Dual Fuel System

Dual Fuel Solutions

for
Power Generation and Transportation

March 2017
Author: Rajesh Rathi

GasTech
A Division of

NEXT
This Presentation GasTech
Profiles GasTech
Introduces Duel Fueling
Elaborates Technology
Showcases Installations
Concludes Value proposition
Enlists Next steps NEXT
Introducing

GasTech
NEXT
Introduction GasTech

GasTech
Is a Division of Control Infotech Pvt. Ltd.

NEXT
Introduction GasTech
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
NEXT
Dual Fuelling GasTech

In simple terms Dual Fuel is simultaneous combustion Methane based

of two fuels; methane based gaseous fuel is utilized in Gaseous Fuel
conjunction with diesel fuel to operate the engine.

+
After conversion, the engine is able to operate on
either 100% diesel fuel, or alternately, on a mixture of Diesel
diesel fuel and methane based fuels. At no time is the
engine able to operate on gaseous fuels exclusively.

NEXT
 Dual Fuelling GasTech

During Dual Fuel Dual Fuel solutions

operation, a reduced are available for
quantity of diesel fuel diesel engines, in
Fuel cost savings vary
acts as the ignition constant speed
according to the
source for the air-gas application
respective cost of each
mixture. Dual Fuel (equipped with
of the fuels. If there is a
System replaces diesel ISOCHRONOUS
major cost differential
fuel with equivalent DIESEL
between the cost of
heat energy of the GOVERNOR), of
diesel fuel and of
methane based fuels rating 50 KVA
methane based fuels,
upwards
for equivalent energy
value, significant fuel
cost savings would
result.
NEXT
System Advantages GasTech
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.

NEXT
Compatible Fuel Gases GasTech

Methane
Based fuels

PNG WHG
CBM Bio-G
Pipeline
CNG LNG
Well-head
Natural Gas
Gas
Coal-bed Bio-Gas
Methane
Compressed Liquefied
Natural Gas Natural Gas
NEXT
Compatible Fuel Gases GasTech
PNG CNG

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 NEXT

Compatible Fuel Gases GasTech
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.
NEXT
Comparison GasTech
Diesel – GAS – Dual Fuel

• Low CAPEX • High CAPEX • Add. CAPEX with fast payback

• Only Diesel • Only Gas • “Fuel flexibility”
• Fast response • Operation in Narrow • Diesel like engine response
• Higher Emissions Window • Reduced Emissions
• High Power Density • Higher O&M costs • Reduced O&M costs
• Lower Power Density • Smaller physical “footprint” vis-à-vis
output

NEXT
Duel Fuel Technology

GasTech
NEXT
Duel Fuel Technology GasTech

NEXT
Duel Fuel Technology GasTech

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.

NEXT
Duel Fuel System Components GasTech
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

NEXT
Duel Fuel System Components GasTech
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 Zero Pressure Main Adjustment

Gas Filter
Solenoid Valve Regulator Screw

NEXT
Duel Fuel System Components GasTech

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.

NEXT
Duel Fuel System Components GasTech

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.

NEXT
Duel Fuel System Components GasTech

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.

NEXT
Duel Fuel System Components GasTech

Main Adjustment Screw

The Screw valve is utilized to optimize the gas flow while commissioning.

NEXT
Duel Fuel Control System GasTech

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.
NEXT
Duel Fuel – FAQ’s GasTech
Engine Durability:
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. NEXT
Installations

GasTech
NEXT
Duel Fuel Installations GasTech
Industry State Engine Make Rating KVA Series No. of Kits
275 Series A-B24 1
CAT 320   1
380 Series I-A15 2
160   1
240 Series II-B26 2
TEA Assam Cummins 320 Series I-A15 1
380 Series I-A15 2
500 Series I-A15 3
285 / 245 Series I-A15 4
Greaves MWM 320   1
500 Series I-B25 4

NEXT
Duel Fuel Installations GasTech
Industry State Engine Make Rating KVA Series No. of Kits
380 Series I-A15 3
CAT
1500   2
180/125   3
• Ceramics 250   2
• Chemicals 500   6
Cummins
• Engineering 625   1
Gujarat / NCR 1000   4
• FMGC
• Pharma 1250   3
• Textile Greaves MWM 500   2
Volvo Penta 500   2
500   2
Kirloskar

NEXT
Duel Fuel Installations GasTech
Industry State Engine Make Rating KVA Series No. of Kits
125   1
140   1
Cambay Basin; Cummins
Jharkhand; NCR; 200   1
OIL & GAS Rajasthan; West
Bengal 380   1

Detroit 380 Series A-A15 1

Andhra Pradesh 62.5   2

Mahindra
STP (Bio Gas UP 82.5   1
application)
380   4
Punjab Cummins
425   2
   Total 68

NEXT
Photo Gallery

GasTech
NEXT
Installation GasTech
Engine Make and Model: Mahindra 41225 GC – 82.5 KVA

NEXT
Installation GasTech
Engine Make and Model: CATERPILLAR 3406 – 320 KVA

NEXT
Installation GasTech
Engine Make and Model: Greaves TBD4 V12– 500 KVA

NEXT
Installation GasTech
Engine Make and Model: Greaves TBD4I V12– 500 KVA

NEXT
Installation GasTech
Engine Make and Model: CAT 3516 – 1500 KVA

NEXT
Value Proposition

GasTech
NEXT
Value Proposition GasTech
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

NEXT
Exclusions GasTech

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

NEXT
Action Points GasTech

Discuss engagement model and timelines

Complete vendor evaluation criteria

Receive your RFQ and Scope of work

Costing and offer submission

Business Conclusion

NEXT
Thank You

GasTech