power point presentation on conversion of Diesel engine into CNG engine

An experience had at JSS academy of Technical Education, Bangalore during winter internship under Expertshub Industry Skill Development Centre

1. PRESENTATION ON CONVERSION OF DIESEL ENIGNE INTO CNG ENGINE

2. PROBLEM STATEMENT We are a part of a company which is the world leader in commercial vehicle segment. Our responsibility as a new product development team is to provide solution to various problem faced by the company.

3. CASE STUDY To meet the upcoming emission norms our company decides to convert an existing diesel engine to a dedicated CNG engine for commercial application.

4. TEAM STRUCTURE

5. Current Market trends/requirement for given engine. An automotive natural gas vehicle uses compressed natural gas as an alternative to the mineral oils can be stated with examples like: Trucks, buses, heavy duty trucks and locomotives.

6. ADVANTAGES OF CNG

7. 20 to 25 per cent less carbon dioxide. Up to 90 per cent less carbon monoxide. 75 to 90 per cent less non-methane hydrocarbons. CNG-powered vehicles have lower maintenance costs. No acid smell from exhaust gases. No heavy metal additives necessary to increase knock rating. No losses through vaporization from the tank and/or while refuelling. No carcinogenic substances. CNG mixes easily and evenly in air being a gaseous fuel.

8. DISADVANTAGES OF CNG

9. Methane emission. Approximately 50 per cent more nitrogen oxides in comparison with Diesel. 10 to 20 per cent less power output with existing engines. Additional fuel station network necessary. Weight and space requirements for gas cylinders in a vehicle. Shorter operating range of vehicles. Running on a close to empty tank reduces the pressure and increases the risk of the valves bursting. Conversion kits tend to come with a high cost.

10. CATEGORIES BOLERO DIESEL PICKUP Converted CNG PICKUP Power & Engine Type MDI 2523 Turbo Charged CNG 2523 turbo charged Compression Ratio 18 : 1 13.7 : 1 Valve Mechanism DOHC( Double Over Head Cams) VVT( Variable Valve Timing) No. of Cylinders 4 4 No. of Valves 16 16 Stroke Length 101.6 mm 120 mm Swept Volume per Cylinder 2523 cc 2523 cc Max. Torque 195 Nm @ 1500 rpm 181 Nm @ 1400 rpm Max. Power 63 bhp @ 3200 rpm 69 bhp @ 3200 rpm Bore Diameter 88.9 mm 81.8 mm Components Low pressure pump, filter, diesel injection pump, diesel tank, fuel injectors, E.C.U. E.C.U, injectors, temperature switch, map sensor, vaporizer, regulator, spark plug. Clearance Volume 37.10 cc 49.66 cc Ignition System Electronic ignition system Electronic ignition system Injection Type CRDI Fuel gallery Type of Catalytic Converter 3 way converter 3 way converter

11. ENGINE DESIGN

12. Reduction of compression ratio from 18:1 to 13.7:1 Increase in height of cylinder head by 2~3mm. Replacement of DOHC system by VVT. Addition of spark plug in cylinder head. Removal the diesel injection pump, diesel injectors, diesel pump and diesel low pressure pump. Recrafted the catalytic converter with some modification.

13. VARIABLE VALVE TIMING

14. In IC engines, variable valve timing (VVT) is the process of altering the timing of a valve lift event, and is used to improve performance, fuel economy and emissions. Late intake valve closing (LIVC) ,Early intake valve closing (EIVC),Early intake valve opening ,Early/late exhaust valve closing. Advantage: better fuel economy Disadvantage: more complex mechanism

15. COMPONENTS OF CNG KIT

16. High Pressure CNG Tank:-A gas cylinder or tank is a pressure vessel used to store gases at above atmospheric pressure. High Pressure Supply Line. CNG Injectors:-Compressed Natural Gas Injector is designed specifically for port fuel injection engines that operate on gaseous fuels.

17. 2 Stage Pressure regulator:-The pressure on the gas is lessened until it matches the amount needed by the fuel injection system. CNG Filler Valve:-The filler valve equipped with non return check valve enable the CNG filling through CNG dispenser. CNG Control Unit:-ECM means electronics circuit module. It’s a brain of Sequential Kit. Controls all the functionalities of CNG kit. Its reprogrammable & we can change setting by laptop via USB or Serial cable.

18. COOLING SYSTEM

19. Purpose: to regulate the engine internal temperature Types : 1)Natural Gas Engine Coolant 2) Finning Supercraft Coolant 3) Diesel Engine Antifreeze Coolant

20. EXHAUST SYSTEM

21. CNG: Composition: 95-98% Methane (CH4) 3 way catalytic converter with higher noble metals concentration. metals like Pt,Ni,Pd ,Rh etc. 2NOx-xO2+N2 2CO+O2- 2CO2 CH4+2O2-CO2+2H2O

22. SWOT ANALYSIS Strength -Evolving Industry -Continuous product innovation & technological advancement -Growth shifting to rural areas -Increasing demand of VFM (value for money) vehicles. -Increasing demand of luxury commercial vehicles. -Manufacturing facilities in Asian nations to control cost.     Weakness -Cars recalled -Growth rate Opportunity -Introducing fuel-efficient vehicles -Strategic Alliances -Changing lifestyle & customer groups -Market expansion -OEM priorities Threats -Intense Competition -Volatility in the fuel prices -Sluggish economy -Fixed cost

23. ESTIMATED COST OF THE PROPOSED TECHNOLOGY MAJOR COMPONENTS -Redesign of engine cylinder head ( RS 100000/-) -Conversion Kit Cost (RS 50000/- ) -Catalytic convertor (RS 30000/-) OVERALL RS 180000/-

24. Marketing concept High annual millage High vehicle age Adequate standard of maintenance Torque and power of engine Lower emission Less noisy

25. THANK YOU