CNG Cylinder

What is CNG Cylinder

Compressed natural gas (CNG) is stored and transported in thick-walled pressurized tanks. These tanks are built in a long cylindrical shape with semi-spherical edges. The shape provides for the equal distribution of stresses from the pressure of the gas. CNG tanks are made of steel, aluminum, or composite materials.

Benefits of CNG Cylinder

Cost savings

CNG is much cheaper than petrol or diesel, so filling up your CNG cylinder will save you money on fuel.

Environmental benefits

CNG produces less pollution and emissions than traditional fuel options, making it a cleaner and more sustainable choice.

Better engine performance

CNG delivers improved power output and engine performance, resulting in a smoother drive with lower maintenance costs.

Safety

CNG cylinders are constructed with strong materials and are designed to withstand high pressure, making them extremely safe.

Availability

CNG is widely available in many parts of the world, making it an accessible and convenient fuel choice for many drivers.

Type 2 CNG Cylinder

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Type 1 CNG Cylinder

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Type 3 CNG Cylinder

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Type 4 CNG Cylinder

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Cylinder Types

This is an all metal cylinder made of steel. There is no covering, other than paint, on the outside of the cylinder. This is the most common type of cylinder.

This is a metal cylinder (steel or aluminum) with a partial wrapping that goes around the cylinder. The wrapping is usually made of glass, aramid or carbon, contained in an epoxy or polyester resin.

This type of cylinder is fully wrapped with the same kind of material used for the partial wrapping of a Type 2 cylinder. This type of cylinder has a metal liner usually aluminum.

This type of cylinder is fully wrapped with the same kind of material used for the partial wrapping of a Type 2 cylinder. This type of cylinder has a plastic liner.

Materials for CNG cylinders

Steel is the most suitable material for Type-1 CNG cylinder which made of all metallic & liner for Type-2 & 3 CNG cylinder also made of steel. Aluminum alloy is also an option for making liner for Type-3 CNG cylinders.
Since requirement of CNG cylinders is very stringent, such like working pressure 200 bar, Burst pressure min 340 bar, Max filling pressure 360 bar, Yield strength 840 Mpa, Tensile strength 940–1100 Mpa (Not more than 1100Mpa), Hardness should not exceed to 330BHN.

Historical Performance of CNG Tanks Cylinders Market

The market experienced steady growth at 8.2% CAGR during the historical period from 2018 to 2023. In the forecast period, the CNG tanks cylinders industry is set to register 6.7% CAGR.

There has been a recent increase in the popularity of compressed natural gas (CNG) as a vehicle fuel, particularly in commercial fleets and public transit. This is likely to increase the demand for CNG tanks cylinders for storing the gas for usage in cars and buses. The growth of CNG as a transportation fuel necessitates the development of refueling infrastructure. This infrastructure expansion would require a greater number of CNG tanks and cylinders.

CNG is seen as a way to reduce carbon emissions in transportation. This will stimulate demand for CNG tanks and cylinders to support the growing fleet of vehicles running on CNG. Governments offer incentives and subsidies to encourage the adoption of clean fuels. These policies can increase the demand for CNG-powered vehicles and, subsequently, for CNG tanks and cylinders.

Apart from transportation, CNG is used in different industrial processes and power generation. The demand for CNG tanks and cylinders in industrial applications is likely to rise as businesses seek clean energy solutions. The diversification of energy sources for transportation and industrial sectors through CNG can enhance energy security. Thereby driving the demand for CNG tanks and cylinders.

The growth of the CNG market might lead to innovations in tank and cylinder design, material, and manufacturing processes, further contributing to market demand. Geopolitical considerations can influence energy transitions. Countries with ample natural gas resources might encourage CNG adoption, boosting the demand for associated tanks and cylinders. As the energy transition spreads to more regions globally, the demand for CNG tanks and cylinders could see increased adoption in previously untapped markets.

How to Choose the Right CNG Storage Option

Choosing the right CNG storage option is essential for every application. When deciding which type is appropriate for the intended purpose, consider the following.

Safety

CNG transportation and storage can lead to a health hazard if the gas leaks. Always ensure the cylinders are stored well and protected from scratches and extreme heat.

Intended application

Different types of CNG tanks are appropriate for different applications. Use the right one that fits the purpose and the environment.

Government regulations

All CNG cylinder production must comply with government certifications. Follow the stipulated regulations for the country you are operating in to avoid problems.

Budget

Type 3 cylinders are the safest, but also the most expensive. It is recommended to choose Type 3 cylinders whenever cost is secondary to reliability and durability of cylinders in the field.

Precautions for use

1. The use and installation of compressed natural gas cylinders for automobiles shall comply with the provisions of relevant standards. They shall be refitted and repaired by a regular Refitting Factory with CNG automobile refitting qualification uniformly issued by authority institute, including the installation and disassembly of cylinders. It is strictly prohibited for unqualified units to refit, repair, disassemble and inspect gas cylinders. It is not allowed to repair, weld and repair gas cylinders. The original manufacturing mark and nameplate of gas cylinders shall be complete, the contents shall be complete and the steel seal shall be clear; Visually check that there is no permanent deformation on the surface of the cylinder, and the cylinder valve shall be intact.

2. Before and after filling, the safety status of gas cylinders and their accessories shall be inspected; The filled gas must be dehydrated, desulfurized and de oiled overpressure filling is strictly prohibited, the natural gas in the bottle shall not be exhausted, and the residual pressure above 0.1MPa shall be reserved; The working pressure of the gas cylinder is the limited filling pressure at the reference temperature (20 ℃), the filling pressure of the gas cylinder shall be adjusted according to the actual temperature during inflation, and the temperature compensation value shall be in accordance with the regulations of the inflation station. The new gas cylinder shall be vacuumized before the first inflation.

3. During the use of the gas cylinder, if it is found that the gas filling is inconsistent with the usual mileage, or the pressure in the gas cylinder decreases significantly after a period of exercise, it is necessary to be vigilant and check whether there is air leakage in time. In case of serious corrosion, damage or doubt on its safety, it shall be inspected in time.

4. The composite material layer of cylinder shall not be scratched, bumped or corroded by acid. The isolation rubber pad shall be used between the gas cylinder and the fastening belt and the installation support and shall be fastened well. The worn and deformed rubber pad shall be replaced in time. For wound gas cylinders, pay attention to the integrity of the winding layer, keep the surface clean and prevent chemical corrosion; Do not place hard objects in the trunk to avoid bumping and knocking the surface of the cylinder. Do not put heavy objects on the gas system pipeline.

5. It is forbidden to contact with grease, chemicals, hardware and other substances, scratch, bump, corrosion and extrusion. The gas cylinder shall not be close to the heat source and exposed to the sun. The distance from the open fire shall not be less than 10m, and the gas cylinder shall not be impacted.

6. The trunk where the gas cylinder is located shall use as few or no electrical components as possible. If it must be used, it shall also have explosion-proof performance and be installed away from the gas cylinder as far as possible.

7. The interfaces of gas cylinder, inflation valve and pressure reducer that are easy to leak shall be inspected frequently.

8. It is strictly prohibited to bake with fire when the cylinder valve is frozen. It is forbidden to heat the gas cylinder with a heat source exceeding 40 ℃; It is forbidden to conduct electric welding and arc striking on the gas cylinder.

9. The isolation rubber pad shall be used between the gas cylinder, the fastening belt and the mounting bracket and shall be fastened well. The worn and deformed rubber pad shall be replaced in time.

10. In case of failure of safety accessories during the use of gas cylinders: cylinder valve, fusible alloy plug, gas leakage cylinder valve switch failure, etc., first move the vehicle to a safe place, set a warning line, and send it to the cylinder inspection unit or natural gas vehicle repair shop for treatment after the compressed natural gas is released. It is forbidden to repair or replace accessories by yourself.

11. Inspection shall be carried out at any time in case of the following accidents:

Accidents, gas cylinders or vehicles on fire, impact, overheating or damage by other means
Damaged or contaminated by chemicals
Cylinder overpressure or damage by hard objects and vehicles
Other abnormal conditions, including natural gas pungent smell (confirmed as non pipeline leakage), unexplained gas pressure drop, abnormal sound and signs of loose installation
Cylinders stored or out of service for more than one inspection cycle shall be inspected before use
Other abnormal conditions occur

Why are exhaust fumes so small in CNG-run vehicles

Exhaust fumes from compressed natural gas (CNG)-run vehicles are relatively small compared to vehicles powered by gasoline or diesel for several reasons:
Cleaner Fuel

CNG is a cleaner-burning fuel compared to gasoline or diesel. It primarily consists of methane, which has a lower carbon content and fewer impurities. When CNG is burned in the engine, it produces fewer harmful emissions such as carbon monoxide (CO), nitrogen oxides (NOx), and particulate matter (PM).

Complete Combustion

CNG has a high octane rating, which means it can be burned more efficiently and completely in the engine. This results in a more complete combustion process, reducing the formation of unburned hydrocarbons and other pollutants that contribute to exhaust fumes.

Lower Sulfur Content

CNG has a very low sulfur content compared to conventional fuels like gasoline and diesel. Sulfur in fuel can contribute to the formation of sulfur dioxide (SO2) emissions, which are harmful to the environment and human health. The low sulfur content in CNG helps reduce the emission of SO2.

Advanced Engine Technology

CNG-run vehicles are equipped with advanced engine technology and emission control systems. These systems, such as catalytic converters and oxygen sensors, help further reduce emissions by converting harmful pollutants into less harmful substances or monitoring the combustion process for optimal efficiency.

Regulatory Standards

CNG-run vehicles are subject to strict emission standards set by regulatory authorities. These standards require vehicles to meet specific emission limits for pollutants such as CO, NOx, and PM. Manufacturers design CNG vehicles to comply with these standards, resulting in lower exhaust emissions.

The general steps involved in converting a diesel vehicle to CNG

A CNG conversion kit needs to be installed in the vehicle. This kit includes components such as CNG storage cylinders, pressure regulators, fuel lines, and injectors. The conversion kit is designed to safely store and deliver CNG to the engine.

The existing diesel fuel system needs to be modified or replaced to accommodate the CNG fuel system. This may involve installing new fuel lines, injectors, and pressure regulators specific to CNG.

The engine may require modifications to optimize its performance with CNG. This can include adjusting the ignition timing, installing new spark plugs, and making changes to the air-fuel mixture.

The engine control unit (ECU) needs to be reprogrammed or calibrated to work with the CNG system. This ensures that the engine operates efficiently and safely with CNG as the fuel.

Proper safety measures need to be implemented during the conversion process. This includes installing safety devices such as pressure relief valves and ensuring that the CNG system meets all safety standards and regulations.

It's important to note that converting a diesel vehicle to CNG should be done by qualified professionals who have experience in CNG conversions. Additionally, the conversion process may vary depending on the specific vehicle and its engine configuration.

Does CNG have any harmful effect on the engine

CNG (compressed natural gas) generally does not have any harmful effects on the engine when used as a fuel in vehicles. In fact, there are several advantages of using CNG as a fuel, including lower emissions and reduced engine wear. However, there are a few considerations to keep in mind:

Combustion Characteristics

CNG has different combustion characteristics compared to gasoline or diesel. It has a higher octane rating, which means it can withstand higher compression ratios without causing knocking or pre-ignition. This can be beneficial for the engine as it allows for more efficient combustion. However, the engine may need to be modified or calibrated to optimize its performance with CNG.

Lubrication

CNG has a lower lubricity compared to gasoline or diesel. This means that it may not provide the same level of lubrication to certain engine components, such as valves and valve seats. To address this, some CNG conversion kits include additives or lubricants to ensure proper lubrication and prevent excessive wear.

Maintenance

CNG-run vehicles may require specific maintenance procedures and intervals. This can include regular inspections of the CNG system, such as checking for leaks, ensuring proper pressure regulation, and inspecting the CNG storage cylinders. It is important to follow the manufacturer's guidelines and recommendations for maintenance to ensure the longevity and performance of the engine.

Conversion Quality

The quality of the CNG conversion and installation is crucial to ensure the proper functioning of the engine. It is important to have the conversion performed by qualified professionals who have experience in CNG conversions. A well-executed conversion will minimize any potential negative effects on the engine.

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FAQ

Q: What is CNG?

A: Ans. CNG stands for compressed natural gas. It is gaseous fuel and is a mixture of hydrocarbons mainly Methane. For use in Automobiles as fuel, it is compressed to a pressure of 200-250 Kg/cm² to enhance the vehicle on-board storage capacity.

Q: Is CNG safe?

A: Ans. Yes, it is safe. The properties of CNG make it a safe fuel. It is lighter than air, so in case of a leak it just rises up and disperses into the atmosphere. Besides, a high auto-ignition temperature of 540 degrees centigrade as against petrol’s 360 degrees centigrade, makes it a safe fuel. Also, in case of a leak, if CNG’s concentration in the air is less than 5% and more than 15%, the gas will not burn even in the presence of a spark.

Q: Are factory fitted CNG vehicles available?

A: Ans. Yes. All major commercial vehicle manufacturers like TATA, Mahindra, Maruthi Suzuki, Eicher, SML etc. have CNG variants of their popular models. Also, many passenger car manufacturers like Maruti, TATA, Hyundai etc. have factory-fitted car models available.

Q: What is involved in converting a vehicle to a CNG-friendly one?

A: Ans. All spark-ignited engines can be converted to CNG, but a specially designed conversion kit is required for the purpose. The kit consists of a cylinder to be fixed in the boot of the car and other equipment to allow gas flow into the engine.

Q: Can a car, fitted with CNG conversion kit, run on Petrol after its CNG gets over?

A: Ans. Yes, after conversion to CNG the vehicle can run on petrol whenever desired simply by flicking a switch on the dashboard.

Q: What is the difference in the tank sizes of CNG and LPG as vehicle fuel is concerned?

A: Ans. CNG storage tank is 3 times of LPG storage tank for the same volume.

Q: How long it will take to fill a CNG vehicle?

A: Ans. For 3/4 wheelers it will take 2 to 3 minutes and for buses with capacity of 50 kg will take 10 to 15 minutes based on capacity.

Q: What are the dimensions and weight of a CNG cylinder?

A: Ans. CNG cylinders are manufactured from a special steel alloy and are seamless in construction. Their compact size allows them to easily fit even in a small car. An empty CNG cylinder with a 50 litre-water-carrying capacity weighs 48 kg, with a length of 835 mm and a diameter of 316 mm. The 50 litre capacity cylinder is the one most regularly used; cylinders with 45 litre, 55 litre, 60 litre and 65 litre capacity are used as well.

Q: What is the capacity of a cylinder, and mileage from one fill?

A: Ans. Under city road conditions and may vary from vehicle to vehicle and driving habits.

Q: What is the pressure of CNG in a cylinder?

A: Ans. CNG cylinders are designed and built in such a way so as to withstand high pressure. The maximum pressure in a CNG cylinder is up to 200 kg/cm2 (g) (about 2840 pounds per square inch (gauge) or psi[g]). CNG cylinders are safe as they are manufactured as per specific requirements and tested before use, in accordance with international specifications and standards and they are duly approved by Chief Controller of Explosives. Moreover, these have been provided with a ‘safety burst disc’ such that in case of inadvertent high-pressure/high temperature at the time of filling or at any other time, this disc is ruptured and pressure released.

Q: How much will be the saving after conversion to CNG?

A: Ans. The fuel bill on the basis of average running of vehicle is reduced by 30-40 percent approximately after conversion of CNG at the present price of CNG in Hyderabad/Vijayawada/Kakinada.

Q: Does CNG kit require servicing?

A: Ans. CNG kit is safe and simple. It gives years of trouble free operation. It doesn’t require frequent servicing. Just as for all other fuels, it is advised to have routine services. An authorized person should be consulted for service. As per Gas Cylinder Rules, 1981, the cylinder should undergo hydro-stretch testing every 3 years to check pressure tolerance.

Q: Does CNG have any harmful effect on the engine?

A: Ans. Owing to CNG’s distinct features, it does not contaminate or dilute crankcase oil, giving a new lease of life to the engine. The absence of any lead content in CNG helps avoid lead fouling of plugs, thereby enhancing plug life. One of the important benefits of CNG is that upon entering the engine in the form of a gas (and not as a spray or mist like other fuels), it doesn’t disturb the presence of lubricating oil in the engine, and reduces chances of wear and tear.

Q: Can a diesel vehicle be converted to CNG?

A: Ans. Yes, a diesel vehicle can be converted to run on CNG, but the conversion cost is higher than the conversion of petrol vehicles and under the current technology it cannot run on dual fuel mode.

Q: Why are exhaust fumes so small in CNG-run vehicles?

A: Ans. CNG is an environment friendly fuel. The natural gas is mainly composed of methane and its exhaust emissions consist of water vapors and a small fraction of carbon monoxide. The absence of carbon and other particulates result in negligible amount of harmful elements in exhaust fumes.

Q: How does large-scale CNG usage benefit the country?

A: Ans. CNG emits less carbon dioxide and other pollutants as compared to liquid fuels. Thus, CNG contributes in lowering air pollution, also helps in improving the Balance of Payments by acting as a substitute for imported liquid fuels, provides more business and job opportunities with the opening up of a new sector, and being competitively priced, it appeases motorists.

Q: Where is the tank placed in car?

A: Ans. The CNG cylinder is fixed in the luggage space of your car. It is fastened with a metal strap so that it does not move while the car is running. As per BIS code, it has to be a permanently fitted tank and should be integral part of vehicle (as per BIS 14899 for fuel tank container and as per LPG/CNG Control order).

Q: Can a diesel vehicle be converted to CNG ?

Q: Why are exhaust fumes so small in CNG-run vehicles ?

A: Ans. CNG is an environment friendly fuel. The natural gas is mainly composed of methane and its exhaust emissions consist of water vapours and a small fraction of carbon monoxide. The absence of carbon and other particulates result in negligible amount of harmful elements in exhaust fumes.

Q: How does large-scale CNG usage benefit the country ?

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Type 4 CNG Cylinder