1. Dual Fuel System Dual Fuel Solutions for Power Generation and Transportation
March 2017
Author: Rajesh Rathi
GasTech
A Division of
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2. This Presentation Profiles GasTech Introduces Duel Fueling
Elaborates Technology
Showcases Installations
Concludes Value proposition
Enlists Next steps
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3. Introducing
GasTech
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4. Introduction
GasTech
Is a Division of Control Infotech Pvt. Ltd.
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5. Introduction
GasTech is a green energy startup promoting the use of Natural gas for Internal Combustion (IC) Engines.
GasTech has special expertise in the Duel Fuel (Diesel + Gas) Solutions for Power generation and Transportation for mixer technology
GasTech will develop dual fuel solutions for higher efficiency Common Rail Direct Injection (CRDI) technology.
GasTech is headquartered in Bangalore. The research wing of the company will be incubated in close collaboration with National Center for Combustion Research and Development (NCCRD) at IIT Madras
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6. Dual Fuelling
In simple terms Dual Fuel is simultaneous combustion of two fuels; methane based gaseous fuel is utilized in conjunction with diesel fuel to operate the engine.
Methane based
Gaseous Fuel +
After conversion, the engine is able to operate on either 100% diesel fuel, or alternately, on a mixture of diesel fuel and methane based fuels. At no time is the engine able to operate on gaseous fuels exclusively.
Diesel
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7. Dual Fuelling
During Dual Fuel operation, a reduced quantity of diesel fuel acts as the ignition source for the air-gas mixture. Dual Fuel System replaces diesel fuel with equivalent heat energy of the methane based fuels
Dual Fuel solutions are available for diesel engines, in constant speed application (equipped with ISOCHRONOUS DIESEL GOVERNOR), of rating 50 KVA upwards
Fuel cost savings vary according to the respective cost of each of the fuels. If there is a major cost differential between the cost of diesel fuel and of methane based fuels, for equivalent energy value, significant fuel cost savings would result.
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8. System Advantages No loss of power
Existing assets can be used for generating power economically
Low Capital cost
Low cost of generation by usage of cleaner and cheaper fuel
Rapid paybacks
Few moving components and hence low maintenance cost
Use of cleaner fuel – improves emissions.
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9. Compatible Fuel Gases Methane Based fuels CNG LNG CBM Bio-G PNG WHG
Pipeline
Natural Gas
Well-head
Gas
Coal-bed
Methane
Bio-Gas
Compressed
Natural Gas
Liquefied
Natural Gas
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10. Compatible Fuel Gases PNG CNG LNG CBM
Gas quality and composition are critical factors for Dual Fuel operation.
PNG (Piped Natural Gas); CNG (Compressed Natural Gas); LNG (Liquefied natural gas); CBM (Coal Bed Methane) have a high concentration of methane and calorific value close to Diesel; resulting in optimization of substitution. For lower quality gasses substitution rates are lower.
LNG
CBM
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11. Compatible Fuel Gases
The Gas quality required is of Fuel Grade. Sufficient filtering means must be installed to ensure particulate and liquid contents are kept to a level approximating fuel grade standards.
It is also important to determine the caustic compounds, if any, present in the fuel which may potentially cause harm to the engine and/or gas components of the System.
The bio-gas fuels derived from landfills, waste treatment facilities, etc., may have high levels of caustic compounds such as sulfur (H2S), which when combined with small amounts of water can form damaging acids. These gasses need to be scrubbed to make them fuel grade.
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12. Comparison Diesel – GAS – Dual Fuel Low CAPEX Only Diesel
Fast response
Higher Emissions
High Power Density
High CAPEX
Only Gas
Operation in Narrow Window
Higher O&M costs
Lower Power Density
Add. CAPEX with fast payback
“Fuel flexibility”
Diesel like engine response
Reduced Emissions
Reduced O&M costs
Smaller physical “footprint” vis-à-vis output
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13. Duel Fuel Technology
GasTech
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14. Duel Fuel Technology
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15. Duel Fuel Technology
The gas used for Dual Fuelling is sourced from either piped gas or from local storage. It is injected into the combustion air stream via a Gas Train consisting of a gas filter, a gas pressure regulator and a solenoid valve. A throttle valve at the end controls the proportion of the gas injected. The gas train is designed to accept input gas at low pressure and deliver it to the engine at a slightly negative pressure.
Dual Fuel System delivers fuel gas to the combustion cylinders via the Gas Train into a special Air-Gas Mixer. The mixer is installed on the engine air inlet before the Turbo charger. Combustion is commenced by Diesel as the ignition source and followed by ignition of the Gas.
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16. Duel Fuel System Components
Air Gas Mixer (AGM):
Ensure total mixing of Gas into Air
Located between the Air Filter and the Turbocharger
Salient features:
Regulated ingress of Gas for different loads
Cost effective and maintenance free, No moving parts.
Very low pressure drop
Applicable for wide range of gasses: Natural Gas, Landfill Gas, Bio Gas
Available in: 50, 100, 140, 200 and 300 mm
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17. The Gas train components are:
Duel Fuel System Components
GAS TRAIN: Condition and control the gas supply to the Air Gas Mixer
- Receives fuel grade gas at a low constant pressure and supplies to the Air Gas Mixer at atmospheric / slightly negative pressure.
The Gas train components are:
DMV Double
Solenoid Valve
Zero Pressure
Regulator
Main Adjustment
Screw
Gas Filter
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18. Duel Fuel System Components
Gas Filter
The filter is designed for installation in interior gas lines and compressed air lines to protect downstream fittings. Filter element is made of random laid non-woven polypropylene fabric and metal support frame with pore width of ≤ 50 μm. Dust, chips and rust as well as other physical gas-accompanying materials and fouling are retained using the random laid non-woven fabric. If the dust storage capacity is exceeded or if there is an excessive pressure difference, the filter loses its protective function.
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19. DMV Double Solenoid Valve
Duel Fuel System Components
DMV Double Solenoid Valve
It is a two single-stage solenoid valves normally closed, slow opening – to maintain engine stability and fast closing – to safeguard the engine. Opening time setting with fast stroke section at valve 2. Manual limitation of flowing gas volume by main volume setting at valve V1. The valve is supplied 24 volts DC from the Control Panel. The control panel operates the valve within the set engine parameters. The valve is closed instantly if any of the control or safety parameters is breached. The Solenoid valve is suitable for gases of families 1, 2, 3 and other neutral gaseous media. Does not contain any non-ferrous metals, suitable for gases of up to max. 0.1 vol. % H2S, dry.
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20. Zero Pressure Regulator
Duel Fuel System Components
Zero Pressure Regulator
The regulator operates according to the differential pressure between the inlet and outlet ports in order to maintain the set delivery pressure. It detects changes in engine vacuum, as engine load increases or decreases and adjusts gas flow rate in order to maintain the set outlet pressure. The regulator supplies gas to the engine at approximately atmospheric pressure. The Zero pressure regulator is suitable for gases of families 1, 2, 3 and other neutral gaseous media. Does not contain any non-ferrous metals, suitable for gases of up to max. 0.1 vol.% H2S, dry.
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21. Duel Fuel System Components
The Screw valve is utilized to optimize the gas flow while commissioning.
Main Adjustment Screw
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22. Duel Fuel Control System
Control Panel
The system is supplied with appropriate Transducers; Sensors; Thermocouples and wiring harness.
The Dual fuel operations are enabled in closed loop environment to ensure engine safety. The Control panel is programmable to set operating limits for the safety - Exhaust Gas Temperature; Engine Vibration and control parameter - Manifold Air Pressure. It continuously monitors these to operate the engine in controlled environment, while in the Dual fuel mode. The Panel opens the solenoid valve when all the parameters are within the set limits and closes it when they are not.
The additional programmable and monitored safety parameters are Air Filter restriction; Gas Supply pressure; Manifold Air Temperature and Regulator Output Pressure. The level of control and monitoring varies with engine size and Methane based fuel being used; the panel is suitably sized for these applications.
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23. Duel Fuel – FAQ’s Engine Durability: Engine Emissions:
Because natural gas burns with virtually no large particulate residues (unlike diesel which produces carbon particles during combustion), cylinder liner and ring wear are reduced and lubricating oil is kept cleaner during dual fuel operation. This leads to longer average intervals between engine overhauls. In addition, the clean burn characteristics of natural gas decrease engine wet-stacking at lighter loads and prevent the build-up heavy carbon deposits in the combustion chamber and exhaust system.
Engine Emissions:
Dual fuel operation will typically reduce production of nitrogen oxides, Sulphur oxides, reactive hydrocarbons, Carbon dioxide and particulates. The exhaust opacity levels are reduced.
Engine Operating Temperatures:
Engine heat rejection rates while operating in dual fuel mode are largely similar to 100% diesel performance. The engine exhaust gas temperature, coolant temperature, oil temperature and intake air temperature levels remain within the limits set by the engine manufacturer.
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24. Installations
GasTech
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25. Duel Fuel Installations
Industry
State
Engine Make
Rating KVA
Series
No. of Kits
TEA
Assam
CAT
275
Series A-B24 1
320
380
Series I-A15 2
Cummins
160
240
Series II-B26
500 3
Greaves MWM
285 / 245 4
Series I-B25
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26. Duel Fuel Installations
Industry
State
Engine Make
Rating KVA
Series
No. of Kits
Ceramics
Chemicals
Engineering
FMGC
Pharma
Textile
Gujarat / NCR
CAT
380
Series I-A15 3
1500 2
Cummins
180/125
250
500 6
625 1
1000 4
1250
Greaves MWM
Volvo Penta
Kirloskar
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27. Duel Fuel Installations
Industry
State
Engine Make
Rating KVA
Series
No. of Kits
OIL & GAS
Cambay Basin; Jharkhand; NCR; Rajasthan; West Bengal
Cummins
125 1
140
200
380
Detroit
Series A-A15
STP (Bio Gas application)
Andhra Pradesh
Mahindra
62.5 2 UP
82.5
Punjab 4
425
 Total 68
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28. Photo Gallery
GasTech
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29. Installation
Engine Make and Model: Mahindra GC – 82.5 KVA
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30. Installation
Engine Make and Model: CATERPILLAR 3406 – 320 KVA
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31. Installation
Engine Make and Model: Greaves TBD4 V12– 500 KVA
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32. Installation
Engine Make and Model: Greaves TBD4I V12– 500 KVA
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33. Installation
Engine Make and Model: CAT 3516 – 1500 KVA
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34. Value Proposition
GasTech
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35. Value Proposition
Long years of experience in quality manufacturing of diverse kind of panels
Electrical and Automation
End-to-end logistical management
Mature commercial processes and tax treatments
Good experience in Packing and shipping
Good record on after market services
Flexibility on space and manpower to serve peak demands
Mature operational leadership
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36. Exclusions We do not undertake engine overhauling
We do not undertake any civil works
We facilitate but do not arrange gas connections
We do not undertake pollution certification
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37. Action Points Discuss engagement model and timelines
Complete vendor evaluation criteria
Receive your RFQ and Scope of work
Costing and offer submission
Business Conclusion
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38. Thank You
GasTech