(Nomination for 2011 AUREA Award): MAZ-BIK 203 CNG - Low-floor city bus powered by natural gas

In association with MAZ plant from Belarus, Kragujevac-based company Vulovic has produced the first low-floor city bus powered by natural gas. About EUR 2 million have so far been invested in the procurement of land, equipping of production units, purchase of technologies, staff training, and launching of the first bus. This company is the only manufacturer of such vehicles in Serbia. The specific characteristic of this bus is reflected in an innovative use of the system of connected gas tanks made of light composite materials. The author of all technical-technological solutions for the low-floor bus is the expert team of Vulovic Transport. It should be mentioned that the engineers from the Military Technical Institute in Belgrade also worked on the project.

The use of tanks made of light composite materials (aluminum and polyester instead of steel) and an innovative system of their connecting solved numerous problems concerning the safety of the vehicle, protection of gas cylinders from physical damages, radiation safety, the vehicle’s weight, as well as the load capacity of the bus body.

In addition to a modern product design and excellent technical characteristics, domestic methane-powered bus is also economically and ecologically feasible for potential buyers. Namely, Maz-Bik 203 CNG model is about 2.5 times cheaper than foreign buses of the kind and it consumes 60% less fuel per 100 km than buses with diesel engines. Also, a bus powered by natural gas reduces harmful influence, such as the emission of nitrogen oxides, smoke, etc., by about 60%. The new model has a platform, display and voice machine so that passengers know at any moment in what part of the city they are and where the next stop is.

The low-floor city bus with Euro 6 standard is manufactured in association with Belarus company Maz, which does not have such model in its offer. The agreed cooperation will provide the partner from Kragujevac with the access to the dealer network of the Minsk-based manufacturer, which has entrusted Vulovic Transport with the operations in the markets of Austria, Slovenia, Italy, Hungary, Romania, Bulgaria, Serbia, and former Yugoslav republics.



INNOVATION

At its own production units in Kragujevac, the company Vulovic Transport has produced the first Serbian low-floor city bus Maz-Bik (short for Bus Industry Kragujevac) 203 CNG powered by compressed natural gas. This company is the only manufacturer of such vehicles in Serbia. The specific characteristic of this bus is reflected in an innovative use of the system of connected gas tanks made of light composite materials. The author of all technical-technological solutions for the low-floor bus is the expert team of Vulovic Transport, while the engineers from the Military Technical Institute in Belgrade also worked on the project.

The use of tanks made of light composite materials (aluminum and polyester instead of steel) and an innovative system of their connecting solved numerous problems concerning the safety of the vehicle, protection of gas cylinders from physical damages, radiation safety, the vehicle’s weight, as well as the load capacity of the bus body. The use of aluminum and polyester in the making of bus roof structure and gas tank covers additionally rationalizes production and makes the aerodynamically shaped bus body even lighter, resulting in additional reduction of fuel consumption.

The expert team of Vulovic Transport has developed an original method to fasten gas tank to the bus roof by welding cylinder holder to the roof grid and then securing cylinders to the holder by tightening screws. In this way, gas installations are completely separated from the passenger space, which significantly increases the safety of passengers. The fill cap for filling the tank with gas is located at a safe distance from the engine, that is, from the source of heat. There are also manual valves and control devices, which help make tanking, the most risky operation on the vehicle, completely safe. The use of tanks made of light composite materials, which are 2-2.5 times lighter than steel ones, significantly reduces the bus’ weight, as well as load on the bus body, so that no additional reinforcements are necessary.

Previous attempts at increasing the use of CNG buses pointed to numerous weaknesses. Namely, buses that are currently in use are mainly based on older technologies so that oil consumption is bigger, the vehicle’s weight is larger, there are problems with sealing and resistance to the influence of methane, which is a chemically highly aggresive compound, while engines are mainly former diesel engines. Gas is stored in tanks under the pressre of over 200 bar in solid and heavy cylinders, which are, due to shortage of space, placed on the bus roof.

Maz Bik-203 CNG bus is powered by natural gas compressed to the pressure of 200 bar, which requires installation of an additional system and gas tank. With full tank, this bus can travel over 500 km (which is more than the average daily kilometrage in the city transport – 280-300 km). The bus uses composite gas cylinders of 1176 l for 230 cubic meters of CNG, which are made by DYNETEK.

The company Vulovic cooperates with the most famous foreign and domestic manufacturers of car components: MAZ Minsk (chassis), Cummins (engine), Allison (transmission) Dynetek Europe Gmbh (gas tanks), Swagelok (valves and pipes), Weh (control board), Severin (gas detection system), DP 21.Oktobar from Kragujevac, Sloga AD Nova Varos, Prva Petoletka – Trstenik, Hidraulika Kurelja- Proleter, MB Mak Cacak, COBEST Mladenovac, Livnica FAP Priboj, Srboauto- Belgrade....).

SOCIAL UTILITY

With the use of CNG as fuel, an excellent progress is made, not only from the aspect of advanced technical solutions, but also when it comes to safety. Gas tanks on the vehicle are a perfect combination of small weight and high safety. For the radius of movement of the new ecological vehicle of over 500 km, the weight of full gas tank does not exceed 700 kg.

In addition to the economic feasibility of the use of CNG buses in the public city transport, it should be again mentioned that CNG buses contribute to the preservation of people’s health to a great extent, mainly because of the following ecological advantages:

· Over 98% lower emission of non-methane hydrocarbons (NMHC)

· Over 90% lower emission of nitrogen oxides (NOx)

· Over 80% smaller influence on the ozone layer

· Reduced emission of sulfur compounds in the products of combustion

· Lower emission of fumes in the process of filling the tank with gaseous fuel

· Lower level of noise is produced by CNG vehicles than by diesel vehicles (CNG buses produce 15 decibel lower level of noise than diesel vehicles, meaning that the rolling stock of, let’s say, 50 CNG buses produces 750 decibel lower level of noise than the same number of diesel buses at any moment)

· Advantages of the use of CNG (Compressed Natural Gas) primarily lie in lower price of fuel and better ecological characteristics of the vehicle.

Other advantages are: greater energy independence of the available oil reserves, creation of new jobs in the natural gas distribution sector, automotive industry and related branches...



FINANCIAL POTENTIAL

The first Serbian low-floor city bus powered by compressed natural gas – Maz-Bik 203 CNG, assembled at the production units of Kragujevac-based company Vulovic Transport, had its premiere at Beotruck 2010. This bus drew the interest of visitors of this international motor show because it was also the only bus with the engine that meets EURO 6 standards. A special interest was expressed by private transportation companies from Belgrade, which decided to buy 32 CNG buses after the promotion of this model at Beotruck 2010.

The buyers of Maz-Bik in 2010 were private transportation companies from Belgrade-based Beobus Association: GP Unacop doo - 10 MAZ BIK 203 CNG buses, Kosava prevoz doo – 12 MAZ BIK 203 CNG buses, B@B Linea doo - 5 MAZ BIK 203 CNG buses, Knezevic trans doo – 5 MAZ BIK 203 CNG buses. With the government’s subventions in the amount of 30% of the bus’ manufacturing price, Vulovic Transport sold these buses at the price of about EUR 140,000 per bus (depending on the additional equipment), which is a very favorable price for a CNG bus if we know that the competitive models cost over EUR 260,000.

The bus produced by Vulovic Transport is fully supported by the Government of Serbia, which grants subventions to domestic bus manufacturers in the amount of 30% of the manufacturing price, thus making the placement of these buses much easier.

By purchasing domestic buses powered by compressed natural gas, buyers get vehicles powered by cheaper type of fuel and with better ecological characteristics. It should be mentioned that this vehicle consumes about 80% less gas. Savings made on the basis of the difference in prices of diesel fuel and natural gas may positively affect not only the owners of CNG buses but also citizens because, if the rolling stock of all public and city transport companies come to comprise these buses, the price of bus tickets will drop as well.

Vulovic Transport’s advantages over the foreign competitors are: reliability, low maintenance costs, and longer life of the vehicle and engine. TEDOM and RABA engines have just been developed, while the production of CUMMINS engines started last century. ZF axles are much reliable and guarantee higher safety and better comfort of the vehicle passengers. Thanks to ALLISON transmission, this vehicle is more dynamic, which positively affects the comfort of passengers and fuel consumption. Unlike competitive models, this drive system, comprising Cummins engine, Allison transmission system and ZF drive axle, is almost 50% lighter than other concepts, which additionally reduces the bus’ weight, as well as fuel consumption.

Market- The most important potential buyers of Vulovic’s buses are: public and private city transport companies; bus, truck and automobile manufacturers; transportation companies; construction companies; taxi associations. Based on the analysis of the bus sales in the last three years in the markets of Serbia, Bosnia and Herzegovina, and Croatia, the conclusion is that there is a constant tendency of the growth of bus sales. The average sales growth rate amounts to about 13% in the market of Serbia, about 7.3% in Bosnia and Herzegovina, and 10.5% in the market of Croatia.

In the first three years of operations (2010-2012), target buyers are public and private city transport companies in the market of Serbia, that is, companies in Kragujevac, Novi Sad and Belgrade. In the fourth and the fifth year of operations, CNG buses will be offered to companies in Nis, Subotica, Sombor and Pancevo.

Having in mind the contemporary shape and design, technical characteristics and economic and ecological feasibility of these buses, a big success should be expected in all markets entrusted to Vulovic Transport by MAZ. These markets are: Croatia, Bosnia and Herzegovina, Montenegro, Albania, Macedonia, Bulgaria, Romania, and certain countries in the European Union: Hungary, Austria, Slovenia, and Italy.

According to the analyses performed by Vulovic Transport, CNG buses have excellent sales prospects in Serbia, especially in the public sector.

City transport companies in Belgrade and Novi Sad were using the prototype of Maz Bik 203 CNG bus for one month and agreed that it had given excellent results in terms of cost-efficiency and reduction of emission of harmful exhaust gases that is undoubtedly the biggest in the cities like Belgrade and Novi Sad.

The characteristics of Maz-Bik 203 CNG bus are as follows:

• Capacity to respond to the buyer’s specific requests – because it is characterized by the possibility, as well as the capacity of the team of constructors to respond to all specific requests of buyers in terms of additional equipment, interior and exterior of the vehicle.
• Adaptability – all activities aimed at hiring, that is, including as many business partners as possible in the production cycle are carried out in order to avoid and eliminate turbulence in the market, disturbances in the operations and dependence on key suppliers.
• Efficiency – because it is constructed and produced “in the right way“, with all necessary performances, attestations, certificates and safety requirements for this type of product and having in mind its purpose, which is the transport of passengers.
• Effectiveness – because it is the “right product – right thing“, considering all its energy, economic and ecological values.

About the company - When it was formed in 2003, Vulovic Transport was a bus transportation company based in Kragujevac. People at the company later came to the idea to have all the buses in their rolling stock manufactured by Belarus-based Maz. The next phase was production of bus and truck components with Vulovic Transport’s own VIN code. The Kragujevac-based company then invested in new production facilities, production, repair service, technology, and employed 105 people.

In addition to producing new buses powered by natural gas, Vulovic Transport also repairs the used buses with engines powered by D2 diesel fuel and installs systems for the use of CNG gas in the ratio 30:70 in favor of CNG gas. The company's product portfolio includes large number of different models of trucks, buses, trailers and semi-trailers.

Belarus Maz is a multinational company with a ramified retail-service network all around the world. The manufacturer from Minsk annually sells 25,000 trucks and 2,500 buses, and it has 23,000 employees. The company manufactures buses, trucks and military vehicles.

If MAZ-BIK 203 CNG bus is your favorite for the innovative investment of the year, you can cast a vote for this nominee on the official website Aurea 2011.

Vulović transport d.o.o. Kragujevac

eKapija.com Beograd

Vojnotehnički institut VTI Beograd

Industrija kamiona MAZ Minsk Belorusija

Dynetek Europe GmbH Ratingen

West Balkans Machinery doo Zemun (Beograd)

Allison Transmission, Inc.Indianapolis Indiana

Swagelok Solon Ohio U.S.

WEH GmbH Germany

Severin Elektrogeräte GmbH Germany

21. Oktobar Kragujevac

Sloga a.d. Nova Varoš

Prva Petoletka a.d. Trstenik

Hidraulika Kurelja Proleter Kragujevac

M.B.-Mak Čačak

Cobest a.d. Mladenovac

FAP Korporacija a.d. Priboj

Srboauto d.o.o. Beograd

Beobus d.o.o. Beograd

Unacop Zemun

Košava prevoz d.o.o. Beograd

B & B Linea Beograd

Knežević-trans d.o.o. Beograd

Vlada Republike Srbije

JKP GSP Beograd

JGSP Novi Sad