Experience in Use of By-Products in India with Focus on Rural Electrification

1. Experience in Use of By-Products in India with Focus on Rural Electrification Jai Uppal, Sr. consultant Sr. Advisor, Center for Alternate Energy Research Gen Secretary - SVSjaiuppal @ yahoo.com(M) +919811171121 International Consultation on Pro-Poor Jatropha Development IFAD, Rome, April 2008

2. Agenda • List of Major By products and Byproducts of Jatropha • Fruit Shell, Seed hull, • De-oiled Cake & Detoxification • Use of Bio-oils and Biodiesel for Rural Electrification • Glycerine

3. Major Byproducts • Pruning and Training Biomass – leaves and branches • Fruit Shell from decortication • Hull and kernel • Cake • Bio-oils/SVO/PPO • Biodiesel • Glycerine/Glycerol

4. Applications Biomass Branches, leaves, fruit shell & de-oiled cake : • Briqueting for direct combustion – Cake – 3000KCal/Kg. Selling at Euro 55/T • Biomass gasifier – being experiment with • Use heat as a fuel for industrial and commercial heating, Power generation and • Biomethane from leaves – 80 to 100 M3/T • Biomethane from fruit shell – no Indian data available • Bio-methanation of cake(VS –80%) – 250 to 450 M3/T = 0.25 to 0.45 T of coal equivalent • Medicines, pesticides, chemicals and latex from the oil, branches, leaves etc ?

5. Detoxification of Seed Cake • Toxicants/Anti-nutritional factors in cake: • Phytates, Saponins,trypsin inhibitor, curcin • lectin • Phorbolesters, alkaloids,cyanogens • Treatment: - • Treatment with Sodium hydroxide/Calcium hydroxide reduces phorbolester content by 86%/90% • Heat Treatment reduces lectin content • Soaking cum boiling and alkali treatment – reduced Saponin content by 85%

6. Detoxification of Seed Cake • Trypsin inhibitor by 83 to 90% • Phytate by 20 to 28% • Tanins by 45 to 60% • However, these methods have not made cake non toxic • Far away as detailed testing, field trials and approvals a long time away.

7. Glycerine • Grades - Crude, Commercial, Pharma grades) • Traditional (low volume, high value product) uses in : Pharmaceuticals, Food & beverages, Cosmetics, Toiletry, dynamites, Lubricants, resins,Tobacco, Paper etc 1500 listed • If prices fall to below $ 500/T (High volume,Low value Products) Platform for Fuel, Plastics, large number of Petrochemicals, Antifreeze, Oxygenates

8. Indian R&D – BD/SVO Use in Engines • Testing Engines all over the country by educational and other institutions in use of SVO & Biodiesel in stationary and transport engine • One study comprehensive single cylinder 7.5 KW Engine (1500 rpm constant speed) using varying blends of Jatropha Oil (JO)and Karanj from 5% to 100% - temperature of Oil raised to about 90 Deg C based on Exhaust gas • Endurance (32 cycles of 16 hrs), Performance and Emission • For JO-100% injector cleaned 3 times in 512 hours of operation while 50% JO and Diesel not cleaned

9. Indian R&D • Carbon Deposits significantly higher • Density and viscosity of engine lube oil went up significantly & had to be changed after about 400 hours but no problems faced by 50% JO – can be addressed by additives to stop oxidation and polymerization • Viscosity of JO went down by more than one fifth if heated to 90 Deg C from ambient temperature • Preheated JO gave lower emission as compared to unheated – lower smoke, CO, HC • Thermal Efficiency of Diesel Engine was almost the same as PH JO while UH-JO was marginally less • However, did not experiment with slow speed IDI engine & thid study has been Taken up by CAER,University of Petroleum & Energy Studies

10. Indian Experience in Use of Biofuels

11. Indian Experience in Biodiesel • Large scale plantation of Jatropha & Pongamia has taken place may be 1 mill Ha despite government Demonstration Project being held up • Almost every Tech. University has a pilot plant of Biodiesel • BD & B5 specs approved by Bureau of Indian Standards • Nearly 1 million tonnes of Biodieselcapacity set upbut low utilization & awaits feedstock – Imported Palm oil costly ! • Field Trial of Biodiesel since 2003 in: • Busses – Mumbai, near Delhi, Hyderabad, Bangalore (on SVOs), Pune, Gujarat etc • Trains – most prestigious trains on B5 & B10 • Mercedes cars – Country wide tour • Stationary and transport Engine trials on various blends of Biodiesel • Many R&D and educational Institute running vehicles & engines on Biodiesel made at their lab scale plants

12. Macro Factors for using Biofuels • Enhances rural employment & rural development, • Replaces fossil Hydrocarbons with RE, • Provides energy security & reduces vulnerability to disruptions & unexpected price hikes, • Potential for use of unused lands & greening of landmass • Improves Environment – Reduces pollution • Mitigates GHGs (potential CDM benefits ) • Disadvantages of use of Biodiesel Vs SVO: – Methanol Toxic & accessibility,transesterification very sophisticated reactionnot suitable for remote villages, added cost,accessibility in Remote areas & transport costs, crude glycerin disposal

13. Indian Experience in Use of SVOand Rural Electrification • Use of Pongamia Pinnata (Karanj) in SVO stationery Engines – small high speed engines of 10 KW and 3.75 KW engines for oil expellers, water pumping and gensets • More than 40 installation in remote villages in Karnataka, Andhra Pradesh and Rajasthan • E.g. Karnataka - 10 location covering 631 HH, 490 lighting points and 10 units for oil extraction 10.5 KW, 3.75 KW engines • Engines without warrantee because Indian Manufacturer not confident.

14. Indian Experience in Rural Electrification • Very little field experience with Jatropha Oil (JO) • Now first success story - small field trial JO using IDI Engines Vs DI injection in IIT K • IDI Engines slower and expected to be more suitable for SVOs • Used in Africa for same applications • Advantage India – Trials undertaken to develop maintenance protocol & good after sale servicing network of supplier

16. Background & Rationale for Selection of Chhattisgarh • DPR made for electrification of 50 Villages – SVO/BD • Chhattisgarh State selected because of history of growing Jatropha in Remote Tribal area for lighting, cooking (wood) & dynamic Pro Biofuels Policies • Excellent Agro-climatic conditions for Jatropha • Small Jatropha plantations still exist in most tribal villages and villagers know how to grow Jatropha – every HH uses as a fence ! • Villagers already aware that Jatropha is non-edible • Many Remote Un-electrified villages • Low income and cannot afford to pay in cash • Size of villages small – average of 45 Households (HH) – say 50

17. Background & Rationale for Selection of Location • HH cash income very low – grow their own food and barter for their requirement. • Level of education and technical skills low • Improve livelihood • SPV route most popular but very capital intensive • Need to innovate with new technology • Villagers willing to use this technology • Our knowledge of the area • Remote villages are not easily accessible in the State of Chhattisgarh (East-Central India) – Kabirdham District – 175 Km from Raipur (State Capital)

19. Rationale of Using Jatropha Oil • Diesel is fuel very expensive and not accessible to the poor villagers • Regular engine servicing available by approved agency from Raipur • Villager already uses average Euro 0.50 per month of Kerosene for lighting & use for 3 to 4 hours per night • Select villages where sufficient Jatropha plantation is available – used traditionally as hedge plantation & agro-climatically suitable & seeds not being utilized • But large availability of seeds is still limited

20. Rationale of Using Jatropha Oil • Therefore: - • Phase I – enough power to provide for operating the expeller and for lighting requirement for 4 to 6 hours per day immediately. • Using diesel engine-generator adapted to Jatropha oil possible after basic training in operation and simple maintenance. • Phase II – Target to take up more plantation so that within 3 -5 years power for 24 hours and use for more applications such as irrigation needs, and commercial needs like wheat flour grinding etc can be met.

21. Jatropha Nursery

22. Phase I - Expeller for Jatropha Oil • Oil extraction can be undertaken in a cluster of villages using reliable smaller engine driven expellers with good efficiency • Simple to use as very minor processing required –filtering • Low/No cost to villagers – Most Economical • High CV/high lubricity/low Sulfur/Low emissions (PM, HC,CO) – environmentally friendly • Highly decentralized • No problem of accidental spilling

23. Small Expeller & filter press – 35/50 kg/hr

24. Jatropha Plant 2 years old

25. Challenges • Determining Village Needs • Motivating villages • Setting up effective & united Village Energy Committee (VEC) and Village Fund • Management & HRD/capacity building/training issues Hardware challenges • Reported carbon deposit on injectors, pistons and engine head due to incomplete combustion of fuel and high viscosity – selection of engine, Filter, Preheat & Start & End with Diesel (?) • Excessive engine wear due to incomplete combustion & lubrication failure due to polymerization of vegetable oil in crankcase – Preheat oil & undertake engine replacement of Engine oil earlier, add antioxidants to Lube oil

26. Development of Jatropha Oil Gensets • Identified suitable engine – slow speed lister engine • Tested engine & optimized – engine using jatropha oil • Operated the engine with oil at various temperature • Performance and endurance of engine checked & effect of oil on lubricant. • Changed the maintenance protocol/schedule • Minor modifications for oil with higher temperature • Ensure quality and reliability of engine

27. SLOW SPEED IDI ENGINE • Double Cylinder • 10 H.P Engine • 1000 R.P.M. • Notice the copper coil winding carrying the JO

28. SLOW SPEED IDI ENGINE • Single cylinder • 600 RPM • 4.5 KW engine with • 3.5 KVA alternator • With heating coils

29. Simplified RE Business Model

30. Simplified RE Business Model

31. Collection of Jatropha Seed

32. RVE Business Model – O&M Costs • Expelling unit sells surplus oil and cake in the market, takes care of its O&M costs & sharing model with villages developed • Each HH contributes: • Euro 0.70 ( Rs 40/-) per month (O&M of village Gen Set) • 100/120 Kg of seeds per year • Extra oil, Cake and fruit hull to be sold to be cover expeller costs • (Each Additional 15/35 Kg to cover the cost of O&M of expeller and create surpluses for future for major repairs & replacement of engines in the village in 7 years)

33. Example of First Pilot Village • Ranidhara village – 15 KM from grid, 107 HH, population of 600 • Community motivation & mobilization – tariff fixing • Capacity building and identification of 3 persons to learn to operate and maintain system • formation of Village Energy Committee (VEC) to handle funds, has a bank account, fixes tariff in consultation • July 2005 to supplement existing plantation 25,000 Jatropha planted by Voluntary work of village on the field boundary

34. Facilities to be Provided • All 107 HH to be provided single (31) or two CFLs as per demand • Provide for 3.5 hrs of HH power & 5 hrs street lighting • 65 HH opted for socket to plug in fan, radio etc. • 30 CFLs for Streetlights and other applications • 12 CFls for expeller-cum-genset room • Total lighting points including street lighting ~225

35. Hardware Input • Building for gensets, expeller and storage • Expeller 35 to 50 Kg of seed per hr • 1 X 7.5 KW Engine for Expeller and genset standby, if required • 3 X 3.5 KVA gensets • Oil consumption of oil on full load (factory trials) of 325gm/KWhr • 1 KW battery backed inverter to ensure that street lights and the lights in the engine room are able to operate till midnight • Only CFL used in the village

36. Technical Issues • Starting problem below 15 Deg C but ambient temperature higher • Soft carbon deposit on Exhaust Valve & Port, Combustion chamber, Nozzle tip etc • De-carbonisation every 250 Hrs and change engine oil • Use oil with additives with engine oil

37. Financial Sustainability Aspects • Agreed ‘tariff’ to cover the cost of operation and maintenance: • Euro 0.35 (Rs 20/-) per light point per month • Euro 0.50 (Rs 30/-) per socket p.m. • Fund collection of ~ Euro 100 (Rs 5500/-) p.m. • Enough Jatropha to be planted in the village & seeds to be supplied for RE

38. Electrification of Villages using Biodiesel • Bokkarkhar Village: - • Availability of electricity 6.5 hrs. • High speed 7.5 KVA Engines cum genset to provide 1.75 KW for lighting – 1 L BD for 2 KWhr • Biodiesel being supplied by government own small biodiesel plant – transportation, accessibility • Charges of Euro 0.25 per month per HH for operating & maintenance • 100,000 Jatropha sapling planted by villagers • A total of 50 projects proposed to be developed • Similar projects for electrifying 6 villages developed on Biodiesel

39. Biodiesel Plant 1 T/Batch

40. The Story is still being written so more for a later date! Thank you !