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Conversion of Diesel Engine for 100 percent Utilization of Raw as well as

Enriched Biogas Rural Electricity Generation
V. K. Vijay*, Ram Chandra*, R. R. Gaur** and P. M. V. Subbarao**
* Centre for Rural Development and Technology, IIT Delhi
**Department of Mechanical Engineering, IIT Delhi

In the present scenario diesel engine are

being extensively used for variety of application
in the villages. Biogas ( raw or enriched) can be
used as an alternative of diesel fuel by dual
fueling or can be used as neat fuel (SI engine
mode) for operation of the diesel engines in
context of various mechanical and electrical
power generations. It has gathered enormous
interest for various reasons such as reduction in
environmental pollution, lowering foreign currency
dependency and to improve rural economy. With
increasing population and the need for rural
employment and productivity, evolution of rural
industries based on biomass based gaseous
fuels is essential. For effective utilization of these
biomass based fuels, it is essential requirement
to evolve simple, reliable and low cost
conversion kits to readily convert existing diesel
engines into biofuel engine. A conversion kit for
diesel engine has been developed at Centre for
Rural Development & Technology and
Mechanical Engineering Department, IIT Delhi,
from which 100 percent replacement of diesel is
possible through biogas and producer gas.

1.

An ignition system for initiating combustion

of air-fuel mixture, Since gaseous fuel have
very high auto ignition temperature e.g.
Biogas has self ignition temperature as
around 650 0C, similarly for producer gas.
Therefore an external source of ignition is
required for starting combustion of gas
mixture.

2.

Reduction of Compression Ratio-Generally

the compression ratio of diesel engine is in
range of 16.5-18.5, which is very high in SI
mode. High compression ratio results higher
brake mean effective pressure and thus at
high pressure spark ignition engine does not
operate effectively and also hand starting of
engine is a difficult task at higher
compression ratio. Therefore the
compression ratio of existing diesel engine
should be reduced to 11:1 to 14:1. However,
in some case of biogas, the same
compression can be
utilized for
satisfactory operation because methane has
very high octane rating as around 130.

Essential Requirements of Diesel Engine in

SI Mode
There is certain requirement that should
meet to the engine for running it in spark ignition
mode for satisfactory operation on biogas or on
producer gas.

3.

An effective system for supplying appropriate

air-fuel ratio with in the range of combustible
zone of the mixture should be incorporated in
the engine for the enhanced engine
performance and ease of operation.

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Methodology of the Diesel Engine Modification

The essential changes that are required, is presented in Figure 1.

Figure 1. Schematic diagram for conversion of diesel engine into single fuel engine (Spark Ignition Mode)

S. No. Items
1

Ignition system

A 6-12 Volt magneto ignition on crank shaft is employed for supplying spark
current to spark plug for initiating combustion process.

A spark plug of 14 mm diameter size is mounted at the place of fuel injector
for initiating mixture ignition.

Battery ignition system can also be used

Removal: Fuel supply system

Fuel tank, fuel supply lines, fuel
filter, fuel pump (partial replacement),
high pressure line and fuel injector.

Addition: Air-fuel supply system

A modified air-fuel supply system is required
to install at intake manifold of the engine
for supplying an adequate fuel-air mixture to
the combustion chamber.

Reduction of compression ratio

Should be decreased to 11:1 to 14:1

from existing.

Ignition System on the Engine

There are two type of ignition system that can
be used in SI mode of diesel engine under most
of the cases:
1.
2.

Magneto Ignition System

Battery (Coil) Ignition System

required for supplying spark current for

initiating the combustion of gas and air
mixture similar to the petrol engine. However,
in magneto ignition system the current required
for starting the combustion is generated by
magneto itself installed on the engine. Thus
does not require any battery or other external
source of current supply.

In battery system 6 - 12 V battery is

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Case- I: Magneto Ignition System

The complete details of ignition system for operation of diesel engine on single fuel
mode are shown in Figure 2.

Figure 2. Detailed sketch of magneto ignition assembly mounted on the crank shaft of the engine
Magneto Ignition System of 6-12 V Scooter
or any motor cycle engine can be mounted for
starting combustion of gas-air mixture inside the
engine cylinder.
Modification of cylinder head and fitting of
spark plug
Installation of spark plug in the cylinder
head requires very careful attention. The removal
of injector leaves a hole, which has been used
for mounting of the spark plug. The existing spark
plug is machined for 14 mm size to fit it firmly at
the place of diesel fuel injector. Care should be
taken to see that the spark plug electrode does
not protrude into the combustion chamber. The
spark gap has been adjusted to 0.75 mm.
Case- II: Battery Ignition System
The installation of battery mode of ignition
system is easier than that of magne to ignition
system. The installation is given in Figure 3.
There are two available options for mounting of
The Indian Cow Oct-Dec, 2005

contact breaker assembly. First one is above the

cam through which fuel pump was operating. At
this position the spark current is available once
in two revolutions of the crank shaft and the ignition timing will be as same at which diesel fuel
was earlier injected. Second available option is
at timing cover of the engine, on cranking arm
shaft by machining a base plate as in case of
magneto ignition system.
Air-Fuel Supply System
The complete details of air-fuel supply of
gaseous fuel-air mixture are shown in Figure 4.
The complete fuel supply system of existing
diesel engine is required to be removed from the
engine, the major removal of items includes:

Removal of diesel fuel supply system

Removing of fuel injection pump


Removing of fuel supply lines and fuel
filter


Removing of high pressure line and fuel
injector

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The Indian Cow Oct-Dec, 2005

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Figure 4. Air-fuel mixing device and venturi dimensions

Reduction of Compression Ratio

D
X

Y
K

Figure 5. Various piston dimension used in changing compression ratio

Table 1. Modified piston dimension for single fuel engine
Sl. No. hp Series Piston dimension in mm
Ratio
Diameter X
Y

Compression
K (piston thickness reduced by)

87.5

40

30

11:1

112.5

46

35

11:1

10

120.0

48

38

11:1

Note: Compression ratio also can be changed by inserting numbers of Sims in between engine
block and cylinder block.
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Air-fuel governing system

In the air-fuel induction system provision
has to be made for controlling the quantity of
gaseous fuel and air through a butter fly valve
as illustrated in the Figure 6. The cross
sectional opening through which mixture
passes is automatically controlled by this
butter fly valve. Since the butter fly valve is
connected with engine governor. The fuel pump
rack is attached with a rotating rod extension
which opens and closes the opening of the
pipe as the engine governor responds
accordingly with engine speed.

Figure 6. Engine governing system

Electricity Generation from Biogas Fuelled
Internal Combustion Engines
Methane produced by the anaerobic
digestion process is quite similar to natural gas
that is extracted from the wellhead. However,
natural gas contains a variety of hydrocarbons other
than methane, such as ethane, propane, and
butane. As a result, natural gas will always have a
higher calorific value than pure methane.
Depending on the digestion process, the methane
content of is biogas generally between 55%-65%.
The remaining composition is primarily carbon
dioxide, with trace quantities (0-15,000 ppm) of
corrosive hydrogen sulfide and water.
The Indian Cow Oct-Dec, 2005

The natural gas has energy content about

10% higher than that of pure methane because of
added gas liquids like butane. However, the
particular characteristics of methane, the simplest
of the hydrocarbons, make it an excellent fuel for
certain uses. With some equipment modifications
to account for its lower energy content and other
constituent components, biogas can be used in all
energy-consuming applications designed for
natural gas.
Today, it is commonly burned in an internal
combustion engine to generate electricity in
developed countries. Practical experience with
small-scale internal combustion engines with a rated
capacity of less than 200-kW indicate an electrical
conversion efficiency of less than 25%. Larger
engines can have greater conversion efficiency. It
has been claimed that an engine with an electrical
conversion efficiency that averages 38% for engines
in the 600-1000 kW range.
When biogas is used to produce electricity,
there is the added potential for harvesting hot water
and steam from the engines exhaust and cooling
systems. Combining hot water and steam
recovery with electricity generation may provide an
overall
conversion efficiency of 80% or more.
Biogas is also burned in boilers to produce hot
water and steam used for heating and sanitary
washing.
Biogas is also successfully compressed for
use as an alternative transportation fuel in light- and
heavy-duty vehicles. To obtain usable methane, the
biogas is scrubbed of its carbon dioxide, hydrogen
sulfide, and water. After scrubbing, the technique
of fueling with biogas is basically the same as that
used for compressed natural gas (CNG) vehicles.

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