The thrust of the project is to manufacture and sale conversion kit to convert gen sets powered by IC engines from liquid fuel to gaseous fuels like compressed natural (CNG) or renewable natural (RNG) gas.
The main problem with a gaseous fueled versions of IC engines (both gasoline and Diesel) is the improper compression ratio, since the engines used as prototypes were designed and optimized for the use of liquid fuel.
The conversion kit as an external device should provide the correct stoichiometric air-fuel ratio for the engine without serious re-design of an IC engine-prototype. The air-fuel mixture should be compressed in a compound charging device (supercharger and turbocharger) to a certain pressure in order to compensate volumetric losses in engine cylinders and to provide close to optimal stoichiometric air-fuel ratio.
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CNG, RNG gaseous fuel powered gen sets
1. CNG, RNG gaseous fuel powered gen sets
NEXTAR CONSULT, Inc.
2911 Bayview Ave, #D101, Тoronto,
ON, M2K1E8, CANADA
Konstantin Starodetko, Ph.D.
+1 252 489 4415
cerg.head@s-charger.ca
cerg.head@gmail.com
http://s-charger.ca/
2. CNG and RNG as an ecologically friendly fuel
2
CNG as fuel is a fossil gas with a methane content of 70% and higher, which is compressed to 250Bar before being distributed and used.
RNG (biogas) as a fuel is a gas, obtained by methane fermentation of biomass. Methane decomposition of biomass occurs under the influence
of bacteria. Biogas contains 50-87% of methane, 13-50% of carbon dioxide, minor impurities of H2 and H2S. After cleaning the RNG (biogas)
from carbon dioxide, biomethane is obtained, which is a complete analog of CNG.
Why RNG (biogas) is environmentally friendly. It is considered that RNG (biogas) is environmentally friendly fuel because during the
process of their using (mainly burning) and producing, overall amount of CO2 and methane stays in equilibrium. RNG use does not increase the
overall level of harmful gases in the environment and stays at the "nature determined" level.
RNG (biogas) sources. There are a few main sources of renewable methane - dairies, landfills, waste products, such as wastewater, food waste
and manure. Also good source for RNG with high percentage of methane is poultry litter.
Current RNG (biogas) use. Many gas distribution companies, e.g. a well established Canadian FortisBC, buys 200,000 gigajoules of RNG
annually from four producers, two on-farm anaerobic digesters and two at landfills. Then the RNG is injected into FortisBC’s pipeline grid.
CNG – Compressed Natural Gas
RNG – Renewable Natural Gas
They both are the fossil and renewable versions of the same methane
Our business model
In opposite to the current RNG use we propose business model where RNG
delivers directly to the end-users for producing electricity in portable and
medium-sized gen sets.
3. Gaseous fueled IC engines
Painful point of the industry
3
parameter
Engine-
prototype
G80 Standby Generator
10 kW Fortress Standby
Generator System
Engine brand Vanguard™ Vanguard Vanguard
Fuel
Unleaded
gasoline. 87
octane/87 AKI
1. Liquid Propane Gas (LP)
2. Natural Gas (CNG or RNG)
1. Liquid Propane Gas (LP)
2. Natural Gas, (CNG or RNG)
Displacement
(cc)
570 570 570
rpm 3,600 3,000 3,600
Rated power,
kW
13.43
8 (LP)
6.5 (CNG, RNG)
10 (LP)
9 (CNG, RNG)
When switching from
liquid fuel (gasoline,
diesel) to gaseous fuel
(LPG, CNG, RNG),
there is a
significant drop
of IC engine
output power
4. Gaseous fueled IC engines
Ways of proper resolving the problem
4
Nextar Consult, Inc as an engineering company proposes to develop and mass produce together with our industry
partner
A CONVESRION KIT
consisting of
a driven air compressor
the corresponding mounting hardware for portable gen sets to gaseous fuels.
The main purpose of this conversion is to provide the optimal combustion process of the air-fuel mixture and to reduce
the level of harmful emissions.
In order to compensate evident volumetric losses and provide right stoichiometric air-fuel ratio it is necessary to supply
engine by the fresh air under certain pressure, 30-60% up to the ambient atmosphere.
5. Gen set main IC engines available on market
5
Honda GX series (GX 100 - GX 390)
General specification of the Honda GX series:
Engine displacement [cc]: 98 – 389
Power [kW] : 2.1 – 7.6
Torque [Nm]: 5.7 – 24.2
Operational frequency [rpm]: 3,600
Subaru EX series (EX 13 – EX 40)
General specification of the Subaru EX series:
Engine displacement [cc]: 126 – 404
Power [kW] : 3.2 – 10.3
Torque [Nm]: 8 – 24
Operational frequency [rpm]: 3,600/4,000
6. Small engines with improved gas exchange process
Supercharged gasoline engines with the displacement from 50cc to 350cc
6
Having created a well leveled supercharger, we tried many versions of
supercharger installation on target motorcycle, and our design is
based on using self-mounting fundamentals.
Any motorcycle operator who handles a simple screwdriver can
mount the supercharger kit.
Not a single part of the target motorcycle or its engine is needed to
be modified at all. When desired, the supercharger kit can be
dismounted and the motorcycle restored to its original appearance.
7. Small engines with improved gas exchange process
Supercharger for motorcycle engines – main parts and mounting hardware
7
Supercharger
The drive supercharger was developed for the target
engine and vehicle. A Rotor-Vane compressor of the
required capacity was designed for increasing the air supply
(up to 2 times) to an engine.
Our supercharger consists of 4 main units: air compressor,
boost storage tank, gas exchange unit, and drive pulley.
Units roles
1. Air compressor pumps and supercharges air.
2. Boost storage tank accumulates compressed air
preliminary supercharged and refrigerated by a
compressor to supply the engine with the correct
amount of air.
3. Gas exchange unit provides normal gas exchange
process between the engine, compressor and boost
storage tank.
4. Pulley to rotate the supercharger counterclockwise via
belt-drive assistance.
8. Small engines with improved gas exchange process
Supercharged Diesel engines with the displacement from 200cc to 990cc
8
Supercharger Kit improves a very common small diesel
engines with the engine displacement from 200cc up to
650cc.
The Supercharger (air compressor) as a main unit of the
Supercharger Kit supplies the naturally aspirated engine
with as much as additional 40% to 75% fresh air. Diesel
engine power and torque increase accordingly.
3D model and draft design of supercharger and
installation kit were developed for TMZ520D – a very
common small diesel engine with the following main
specifications:
1. single cylinder,
2. Bore/Stroke – 85mm/92mm,
3. engine displacement: – 520cc,
4. power – 9.5kW@3,600rpm.
9. Gen set power units based on a family of Diesel engines
Supercharged gaseous fueled Diesel engines for co-generation purposes
9
The main problem with the gaseous versions
of Diesel engines is the improper compression
ratio, since the engines used as prototypes
were designed and optimized for the use of
liquid fuel.
The air-gaseous fuel mixture should be
compressed in a compound charging device
(supercharger and turbocharger) in order to
compensate volumetric losses in engine
cylinders and to provide close to optimal
stoichiometric air-fuel ratio.
It is planning to establish mass manufacturing
of the commercially available conversion kits
to convert residential, non-portable Co-
generation power units powered by Diesel
engines with the displacement 5-12 l, to run
on 100% natural gas.
General layout of the
gen set powered by
4.8 l DEUTZ engine
equipped by compound
(supercharger and
turbocharger) charging
system.
10. Approval the “supercharging small engine” concept by the world engineering community
SAE conference report
10
A reliable way to supercharge small engines was
presented in our paper and report at Society of
Automotive Engineers (SAE) conference.
The paper and presentations were appreciated very
much by the conference participants and specifically
by executives of numerous motorcycle OEMs
including representatives of the Big Motorcycle Four.
Our publication and the following fruitful discussion
is accepted as project approval by the global
automotive engineering community.
11. Early Adopters 20 +
Pilot projects 2-3
Industry partners
1. Duryea Technologies (USA)
2. Alpha Manufacturing(USA)
Adaptation R&D
Nextar Consult Inc.
Lakehead University
Gen set end-users
Portable owners
Home Standby owners
Commercial standby
exploiters
Stage 1. Adaptation R&D. Development and
protection of the IP + engineering design of "a first
solution" level.
Parties:
Nextar Consult Inc.
Lakehead University
Industry Partner
Stage duration: 6 months
Funds required: $75,000
Stage 2. Development of TRL 8/9 conversion kit
prototype.Manufacturingof pre-production gen sets
samples (30+) for early adoptersand pilot projects.
Parties:
Nextar Consult Inc.
Lakehead University
Industry Partner
Stage duration: 12 months
Funds required: $275,000
Stage 3. Preparation mass manufacturing of the
conversionkits and gaseousgen sets . Searching for
clients and work with PO.
Parties:
Nextar Consult Inc.
Industry Partner
Strategic Partner
Stage duration: 8 months
Working capital needed: $200,000
Stage 4. Mass manufacturingphase. Sales gen sets
through distribution channels of a Strategic Partner.
ROI beginning phase.
Parties:
Nextar Consult, Inc.
Industry partner
Strategic Partner
Stage duration: up to 36 months
Working capital needed
Stages 2, 3 and 4 may overlap
grants, business loans
Principal + Interest
Strategic partnership
Nextar Consult
Strategic partner
Investment
Grants:Ontario Centres of Excellence
Funds: Go Fund You, LLC (USA)
Business loans: BDC (Canada)
Gaseous
gen sets
Superchargers and
mounting kits
5
3
8
Testing, Feedback,
Advertising
Pilot gaseous gen
sets samples
11 Business Model and Stages of the Project Development
Strategic
partner(s)
1.Gas distribution companies
Enbridge, Atco Gas, …
2. Gen set manufacturers
Briggs and Stratton,
Genrep, Generac,…
3. Other companies, involved
in green projects
Global Clean Energy
Holdings, …
7
PO & Cash
Flow
Gaseous
gen sets
PO & Cash
Flow
6
Nextar Consult, Inc
2
Conversion
kits
PO & Cash
Flow
1
Funds Conversion kits
4
12. Conclusions
12
For the successful development the market niche of portable gen sets powered by gaseous fuels Nextar Consult is
looking for the opportunities to establish cooperation with a number of large market players.
Gas distribution companies
We are looking for an opportunity to establish a strategic partnership with companies that are gas distributors and
gas suppliers.
Reasons for the cooperation of natural and bio gas supplier with Nextar Consult:
1. The client base of partner companies is increasing and there is an increase in the volume of gas sales.
2. Specialists of partner-companies bring additional revenue by providing installation and maintenance
services for our conversion kits or portable gaseous gen sets.
3. Partner companies receive commission income from the sales of our conversion kits and gen set.
OEM and multi brand gen set dealers
It is desirable for Nextar Consult to establish a strategic partnership with OEM and multi brand dealers of gen set
in order to prepare and market a new product - gaseous fuel powered portable gen sets with improved consumer
properties that will allow it successfully compete with those already available on the market.
13. Our Industry Partner - Duryea Technologies (PA, USA)
13
Duryea Technologies’ mission is to:
maximize the energy efficiency of motor
and generator-based applications.
Products include:
brushless alternators,
compressor drives for electric air conditioning,
hydraulic pump drives and other hybrid electric
technology for the fleet and consumer vehicles.
The Duryea Electric Supercharger and MODE Power
System for distributed energy projects are recent
developments.
Duryea Technologies ordered Nextar Consult to design a
low pressure compressor for the one of their applications.
14. Low pressure compressor for the Industry Partner
Engineering solution Nextar Consult
14
Main specifications:
• productivity – 150ccm per revolution;
• normal operational frequency – 5,500rpm;
• maximum frequency – 7,500rpm;
• pressure – not greater than 2 barg.
This compressor is an engineering scaling developed
by Nextar Consult and CERG - IAIT technology.
The technology of an advanced Vane compressor as
a motorcycle supercharger was approved by
international Automotive engineering society (SAE
article and report).
Working prototype of TRL 8/9 level is approved.
15. Low pressure compressor for the Industry Partner
Current status and problems
15
The following documents were signed:
• NDA
• a “hybrid” contract in which Nextar Consult acts simultaneously as an engineering and manufacturing company
• addition agreement to the contract
Business Development Bank of Canada approved business loan to fulfill the contract
Theoretical problems.
• It is required to carry out research work on the selection of materials to improve the durability and efficiency of
compressors
• It is necessary to involve universities, R&D Labs for conducting theoretical research on the selection of “right"
materials
Practical implementation.
• Development of blueprints. Qualified engineers and technologists are involved in the implementation
• Business-model: royalty as a part of the special price for 1-2 compressor's components which Nextar Consult
will manufacture and supply exclusively to the company D., Inc.
16. Company Resume
Nextar Consult is engaged in commercialization of a number of its own engineering, scientific and technical
developments.
Nextar Consult works in close collaboration with CERG (Combustion Engine Research Group) – non-formal group of
engineers, scientists and researchers under aegis of International Academy of Information Technologies, Minsk, Belarus.
Upon necessity Nextar Consult uses their scientific and engineering knowledge.
Nextar Consult has established contacts with executives of OEMs in the following industries:
Canada, USA and Europe:
Automotive
Motorcycles
IC engines
Compressors and Vacuum Pumps
China:
Motorcycles
Automotive
IC engines
16
17. Areas of Interests
17
Automotive and IC engine Industry
During the years, our team was engaged in the deep theoretical investigation of IC engine thermodynamic theory. The main purpose was to investigate the possibility of
creating an ICE that would work on a cycle, close to the Carnot cycle, namely, the temperature and pressure of exhaust gases should correspond to the temperature and
pressure of the ambient atmosphere. In other words, all the heat energy of a burnt fuel inside such an internal combustion engine must be completely converted into
mechanical work. We issued a lot of publications, patents, articles, reports, including in SAE. More information about our approaches and investigations in the field of cars
care popular article “Car Emission Scandal: Why Is It So Hard to Make Clean Diesel Cars” available here: http://bit.ly/sb2engine
Motorcycle and small IC engine Industry
Having revised world motorcycle market we discovered that there is no adequate proposal of supercharging and turbocharging means and devices for small engines. We
have done a lot of theoretical and practical work on the development of the methodology and approaches of supercharging means for vehicles powered by 50cc-125сс
4-stroke engines. We published articles and made reports, e.g. https://bit.ly/saepapr/ The results of work were approved by automotive engineering community. Also our
project was approved by the Chinese government for commercialization purposes, and they even awarded us by special grant. More details about current status of the
project “Supercharged Motorcycle ” are available here: https://bit.ly/suprbike
Other projects for Automotive and Motorcycle Industry
There are also a number of projects developed by us for the Automotive industry: “Internal combustion engine with 2-stroke/4-stroke switching during its operation”,
“Supercharged Two Stroke Engine”, “Supercharging Bolt-On Device for American V-Twin Motorcycle” and many others.
Conclusions
It is well known that Automotive Industry is a tough industry for any innovations coming from outside. Spending a lot of time, having got numerous contacts with
Automotive industry executives, passing through many negotiations with them, we came to the conclusion that if we have not got the working prototype of TLR5/6 level
we have not got any chances to implement our ideas to the Automotive industry at all.
Compressors and Vacuum Pumps Industry
That is why we came to the conclusion to apply our knowledge and experience to develop innovations for Compressors and Vacuum Pumps Industry. Our team has deep
theoretical and practical background in different kinds of compressors and pumps, especially centrifugal, piston, free piston and rotary Vane compressors. Our
communications with 40+ OEM of the industry showed a shorter path from creation of innovation to its commercialization in opposite to the Automotive Industry.
18. Konstantin Starodetko, Ph.D.
An experienced entrepreneur and scientist. Scientific Head, Managing Director of CERG
(Combustion Engine Research Group). Has extensive skills set encompassing business
management, technology implementation, development of networking and enterprise
application technologies. Holds over 60 publications, including patents and innovations, while
most of them are related to the advanced engine, power train and drive designs.
Nextar Consult Key Team Members
George Starodetko, M.Sc.
George E. Starodetko holds his Master degree in Engineering since 1987. He combines IC
engine and computer programming knowledge and skills and that makes him a unique
specialist for the entire group. He has performed all or the most of computations and
designed computer programs related to the group’s works. Material figures for many
publications were provided thanks to the programs designed by G. E. Starodetko. His own
publication list contains over ten items.
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