1. Introduction

Energy sustainability and environmental issues pose greater challenges on different primary

energy sectors as the global energy demand increases and it is projected to further increase with

an upsurge in population. On the other hand, energy sources from conventional fossil-based fuels

are depleting, forcing explorations in challenging and difficult locations. As a result, the use of

alternative fuels received dramatic consideration to substitute these conventional fuels, of which

natural gas took the significant share. However, the share of natural-gas vehicles in the current

Depletion of petroleum products is providing reasons for research of its alternate means, In the upcoming years, alternative fuels are expected to substitute conventional fuels concerning environmental and energy security issues. While the future trend in the transportation sector is inclining toward electric vehicles, a leap jump is unlikely due to existing infrastructure and resources. There is a need for an alternative transitional fuel that can lead toward 21st century ambitions of zero-carbon emission. As a result, natural gas has become the leading candidate to fill the gap in recent trends such as CNG or Natural Gas, which looks promising in the future. It will help to bring down the percentage of harmful emissions, regardless of any vehicle type or category. We have been using CNG as a fuel in stationary engines for a long time, but the trend of using CNG as a transport engine fuel has been developing due to use of new types of lightweight high-pressure storage cylinders. We can use compressed natural gas in IC engines in various methods and with little modifications. It is revealed that there is a decrease in performance characteristics while the emissions characteristics for CNG are better as compared with diesel or petrol.

 

1. 1.  Problem Statement

Element	Description
The problem of ...	High emissions, high maintenance cost , high running Costs
And results in ...	Increase in pollution from automotive vehicles running on conventional liquid fuels
Benefits of a solution ...	lower maintenance cost , Environmental Friendly

 

1. 2. Background

In 2 December 2020: Ministry of Local Development revealed an enlarged plan was presented by Prime Minister to convert 2,300 public buses in Cairo and Alexandria over five years.  MUT is one of the few companies that took a leadership role in starting this trial. Our Engineering department studied and worked hard to find the suitable solution in order to proceed with this initiative.

 

 

2. Proposed TECHNICAL APPROACH

IMUT Engineering Corp. offers wide range of solutions regarding diesel to natural gas transformation we develop and sell diesel-to-natural gas engine conversion systems (DNG) , including new natural gas engines that utilize the company’s technology -- providing global customers with innovative alternative energy and emissions control solutions that are sustainable and affordable.

1. 1. Requirements

A study will be done to classify all the busses in order to identify the needs of each category, the selection of the proper components will be done based on the specification of each powertrain.

 

" Development is based on Preliminary calculations for every vehicle needs to be Converted "

 

1. 2. Design

The Design team defines the scope and targets for each design and development activity.

A unique solution is presented with integrated modern technologies to secure high capability at an affordable value proposition. Solution was designed by an IMUT international team of engineers, with years’ experience in the vehicle industry. The IMUT solution and design philosophy reduces significantly the life cycle cost of the vehicles together with a higher availability.

0. 3. Our Duties
1. develop a conceptual design of a least-cost CNG distribution system and develop estimations of distribution costs from the trunk line to the consumption centers, differentiated by common costs and costs attributable to specific user category;
2. develop a conceptual design of a least-cost natural gas distribution system
3.  develop a practical and expedient plan and develop a detailed schedule for project implementation;
4.  prepare terms of reference for project design, implementation, construction supervision, and social and environmental impact monitoring;
5. design suitable organizational and administrative arrangements for the efficient management and supervision of project implementation and subsequent operations and maintenance of the facilities, including the requirements for consulting services;
6. design technical justification for the proposed Project, and compare the advantages and disadvantages of using CNG;
7. prepare a project framework, a procurement package list, and proposed project

implementation manual to ensure timely, effective, and efficient project

implementation.

1. 4. Quality Assurance Plan

Quality Policy

 All employees shall maintain high quality awareness, with the goal of continuous improvement.      All managers and supervisors have responsibility to continuously promote quality awareness for all employees.

2.QMS Purpose

The QMS provides a time-tested framework for guiding management review, design and document control, production, equipment procurement, subcontractor management, customer satisfaction, corrective and preventive action, and process improvement on all projects. The QMS provides standard work processes to assure staff across all functional groups understand their responsibilities, and understand how to hand off information to other functional groups, while maintaining compliance with customer requirements, company standards, and statutory regulations. QMS is to be applied on stages of all projects, including:  design, material supply, production, Inspection, delivery, testing/commissioning and warranty.

3. Case study

IVCO Conversion

1. 1. development

 

Development is based on Preliminary calculations for every vehicle

 

1. 2. Engine & Tanks

	Iveco Engine Old configuration	Cummins Engine New configuration
Power	194 kw  (264 HP)	235 kw (320HP)
Torque	930 Nm @ 1250 rpm	1200 Nm @ 1400 rpm
Displacement	5.9 litres	8.9 litres
Bore x Stroke	102 x 120 mm	114 x 144.5 mm
Fuel tank	300 L	8 x Tanks Type 1 CNG equivalent to 280 L (water )
Price for refuelling	1950 L.E	800 L.E
Range	250-300 km depending on load	300-350 km depending on load

 

 

 

 

 

 

 

• Tanks used is from Gastec imported from Italy manufactured by Faber cylinders, CNG Type 1 with one tank capacity 140 L.
• Conversion was done with the least components changes, same radiator and intercooler was used.
• ZF transmission Eco mat 4 was overhauled.