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Integrated reducer-filter-injector unit for natural gas engines

Periodic Reporting for period 1 - InjectoReducer (Integrated reducer-filter-injector unit for natural gas engines)

Reporting period: 2016-10-01 to 2017-03-31

Converting conventionally fuelled vehicles to run on cheaper and more sustainable fuel alternatives like Liquefied Petroleum Gas (LPG) and Compressed Natural Gas (CNG) has the ability to make an immediate-to-medium-term impact towards creating cities with minimum emissions. This requires modifying the fuel injection system to use the alternative fuels via a conversion kit. Unfortunately adoption rates are not as high as would be hoped to acheive the benefits this mature technology offers. This is due, in part, to the high cost of the conversions; upto 15% of the new vehicle's value. This is because the time required to do the installation and the high cost of labour. At Rail, we have identified this and envisaged a novel approach to conversion kits manufacture. Designing a system optimised for installation, we have developed a patented an innovation that halve installation time, reducing the acquisition cost of conversion by 50%. Our solution, InjectoReducer, provides an enabling technology towards meeting the rule requirement for Euro 4-6 Regulation Compliance. It offers reduced installation costs, increased energy efficiency, reduced emissions, increased ease and speed of installation as well as servicing. As such, InjectoReducer has been developed in line with Europe's transport and mobility goals for the year 2050. Our solution will be an enabling innovation towards ridding cities of conventionally-fuelled cars in cities as well as reducing 60% of transport emissions by the middle of the century. The objective of this project is to prepare a range of industrially ready InjectoReducer variants for LPG and CNG, for 1-2 cylinder and 3-4 cylinder engines, in the Original Equipment Manufacturers (OEM) and Aftermarket fitment market, which will be distributed through our growing, global distribution network.
At Rail SRL we have been undertaking a Feasibility Study during the last 6 months, in order to analyse and develop our project.
On the technical side, we have been working on reducing the size of the original 3 and 4 cylinders LPG prototype, for an even easier installation in the engine bay. We have progressed in developing a prototype CNG variant for 1 and 2 cylinder engines for OEM application and we have identified the need for a third variant; CNG for 3 and 4 cylinder engines. We have also analysed our supply chain with respect to our plans for starting industrial production of InjectoReducer.
We have prepared an Execution Plan for the project, covering tasks such as planning, budget, risk analysis and organization. At a commercial level we have identified, and studied in detail, our target markets in order to prepare our marketing strategy. And we have performed a Freedom-to-Operate analysis, which is required to check and validate the innovation of our product. And lastly, we have prepared financial projections in order to evaluate the return on investment of the project.
InjectoReducer is the first “optimised-for-installation” solution for the conversion of petrol cars to clean-burning, gas alternatives LPG and CNG. This reduces significantly the cost of conversion for car owners, giving them a greater economic incentive to switch to these cheaper, yet cleaner, fuels. For installers, they are able to increase their productivity, performing more conversions per day. For government authorities interested in incentivising car owners to switch to gas through financial subsidies, the reduced installation cost of InjectoReducer will achieve greater impact for lower investment.
For society as a whole, particularly cities and heavily urbanised areas, InjectoReducer, based in mature gas fuel technology, will have an immediate-to-medium-terms impact, unlike emerging hybrid and electric alternatives, on reducing the carbon footprint of the existing vehicle fleet and polluting exhaust emissions.