1

Steam Engine…..runs by steam

James Watt
1769
 2

Petrol Engine….runs by petrol

Karl Friedrich Benz

1878
 3

Diesel Engine….runs by diesel

Rudolf Diesel

1892
 4

Biofuel Engine…..runs by ?!?

?
2010
 INAUGURAL LECTURE
18 February 2010

BIOFUEL ENGINE: A NEW CHALLENGE

By

Prof. Dr. Masjuki Hj. Hassan

Department of Mechanical Engineering
Faculty of Engineering
University of Malaya
50603 Kuala Lumpur, Malaysia.

Email: masjuki@um.edu.my
 6

The Greatest Threat

“Global warming is a brutal

and urgent reality...the
greatest threat hanging over
the future of mankind.”
Former French President
Jacques Chirac

Violent weathers are coming

magazine covers courtesy

of Chris Rose
 7

CO2: The Most Significant Greenhouse Pollutant

C + O2 CO2
(Combustion)
Global Warming: The Greatest Threat © 2006 Deborah L. Williams

Burning carbon-containing fossil fuels

produce carbon dioxide
 8

“Greenhouse
Increasing greenhouse effect”
gases trap more heat
 9

Greenhouse gases

Nitrous oxide
Carbon dioxide Methane

Sulfur hexafluoride
 10

What’s next—what can we do?

11
 12

Brazil’s Ethanol caused 60-80% reduction in GHG

 13

Biofuel: Think outside the Barrel!

Brazil and USA produces world’s 89%

ethanol (2008).

In USA and Brazil today,

Ethanol (E-85) is cheaper!
 14

Possible?
THE BRAZIL’S STORY!

17 million Flexible-fuel

vehicle (FFV) or dual-fuel vehicle

automobiles sold by 2009.

 Petroleum usage reduction

of 40% for cars & light trucks.

Will it be possible for Malaysia?

 15

Factors of Biofuel Development

Food security
Renewable
Net Energy Output Biodiversity
GHG reduction
Water Resource
Job Creation
Nutrient and
Energy pesticides
Rural development
Security
Conversion Technology Feedstock and soil
Biofuel
Develop Change in land use
ment Contamination and air
quality
Rural
Develop-
Climate
ment &
change poverty
alleviation
 16

Energy Security
Energy Crisis is Economic Crisis

• Growing Economy, Growing Consumption of Energy

Ever-growing demand vs. low supply

• Raising Gap between Demand and Supply of Oil

Petro-dependency

• Energy-consuming Structure

Alternatives to Short Supply of Oil

• Renewable Energy

Regional Cooperation and/or Competition

• Petro-diplomacy

Courtesy: Won-Ho Kim, Director, KIEP

 17

(Source: US, DoE)

 18

Life Cycle Analysis of Petroleum

Fuels

Crude oil
extraction Petro-Fuel
and
pretreatment

Greenhouse Gas

Change in Feedstock Transesterification

land use: Production: Process:
Deforestation, land, fertilizer, Vegetable oils,
N-Drainage pesticides, fuel for Catalyst,
from soil transportation Alcohols

Life Cycle Analysis of Biofuel

(Jayed et al. 2009)

 19

Estimated GHG reduction from biofuels

compared with gasoline and no. 2 diesel
Biodiesel Biodiesel Ethanol from
Ethanol from Ethanol from Ethanol from from from cellulosic
grain sugar sugar cane, Rapeseed Palm oil, feedstock,
(US/EU) beet,EU Brazil ,EU Malaysia IEA
0%

20%

40%

60%

80%

100%

(IEA, 2006)
 20

Policy
Country Official Biofuel Targets
Brazil 20–25% anhydrous ethanol with petrol; minimum
blending of 3% biodiesel to diesel by July 2008 and 5%
(B5) by end of 2010
Canada 5% renewable content in petrol by 2010 and
2% renewable content in diesel fuel by 2012
European 10% in 2020 (biofuels); target set by European
Union Commission in January, 2008
UK 5% biofuels by 2020

Unfortunately, Malaysia does not have any biofuel

commercialization target yet.

The B5 biodiesel programme is targeted to be revived next year (2011),

upon approval from the cabinet - Bernama, The Malaysian Reserve, 29 January, 2010
 21

Emission Standard
% reduction

100
90
80
70
60
50
40
30
20
10
0 PM
1984

1986

1988

1990

HC+NOx
1992

1994

1996

1998

2000

2002

2004

2006

2008

2010
Euro I Euro II Euro III Euro IV

EU Diesel cars Emission Standards

 22

Emission Standard
% reduction

100
90
80
70
60
50
40
30
20
10
0 PM
1980

1982

1984

1986

1988

1990

NOx
1992

1994

1996

1998

2000

2002

2004

2006

2008

2010
Euro I Euro II Euro III Euro IV Euro V

EU heavy-duty diesel vehicles Emission Standards

 23

Biomass Conversion Process

Biomass

Thermo chemical
Conversion
Biochemical
Pyrolysis Gasification Liquefaction Conversion
Syn-oil Syn-gas Bio-
chemicals
Alcoholic Chemical Enzymatic Transesterificatio
Fermentation Hydrolysis Hydrolysis n

Bioethanol Biodiesel
 24

What is Biodiesel?
Greek, bio (means life) + diesel (from inventor of
diesel engine, Rudolf Diesel)=Biodiesel

Biodiesel is fungible to No. 2 diesel fuel without

any engine modification.

Technically, biodiesel is a diesel engine fuel

comprised of monoalkyl esters of long-chain fatty
acids that is derived from vegetable oils or animal
fats and meets the ASTM D 6751 standard
specifications.
 25

How Biodiesel is produced?

Alkaline
KOH, NaOH
Catalyst
Homogeneous
Catalysts
Acid H2SO4,
Catalytic Catalyst HCl
Method
Enzymes
Heterogeneous
Transesterification Catalysts
Titanium silicates, alkaline
earth metal compounds,
Noncatalytic Supercritical anion exchange resins
Method Methanol (SCM)
 26

How Biodiesel is produced?

Methanol
or, Ethanol

Transesterification
or alcoholysis is the usual conversion
process used to convert triglycerides of
vegetable oil to fatty acid methyl esters Biodiesel
Vegetable
(FAME) by displacing alcohol from an oil +
ester by another alcohol. Glycerin

Catalyst
 27

Feedstock

Southeast Asia- Palm Plantation

 28

Palm oil seeds

Palm have the highest biodiesel yield

The use of fertilizer and pesticides are very low in palm plantations.
Grows well in tropical weather.
 29

Jatropha Plantation in Indonesia

 30

Biodiesel Feedstock
 31

Non-edible oil Jatropha

Neem Seed

Mahua
 32

Coconut
Plantatio
n
 33

Engine Problems
While using Biofuel
 34

Corrosion in Filter

Fig. SEM image of the new (a) and used (b and c) bronze filter. Pitting
corrosion appeared after several hours of operation with biodiesel at 70 °C .

(Sgroi, et al., 2005)

 35

Pitting Corrosion on Return Fuel Line

Corrosion hole:
depth about 15 m

25 mm 25 mm

(a) Diesel (b) Biodiesel

Microscope photograph of the crystal structure
in the return pipe at cross-sectional view
(Nakamura et al. 2008)
 36

Storage instability of Biodiesel

Biodiesel fuels are more susceptible to oxidative
degradation than fossil diesel fuel.
Due to high content of di- and higher
unsaturated esters, the methylene groups adjacent to
the double bonds are particularly susceptible to radical
attack as in the first step of fuel oxidation process.
Key Factors of Oxidation Rate:
1. Presence of air,
2. Elevated temperatures,
3. Presence of metals that facilitate oxidation
4. Chemical structure of the biodiesel where
unsaturated methyl esters with more double bond is
more incline to oxidation.
 37

Cylinder Head Carbon Deposition

Cylinder Head after

using
a) No. 2 Diesel
b) 95% No. 2 diesel &
5% palm olein
c) 90% No. 2 diesel &
10% palm olein
d) 85% No. 2 diesel &
15% palm olein

(Husnawan, et al., 2009)

 38

Severe Corrosion in Petrol Engine

Results of
high alcohol
content fuel
and leakage
in petrol
engine
(Source: Wikipedia)
 39

Fuel Tank Deformation

(a)

(a) Fuel tank

used for
biodiesel
(b) Fuel tank
used for
(b) biodiesel
with
oxidation
stabilizer
 40

Injector Coking
(a) (b)

Carbon deposition
in injector tip after
using
a) No. 2 Diesel
b) 95% No. 2 diesel &
5% palm olein
 41

Key Fuel Properties

Viscosity: High viscosity of biodiesel changes the
injection spray characteristics as well as
combustion. Prone to cause the following problems:
 Carbon deposits on piston, piston rings,
valves, engine head and injector tips
 Cold weather starting
 Heavy gum and wax formation
 Fuel delivery problems, poor nozzle spray
atomization
 Corrosion of high pressure injecting pump,
injectors, injector nozzles, supply or feed
pumps, high pressure pipes
 42

Key Fuel Properties

 Flash point: The flash point of diesel is half of that of
biodiesel fuel and therefore it represents an important
safety asset for biodiesel transport and storage.

 Cetane number: The cetane number of a fuel describes

its propensity to combust under certain conditions of
pressure and temperature. High cetane number is
associated with rapid engine starting and smooth
combustion. Biodiesel has a slightly higher cetane
numbers than diesel. Cetane number increases with
increasing length of fatty acid chain and ester groups.
 43

Key Fuel Properties

 Acid number: It is a measure of free fatty acids
contained in a fresh fuel sample and also of free
fatty acids and acids due to degradation in aged
samples. Higher acid content can cause severe
corrosion in fuel supply system.

 Free glycerin: High free glycerol levels can also

cause injector coking, filter plugging, injection
problems. Incomplete separation during production
of biodiesel leaves free glycerin in biodiesel.
 44

Biodiesel Engine
 The proposed biodiesel engine should have a modified
fuel supply system.

 This is because when biofuel comes into direct contact with

the fuel supply system, it will cause wear, corrosion,
material degradation, elastomer softening, etc.

 Hence, the materials used for the new biodiesel engine’s fuel
supply system should be biodiesel compatible.

 The Fuel Supply System of a diesel engine composed of:

Fuel Tank, Fuel Pump, Fuel Filter, Fuel Line, Valves,
Piston, Cylinder Head, Piston Rings.
 45

Why “Biodiesel Engine” requires

biodiesel compatible materials?
 Higher organic number of biofuel may damage rubber parts
of the fuelling system such oil-seal and gasket (Graboski and
McCormick, 1998).

 Due to its excellent solvent properties, biodiesel can

dissolve elastomers and swell trilobutyldiene and nitrile
rubber, common automotive seal and gasket material(R.
Baranescu, 1994).

 Due to high acid value, biofuel cause corrosion in fuel lines,

tank and fuel pumps.
 Therefore the selection of corrosion and wear resistant
materials for the fuel system of biodiesel engine is vital.
46

Probably Necessary

Cold Start system

Not Necessary
How Brazil Adopted Ethanol in Flex-

Exhaust System
Intake manifold
Motor Oil
Basic Engine
Catalytic Converter
Fuel Tank
Evaporative System
Ignition System
Fuel Filter
Fuel Vehicles?

Fuel Pressure Device

Fuel Pump
Fuel Injection
Carburetor

Content

10~25%
25~85%
Ethanol
Engine

5~10%
in the

≥85%
Parts

≤ 5%
Fuel
FFV
Recommended Vulnerable Material for E10
Material
Metals Elastomers Polymers
­ luminium
A -Fluorocarbons -Acetal
-Carbon Steel -Fluorosilicone -Polyamides
-Stainless Steel -Buna-N (hoses & -Polypropylene
Recommended -Bronze gaskets) -PTFE
Material Note: E-blend -Natural Rubber -Fiberglass
fuels 10% do -Polychloroprene reinforce
×a
not pose (hoses & gaskets) polymer
materials -Polysulfide
compatibility Rubber
issue for metal.
-Zinc- -Buna-N (Seal -Polyurethane
Vulnerable galvanized only) Alcohol-
Material -Polychloroprene
(Seal only)
-Urethane Rubber

Source: Edward WE, EPA Region 3 Primer Ethanol Material Compatibility, 2007
Recommended V.S. Vulnerable Material for E85
Material
Metals Elastomers Polymers
­ lack Iron
B -Buna-N -Polypropylene
-Bronze -Fluorocarbons -Thermoplastic
-Mild Steel -Nitrile Rubber piping
Recommended -Stainless Steel - -Thermoset
Material -Unplated Steel Polychloropren reinforced fibreglass
-Nickel Plating for e tanks.
Aluminum or Brass -PTFE

-Aluminum -Natural -Polyamides

Vulnerable -Brass Rubber -Polyurethane
Material -Copper Alloys -Cork gasket -Polyvinyl chloride
-Lead material -
-Lead Solder -Leather Methylmethacrylate
-Tern-plated steel plastics
(Fuel Tank) -Certain polymer
-Zinc (Epoxy and
polyester resin)

Source: Edward WE, EPA Region 3 Primer Ethanol Material Compatibility, 2007
 49

Recommended Material for Biodiesel

Main parts Components Materials

Fuel Tank Housing Steel, plastic, paint coating

Gasket Elastomer, paper, cork, copper, synthetic materials
Fuel Feed   Aluminum alloy, iron based alloy.
Pump
Fuel Lines High pressure Steel
Low pressure Plastic, rubber
Fuel filter Filter cartridge Paper
Housing Aluminum, plastic
Fuel Pump   Aluminum alloy, iron based alloy.
Fuel Injector   Stainless steel
Cylinder Cylinder head Gray cast iron, cast aluminum, forged aluminum
Cylinder Barrels Gray cast iron, steel, cast aluminum
Cylinder liner Gray cast iron, aluminum
Valves Steel casting
Piston Piston Sand-cast aluminum, Die-cast aluminum, Forged aluminum, gray
assembly cost iron.
Piston pin Steel
Piston ring Special cast iron, steel
Connecting rod Steel, duralium

(Bosch,2004)
 50

Design of Fuel System

• Filter: A diesel particulate
filter with filter regeneration
technology would be adaptable
for biodiesel engine. The use of
biodiesel will require to
change filters twice more
frequently as in normal use.
Engine oil ash builds up on the
surface of the inlet face of the
filter, and will eventually clog
the pores. This increases the
pressure drop over the filter.
 51

Design of Fuel System

• Fuel Pump: Diesel fuel pump
faces two problems when it
pumps biodiesel.
• One, biodiesel is more viscous
than diesel, so the pumping
capacity of the new biodiesel
engine’s fuel pump has to be
slightly more than the ordinary
one.
• Two, biodiesel corrodes pumps
materials. So, only biodiesel
compatible materials should be
used for the biodiesel engine’s
fuel pump.
 52

Design of Fuel System

To avoid
Plugging
Coke formation

The temperature
of the nozzle has
to be measured
and kept below
250 ◦C using
cooling water
Injector for biodiesel operation
(Sgroi et al. 2005)
 53

Biofuel Research in University of Malaya

Department of Mechanical Engineering

Experts
a. Prof. Dr. Masjuki Hj. Hassan,
b. Dr. Md. Abul Kalam,
c. Prof. Dr. A.S.M.A. Haseeb
d. Prof. Dr. T.M. Indra Mahlia

Facilities and Expertise

 Engine tribology aspect (i.e. corrosion, wear and lubrication),
 Engine Emissions: Various regulated (i.e.CO, HC, PM, NO x, CO2) and
unregulated (i.e. PAH) engine emissions,
 Engine performance,
 Endurance test,
 Fuel deposition characterization and
 Fuel and lube oil additives effectiveness measurement
 54

Dept. of Mechanical Engineering : Research Facilities

Four Ball Tribo-Tester

Biceri Reciprocating Wear Tester

 55

Diesel Engine Test Bed

Fuel Consumption meter

for diesel engine test bed
 56

FT-IR

Horiba Exhaust Gas Analyzer

 57

Viscometer

Cygnus Wear Tester

 58

Ducom HFFR-wear machine

Multi-element Oil Analyzer (MOA)

 59

Single cylinder diesel engine test-bed

Mech. Eng. Dept. Biodiesel Plant

(Purchased 2010)
 60

Particle Quantifier (PQ)

Titrator (TAN/TBN)
 61

Moisture Content Analyzer

Karl Fisher

Bacharach Gas Analyzer

 62

Bosch Gas Analyzer

Hartridge Smoke Meter

 63

Gas chromatograph

CNG/DI Test Bed

 64

Department of Chemical Engineering

Experts
 Prof. Dr. Mohamed Kheireddine Aroua
 Prof. Dr. Mohd Ali Hashim
 Prof. Dr. Nik Meriam Nik Sulaiman
 Associate Prof. Ir. Dr. Abdul Aziz Abdul Raman
 Dr Rozita Yusoff
 Dr. Farouq Sabri Mjalli

Facilities and Expertise

 Processing technology,
 Separation process of transesterification,
 The use of different bio-catalyst,
 Biodiesel production
 Key fuel properties estimation-formulation-measurement for
different feedstock and blends
 65

Faculty of Science
Experts
 Prof. Datin Dr. Aishah Binti Salleh
 Prof. Dr. Amru Bin Nasrulhaq Boyce
 Prof. Dr. Phang Siew Moi
 Prof. Dr. Zainudin Bin Arifin
 Assoc. Prof. Dr. A.B.M. Sharif Hossain
 Dr. Ong Hean Chooi

Facilities and Expertise

 Wastes from palm oil, corn oil, sunflower oil, soybean oil, canola, rice bran oil
have been successfully converted into biodiesel after several treatments
followed by the transesterification process.
 Beef tallow, chicken and fish byproducts are also used as feedstock for their
new projects.
 The most recent project on biodiesel from algae where they have successfully
produced a small amount of biodiesel from two local species.
 Bioethanol
 66

How can ‘Biodiesel Engine’ revolutionize

the automotive and agricultural industry?
• Simple, by planning and working together.

Researcher Businessman Government

(Oil Company, Car Maker)
Three-Gaps-Theory as proposed by Gebeshuber et al. 2009
 67

Research Approaches for

Biodiesel Engine
Production Engine
Fuel Property
Process Modification
• Effective • Modification of • Modify Engine
Catalyst key fuel Fuel System
• Easier and properties of • Change
Quicker biodiesel materials used
Separation • Finding multi- in fuel pump,
Process functional fuel fuel line, filter,
additive nozzle
• Optimum Fuel • Set an
Blend optimum
ignition timing
 68

?
Green Car>Biodiesel Engine

Green Technology 2010

 69

Biofuel Embrace
and Craze
Malaysian debut in
Biodiesel? Like
‘cendawan busut’ after
the morning rain. OK la!
 70

Thank You