List of Major By products and Byproducts of Jatropha

• Fruit Shell, Seed hull, • De-oiled Cake & Detoxification• Use of Bio-oils and Biodiesel for

Rural Electrification• Glycerine

Major Byproducts

• Pruning and Training Biomass – leaves and branches

• Fruit Shell from decortication• Hull and kernel• Cake • Bio-oils/SVO/PPO• Biodiesel• Glycerine/Glycerol

Applications Biomass Branches, leaves, fruit shell & de-oiled cake :• Briqueting for direct combustion – Cake –

3000KCal/Kg. Selling at Euro 55/T• Biomass gasifier – being experiment with• Use heat as a fuel for industrial and commercial

heating, Power generation and• Biomethane from leaves – 80 to 100 M3/T• Biomethane from fruit shell – no Indian data

available• Bio-methanation of cake(VS –80%) – 250 to 450

M3/T = 0.25 to 0.45 T of coal equivalent• Medicines, pesticides, chemicals and latex from

the oil, branches, leaves etc ?

Detoxification of Seed Cake

• Toxicants/Anti-nutritional factors in cake:• Phytates, Saponins,trypsin inhibitor,

curcin• lectin• Phorbolesters, alkaloids,cyanogens• Treatment: - • Treatment with Sodium

hydroxide/Calcium hydroxide reduces phorbolester content by 86%/90%

• Heat Treatment reduces lectin content• Soaking cum boiling and alkali treatment

– reduced Saponin content by 85%

Detoxification of Seed Cake

• Trypsin inhibitor by 83 to 90%• Phytate by 20 to 28%• Tanins by 45 to 60% • However, these methods have not

made cake non toxic• Far away as detailed testing, field

trials and approvals a long time away.

Glycerine

• Grades - Crude, Commercial, Pharma grades)

• Traditional (low volume, high value product) uses in : Pharmaceuticals, Food & beverages, Cosmetics, Toiletry, dynamites, Lubricants, resins,Tobacco, Paper etc 1500 listed

• If prices fall to below $ 500/T (High volume,Low value Products) Platform for Fuel, Plastics, large number of Petrochemicals, Antifreeze, Oxygenates

Indian R&D – BD/SVO Use in Engines

• Testing Engines all over the country by educational and other institutions in use of SVO & Biodiesel in stationary and transport engine

• One study comprehensive single cylinder 7.5 KW Engine (1500 rpm constant speed) using varying blends of Jatropha Oil (JO)and Karanj from 5% to 100% - temperature of Oil raised to about 90 Deg C based on Exhaust gas

• Endurance (32 cycles of 16 hrs), Performance and Emission

• For JO-100% injector cleaned 3 times in 512 hours of operation while 50% JO and Diesel not cleaned

Indian R&D• Carbon Deposits significantly higher • Density and viscosity of engine lube oil went up

significantly & had to be changed after about 400 hours but no problems faced by 50% JO – can be addressed by additives to stop oxidation and polymerization

• Viscosity of JO went down by more than one fifth if heated to 90 Deg C from ambient temperature

• Preheated JO gave lower emission as compared to unheated – lower smoke, CO, HC

• Thermal Efficiency of Diesel Engine was almost the same as PH JO while UH-JO was marginally less

• However, did not experiment with slow speed IDI engine & thid study has been Taken up by CAER,University of Petroleum & Energy Studies

Indian Experience in Use of Biofuels

Indian Experience in Biodiesel• Large scale plantation of Jatropha & Pongamia has taken

place may be 1 mill Ha despite government Demonstration Project being held up

• Almost every Tech. University has a pilot plant of Biodiesel

• BD & B5 specs approved by Bureau of Indian Standards • Nearly 1 million tonnes of Biodiesel capacity set up

but low utilization & awaits feedstock – Imported Palm oil costly !

• Field Trial of Biodiesel since 2003 in: – Busses – Mumbai, near Delhi, Hyderabad, Bangalore (on

SVOs), Pune, Gujarat etc – Trains – most prestigious trains on B5 & B10– Mercedes cars – Country wide tour– Stationary and transport Engine trials on various blends

of Biodiesel– Many R&D and educational Institute running vehicles &

engines on Biodiesel made at their lab scale plants

Macro Factors for using Biofuels• Enhances rural employment & rural

development, • Replaces fossil Hydrocarbons with RE,• Provides energy security & reduces vulnerability

to disruptions & unexpected price hikes,• Potential for use of unused lands & greening of

landmass• Improves Environment – Reduces pollution• Mitigates GHGs (potential CDM benefits )• Disadvantages of use of Biodiesel Vs SVO:

– Methanol Toxic & accessibility, transesterification very sophisticated reaction not suitable for remote villages, added cost, accessibility in Remote areas & transport costs, crude glycerin disposal

Indian Experience in Use of SVOand Rural Electrification

• Use of Pongamia Pinnata (Karanj) in SVO stationery Engines – small high speed engines of 10 KW and 3.75 KW engines for oil expellers, water pumping and gensets

• More than 40 installation in remote villages in Karnataka, Andhra Pradesh and Rajasthan

• E.g. Karnataka - 10 location covering 631 HH, 490 lighting points and 10 units for oil extraction 10.5 KW, 3.75 KW engines

• Engines without warrantee because Indian Manufacturer not confident.

Indian Experience in Rural Electrification

• Very little field experience with Jatropha Oil (JO)

• Now first success story - small field trial JO using IDI Engines Vs DI injection in IIT K

• IDI Engines slower and expected to be more suitable for SVOs

• Used in Africa for same applications• Advantage India – Trials undertaken to

develop maintenance protocol & good after sale servicing network of supplier

Background & Rationale for Selection of Chhattisgarh

• DPR made for electrification of 50 Villages – SVO/BD

• Chhattisgarh State selected because of history of growing Jatropha in Remote Tribal area for lighting, cooking (wood) & dynamic Pro Biofuels Policies

• Excellent Agro-climatic conditions for Jatropha• Small Jatropha plantations still exist in most

tribal villages and villagers know how to grow Jatropha – every HH uses as a fence !

• Villagers already aware that Jatropha is non-edible

• Many Remote Un-electrified villages• Low income and cannot afford to pay in cash• Size of villages small – average of 45 Households

(HH) – say 50

Background & Rationale for Selection of Location

• HH cash income very low – grow their own food and barter for their requirement.

• Level of education and technical skills low• Improve livelihood• SPV route most popular but very capital intensive• Need to innovate with new technology• Villagers willing to use this technology• Our knowledge of the area• Remote villages are not easily accessible in the State

of Chhattisgarh (East-Central India) – Kabirdham District – 175 Km from Raipur (State Capital)

Rationale of Using Jatropha Oil • Diesel is fuel very expensive and not

accessible to the poor villagers• Regular engine servicing available by

approved agency from Raipur • Villager already uses average Euro 0.50 per

month of Kerosene for lighting & use for 3 to 4 hours per night

• Select villages where sufficient Jatropha plantation is available – used traditionally as hedge plantation & agro-climatically suitable & seeds not being utilized

• But large availability of seeds is still limited

Rationale of Using Jatropha Oil

• Therefore: - • Phase I – enough power to provide for operating

the expeller and for lighting requirement for 4 to 6 hours per day immediately.

• Using diesel engine-generator adapted to Jatropha oil possible after basic training in operation and simple maintenance.

• Phase II – Target to take up more plantation so that within 3 -5 years power for 24 hours and use for more applications such as irrigation needs, and commercial needs like wheat flour grinding etc can be met.

Jatropha Nursery

Phase I - Expeller for Jatropha Oil

• Oil extraction can be undertaken in a cluster of villages using reliable smaller engine driven expellers with good efficiency

• Simple to use as very minor processing required –filtering

• Low/No cost to villagers – Most Economical

• High CV/high lubricity/low Sulfur/Low emissions (PM, HC,CO) – environmentally friendly

• Highly decentralized • No problem of accidental spilling

Small Expeller & filter press – 35/50 kg/hr

Jatropha Plant 2 years old

Challenges• Determining Village Needs • Motivating villages• Setting up effective & united Village Energy Committee

(VEC) and Village Fund• Management & HRD/capacity building/training issues Hardware challenges• Reported carbon deposit on injectors, pistons and engine head

due to incomplete combustion of fuel and high viscosity – selection of engine, Filter, Preheat & Start & End with Diesel (?)

• Excessive engine wear due to incomplete combustion & lubrication failure due to polymerization of vegetable oil in crankcase – Preheat oil & undertake engine replacement of Engine oil earlier, add antioxidants to Lube oil

Development of Jatropha Oil Gensets

• Identified suitable engine – slow speed lister engine

• Tested engine & optimized – engine using jatropha oil

• Operated the engine with oil at various temperature

• Performance and endurance of engine checked & effect of oil on lubricant.

• Changed the maintenance protocol/schedule• Minor modifications for oil with higher

temperature• Ensure quality and reliability of engine

SLOW SPEED IDI ENGINE

• Double Cylinder• 10 H.P Engine • 1000 R.P.M.• Notice the copper

coil winding carrying the JO

SLOW SPEED IDI ENGINE

• Single cylinder• 600 RPM• 4.5 KW engine with• 3.5 KVA alternator• With heating coils

Simplified RE Business ModelNumber of HH per village 50

Number of 11 W CFL connections 110

Total Load 1.5 KW

Hours of Operation per Night 5 Hrs

Total Units of per Night 7.5 KWhr

Amount of Oil Required per KWhr 0.4 kg

Oil Required 3.0 Kg

Oil Required per Year 1100 kg

Seeds required per year @ 4kg/kg of oil 4400 kgNumber of Jatropha plants required @1kg per plant & covering for other additional costs

5000

Simplified RE Business Model

Number of plants per Ha 2000

Area of Land required 2.5 Ha

Density of Fence 1 M

Total of Boundary length 5000 M

Avg plants per HH 100

Total of Boundary length 100 M

Perimeter of Field size (625 sq M) per HH 25MX25 M

Collection of Jatropha Seed

RVE Business Model – O&M Costs

• Expelling unit sells surplus oil and cake in the market, takes care of its O&M costs & sharing model with villages developed

• Each HH contributes:– Euro 0.70 ( Rs 40/-) per month (O&M of village

Gen Set)– 100/120 Kg of seeds per year– Extra oil, Cake and fruit hull to be sold to be cover

expeller costs

• (Each Additional 15/35 Kg to cover the cost of O&M of expeller and create surpluses for future for major repairs & replacement of engines in the village in 7 years)

Example of First Pilot Village• Ranidhara village – 15 KM from grid, 107

HH, population of 600• Community motivation & mobilization –

tariff fixing • Capacity building and identification of 3

persons to learn to operate and maintain system

• formation of Village Energy Committee (VEC) to handle funds, has a bank account, fixes tariff in consultation

• July 2005 to supplement existing plantation 25,000 Jatropha planted by Voluntary work of village on the field boundary

Facilities to be Provided

• All 107 HH to be provided single (31) or two CFLs as per demand

• Provide for 3.5 hrs of HH power & 5 hrs street lighting

• 65 HH opted for socket to plug in fan, radio etc.

• 30 CFLs for Streetlights and other applications

• 12 CFls for expeller-cum-genset room • Total lighting points including street lighting

~225

Hardware Input

• Building for gensets, expeller and storage• Expeller 35 to 50 Kg of seed per hr  • 1 X 7.5 KW Engine for Expeller and

genset standby, if required• 3 X 3.5 KVA gensets • Oil consumption of oil on full load (factory

trials) of 325gm/KWhr • 1 KW battery backed inverter to ensure

that street lights and the lights in the engine room are able to operate till midnight

• Only CFL used in the village

Technical Issues

• Starting problem below 15 Deg C but ambient temperature higher

• Soft carbon deposit on Exhaust Valve & Port, Combustion chamber, Nozzle tip etc

• De-carbonisation every 250 Hrs and change engine oil

• Use oil with additives with engine oil

Financial Sustainability Aspects

• Agreed ‘tariff’ to cover the cost of operation and maintenance:

• Euro 0.35 (Rs 20/-) per light point per month

• Euro 0.50 (Rs 30/-) per socket p.m.• Fund collection of ~ Euro 100 (Rs

5500/-) p.m. • Enough Jatropha to be planted in the

village & seeds to be supplied for RE

Electrification of Villages using Biodiesel

• Bokkarkhar Village: - • Availability of electricity 6.5 hrs.• High speed 7.5 KVA Engines cum genset to

provide 1.75 KW for lighting – 1 L BD for 2 KWhr• Biodiesel being supplied by government own

small biodiesel plant – transportation, accessibility

• Charges of Euro 0.25 per month per HH for operating & maintenance

• 100,000 Jatropha sapling planted by villagers• A total of 50 projects proposed to be developed• Similar projects for electrifying 6 villages

developed on Biodiesel

Biodiesel Plant 1 T/Batch

The Story is still being written so more for a later

date!

Thank you !