1. 1 Bio-Diesel as Fuel for Diesel Vehicles – OEM’s Viewpoint of Requirements & Issues Dr. Mathew Abraham Mahindra & Mahindra Ltd. & SIAM Petroleum Federation of India National Seminar on Bio-Fuels – Needs of the Hour, New Delhi 13 Oct. 2008 SIAM

2. 2 Vegetable Oil Trans- Esterification Bio-Diesel AUTO F U E L BIO RAW MATERIALS Feed StockProcessProduct Bio Fuels for Automotive Use SIAM

3. 3 What is Biodiesel ? Biodiesel is monoalkyl ester of long chain fatty acids produced from the Trans-esterification reaction of vegetable oil with alcohol in the presence of catalyst & can be used as fuel SIAM

4. 4 What is Biodiesel ? Contd…..  Bio-Diesel may be in the form of : Fatty Acid Methyl Ester or Fatty Acid Ethyl Ester  Main Characteristics: Better lubricity High Flash Point Comparable Heating Value content Readily mixes with diesel Ready to use in diesel run engines SIAM

5. 5 Raw materials for Biodiesel Soyabean oil Palm oil Waste Cooking oil Jatropha oil Karanje oil Rape seed oil Sunflower oil Cotton Seed oil Beef Tallow oil USA, Canada South East Asian Countries USA, Canada India, China, India Europe Greece Ireland Europe SIAM

6. 6 Status of Biodiesel in Automotives  B2 (2% Biodiesel) : being used at some places as a fuel additive / lubricity enhancer  B5 (5% Biodiesel) :Already approved by FIE manufacturers & running very successfully in some parts of world without any problems.  B10-B20 (10-20% Biodiesel) under assessment  100 (100% Biodiesel) : future option  2 nd Generation biofuels (BtL/GtL): techno-economic studies being done world-wide. Cost effective process still a Challenge. USA uses B20 blends popularly EU – 5-15% Blending Targets of EU is 5.75% by 2010 and 20% by 2020 India planning 5% blending mandatory. SIAM

7. 7 CH2OCOR’ | CHOCOR” | CH2OCOR ”’ + 3 ROH Catalyst CH 2 OH CHOH CH 2 OH + ROCOR + + Jatropha Oil Alcohol NaOH Glycerine Bio-Diesel Trans-esterification Process SIAM

8. 8 Bio-Diesel Quality Depends on : *Rawmaterial or Source of oil *Trans-esterification Process Alcohol Selection Alcohol to Oil Ratio Catalyst Used Process Control Product Quality Cost Yield Process Speed Process FactorsImpact on Product Bio Diesel Process & Product Quality Optimum & Stable Bio- Diesel SIAM

9. 9 Fuel Quality Aspects Several Countries have developed national specifications for Biodiesel Bio-diesel Specs worldwide : Country /AreaSpecifications EUEN 14214 USASTM D 6751 GermanyDIN E 51601 IndiaIS 15607:2005 BrazilANP42 Japan JASO M360 SIAM

10. 10 PropertyUnit EN 14214:2003 IS 15607:2005 ASTM D6751-02 Ester content% m/m,min96.50 NA Density at 15 o CKg/m 3 860-900 NA Kin. Viscosity at 40 o Cmm 2 /sec3.5-5.02.5-6.01.9-6.0 Flash Point o C,min120 130 Sulpher Contentmg/kg,max1050 15 max Cetane No. 51 min 47 min Water Contentmg/kg,max500 0.05 %vol (water & Sediments Copper Strip Corrosion 3 h at 50 0 C RatingClass 1 No. 3 max Oxidation Stability hours,min (at 110 o C) 6.00 NA Comparison of EU, BIS & ASTM Standards Comparison of EU, BIS & ASTM Standards SIAM

11. 11 Comparison of EU, BIS & ASTM Standards PropertyUnit EN 14214:2003 IS 15607:2005 ASTM D6751:02 Acid Valuemg KOH /g0.50 0.80 Iodine Value g Iodine/ 100g max 120to reportNA Methanol or Ethanol% m/m,max0.20 NA Free Glycerol% m/m,max0.02 Total Glycerol% m/m,max0.25 Group I Metal (Na+K)mg/Kg,max55*5 Group II Metal (Ca+Mg)mg/Kg,max55*NA Phosphorus Contentmg/Kg,max10 0.001 %mass Distillation Temp. (90% recovery,T90) o C,max o C,maxNA 360 * Amended in the 2007 revision which is under release SIAM

12. 12 Impact of Process Quality on Bio-diesel Property Effectiveness of Trans Est. process Completeness of Trans Est. process Unsaturated Fatty Acid Effective Catalyst Removal Effective Methanol Removal Feedstock Property Contamination on process Insufficient Water Removal Free Methyl Ester Free Glycerin Oxidation Stability Gr. I & II Metals Free Methanol Acid, Oxidation Stab. Sulphur level Water Content SIAM

13. 13 Comparison of Bio-Diesel Data SIAM

14. 14 SIAM Effect of Oxidation Stability Additives

15. 15 Biodiesel ages more quickly than fossil diesel fuel due to the chemical structure of fatty acids and methyl esters present in biodiesel. Typically up to 14 types of fatty acid methyl esters in the biodiesel. Saturated fatty acid methyl esters (C14:0, C16:0) increase cloud point, cetane number & improve stability whereas more poly-unsaturates (C18:2, C18:3) reduce cloud point, cetane number and stability. Storage Stability of Bio-Diesel SIAM

16. 16 At low operating temperature, fuel thickens & affect flow to fuel lines, fuel pumps & injectors – Deteriorates Performance. Cold filter plugging point of biodiesel is very poor CFPP depends on Raw material used for Bio-Diesel – Karanje, Palm etc has poor CFPP. Jatropha has good CFPP Need to include CFPP in Bio-Diesel Specs Cold Flow Properties of Bio-Diesel SIAM

17. 17 Blocked nozzlesPotassium & Sodium compounds, Solid particles Biodiesel process chemicals Filter clogging Injector coking Corrodes non ferrous metals, Soaks cellulose filters,Sediments on moving parts & lacquering Free glycerin, mono- & di- Glyceride Corrosion of FIE Sludging Corrosion, sustains bacteria Increase conductivity of fuel Free water in mixtures Filter pluggingReversion of Biodiesel to fatty acid Dissolved water in Biodiesel Corrosion of FIECorrodes Aluminums & Zinc Low Flash point Free Methanol in Biodiesel Fuel LeakageCauses some Elastomers including nitrile rubbers to soften, Swell Fatty acid methyl esters Failure ModeEffectFuel Characteristics Potential FIE /Engine Problems SIAM

18. 18 Potential FIE /Engine Problems Filter plugging Lacquering formation in hot areas Deposits especially from fuel mixes Polymerization products Similar to fatty acid Higher molecular org. acids Corrosion of FIECorrodes metallic parts Acids (Formic,acetic) Reduced service lifePotential lubricity Problems Solid Impurities Pump seizures Early life failures Peer nozzle spray Generates excessive heat locally in rotary pumps higher stress on components High Viscosity at low Temperature Corrosion of FIE Filter plugging Sediments on parts Provides an electrolyte & hastens corrosion of Zinc Salts of Organic acids compounds formed Free fatty acid SIAM

19. 19 Pollutants (g / km) Percentage Improvement for each Fuel B10B20B100 HC182440 NOx0.0-2.6-4 CO000 CO20.4-0.3-1.6 PM122036 Emission Test results on SUV with CRDi meeting Euro III emission Emission Advantage with Bio-Diesel SIAM

20. 20 Performance StudySome Highlights Performance Study - Some Highlights Test DescriptionEffect Bio-diesel over Diesel B10B20B100* Fuel Economy (kmpl)No change Power @ Wheel (kw)No change1-2%10-12% Acc n speedwiseNo change 10% distancewiseNo change 2% Max Speed (kmph)No change 5% Gradability (angle deg.)No change ----- Engine Noise (db)No change 5% * Engine tested as it is without modification over normal Diesel settings SIAM

21. 21 Finding of Engine Durability studies If the Acid value, Moisture content & Oxidation Stability parameters of the fuel exceeds the prescribed limits, ageing starts & Bio Diesel degrades to the point where it is out of specifications The Effects of fuel ageing on the Engine and FIP : Ageing ProductConsequences for the FIE Polymers, Insoluble (gum, sludge) Filter clogging Deposit formation inside the entire FIE Sticking moving parts Injector coking Polymers, SolubleResin forming inside the entire FIE Ageing acidsCorrosion of metal parts Soap formation with metal ions deriving from wear or corrosion (deposits) PeroxidesEmbitterment of elastomers SIAM

22. 22 Material Compatibility Results Components / Test Desc. Observations / Results Fuel tankSame as diesel till B10 Fuel Line / HosesNatural Rubber needs to be changed to Polymer Fuel FilterOK for B5 & B10 Material review required beyond B10 FIPNatural rubber O-Rings, Seals and Gaskets to be replaced with Viton Material SIAM

23. 23 Engine Durability Aspects  Ensuring Fuel Quality: OEMs are concerned that Biodiesel which is not of adequate purity & quality affects engine & fuel system component durability.  Ensuring Fuel Stability: Biodiesel may undergo oxidation during storage, handling & use, causing fuel system deposits. These deposits could cause plugging & damage engine fuel system components. SIAM

24. 24 Key Benefits Reported from Studies Benefits: Reduction in HC, PM, CO emission – % gain depends on Blend ratio, vehicle type, Emission level etc No deterioration in performance of the vehicle in terms of Fuel economy, Drivability up to B10 blends The cold temperature Startability & Performance good No Adverse effect on the engine durability Engine & FIP Wear within the prescribed limits Lube oil analysis results shows satisfactory results Fuel Filter life with B10 comparable to Neat Diesel SIAM

25. 25 OEMs recognize environmental & sustainability benefit of Bio-Diesel & encourage its implementation in phases Sufficient Infra structure Facilities Should be Ensured for Continuous Supply of Bio-diesel to Oil Companies for a Sustained Mixing of Blends Govt policies & tax structure to encourage the rural sector farmers to grow Jatropha or Kranje plantations. Encourage private-public partnerships to work out viable model for Bio-plant farming. Farmers need incentives to get over the gestation period- 3 years for Jatropha & 5 years for Karanje B5 can be implemented in India in the near future. Beyond that has to be proceeded after proper studies Issues for Bio-Diesel Implementation SIAM

26. 26 Ensure Fuel Quality is big Challenge & needs Specific Attention. Moisture, Oxi. stability & Acid value require Control. Ensure Bio-diesel Meets the specification IS 15607 & Be Mandatory for Any Supplier of Bio-Diesel in India. Need for Quality Bio-diesel is Still not Appreciated by Bio-diesel manufacturers in India Durability issues with higher Blends have to sorted out before considering it. Increase Deposit Forming Tendencies on FIE Parts May Hamper Blends Above B10. Sufficient Lead Time Must be There Before Bio-Diesel Implementation for Pilot Field Studies. FIE suppliers need approve OEMs to go ahead with higher blends Issues for Bio-Diesel Implementation SIAM

27. 27 SIAM