NaturaFill: Fuel for Thought

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1 NaturaFill: Fuel for Thought Project Brief Grand Rapids, MI Engineering Senior Design Project Team 13 Team Members: Karl Bratt Jonathan Haines Andrew Hall Brandon Koster

2 I. Overview A. Team Jonathan Haines Karl Bratt Senior studying Mechanical Engineering with a Business minor Hometown: Racine, WI Senior studying Mechanical Engineering with a Mathematics minor Hometown: East Brunswick, NJ

Andrew Hall Senior studying Electrical and Computer Engineering Hometown: Mc Cordsville, IN Brandon Koster Senior studying Mechanical Engineering with a Business minor Hometown: Visalia, CA B.

This increase in supply has forced the price of natural gas down 70% over the last five years.1 The current pipeline natural gas of about $3.80 per million BTU2 has an energy equivalent price of $0.

3 Andrew Hall Senior studying Electrical and Computer Engineering Hometown: Mc Cordsville, IN Brandon Koster Senior studying Mechanical Engineering with a Business minor Hometown: Visalia, CA B. Background As a result of new shale gas discoveries and new drilling technology the supply of natural gas in the United States has increased substantially. This increase in supply has forced the price of natural gas down 70% over the last five years.1 The current pipeline natural gas of about $3.80 per million BTU2 has an energy equivalent price of $0.42 per gasoline gallon equivalent (GGE)3. Natural gas is also a cleaner burning fuel, compared to gasoline it has 70% less carbon monoxide (CO) emissions, 87% less nitrogen oxide (NOx) emissions and almost 20% less carbon dioxide (CO2) emissions. The biggest hurdle to widespread consumer adoption of natural gas vehicles is the lack of a fueling network compared to gasoline fueling stations. The ability to fuel a vehicle at home side- steps waiting for an adequate fueling network to be built out. Other home refueling units are not being adopted because of their high cost around $5000 minimum and their reliability issues. Both of the team s mentors have expressed that a lower cost home refueling unit would be a massive catalyst for consumer adoption of natural gas vehicles. 1 prices/natural- gas/5- year/ price.net/ 3 2

4 C. Purpose The purpose of our project is to design, build, and test a natural gas home refueling appliance that is lower cost and more reliable than appliances currently on the market. D. Objectives Performance Objectives $1000 cost to manufacture 0.5 GGE per hour fill rate 60 db noise from 10 ft away Qualitative Objectives Safe for use inside a residential garage As simple and easy to use as a gas pump Aesthetically pleasing design II. Current Status A. Mentor Communication Jimmy Moredyk Moredyk Energy, Inc. Mr. Moredyk is VP of Operations and Co- founder of Moredyk Energy, the only company based in West Michigan that offers compressed natural gas (CNG) vehicle conversions and refueling systems. He will serve as a resource regarding the natural gas vehicle industry at large. In the team s first meeting with him, he expressed excitement about the idea of a lower cost fueling appliance and noted that if our unit meet our performance specifications he would sell many, many units even if the price were as high as $3000. The team is keeping in communication with him via and would like to schedule another meeting in November to go over our project status. Lee Otto CNGPUMP Mr. Otto is the founder of CNGPUMP, a company exploring new natural gas compression technologies. He will serve as a resource regarding natural gas compression technology. In the team s first conference call with him he was also very excited about the project and gave the team many of good ideas to consider and also guidance regarding problems he has had in the past and how to avoid them while designing our unit. The team is keeping in communication with him via and would

5 like to schedule another conference call in November to go over the progress that the team is making.

B. Design Alternatives 1. Hydraulic/Pneumatic Double Action Cylinder Compressor http://chemacinc.com/?

for unbalance issues Lower operating speed Potential Disadvantages Needs hydraulic pump or air compressor to operate More potential for

6 B. Design Alternatives 1. Hydraulic/Pneumatic Double Action Cylinder Compressor Potential Advantages More proven for natural gas compression applications Much fewer complex linkages Much less potential for unbalance issues Lower operating speed Potential Disadvantages Needs hydraulic pump or air compressor to operate More potential for excessive noise Needs an additional cylinder for more than two stages 2. Wobble Plate Compressor swansea.co.uk/aircon/images/013_compressorwobbleplate.jpg

7 Potential Advantages Does not need hydraulic pump or air compressor to operate Less noise potential All stages can be milled into the same part Potential Disadvantages Less proven for natural gas compression operations Many more complex linkages Much more potential for unbalance issues Higher operating speed III. Major Obstacles Going Forward A. Appliance Design Compression and Heat Transfer Modeling After the initial calculations using EES, which assumed an ideal gas, the team now has to move on the more complex modeling. The team plans on using Autodesk Simulation CFD to do these simulations because it appears to be the software package best suited to model compression that results in a high amount of heat transfer. This will be an obstacle for the team because they have never used this software package before and will need to learn in well in order to create a good model. B. Prototype Construction Seal Technology The system requires tight seals to enable compression up to 3600psi. When natural gas is compressed more than 3000psi, this seal tightness is most crucial. Part of what makes this seal effective is a mirror finish to the inside of the cylinders. One possibility is to incorporate opposing C- band rings to form a seal between the piston and cylinder. Another consideration incorporates the use of oil to further lubricate the shaft. Components / Parts Due to the complexity of our project, parts and components tend to be expensive. In overcoming this obstacle, our team hopes to gather corporate donations for the more complex components. C. Prototype Testing Natural Gas Substitute Due to the flammable nature of natural gas, the college has requested that we leak test our devise with a non- combustible gas of relatively similar properties to natural gas.

FINAL DESIGN REPORT NATURAFILL: FUEL FOR THOUGHT. Team 13 Karl Bratt Jonathan Haines Brandon Koster

FINAL DESIGN REPORT NATURAFILL: FUEL FOR THOUGHT Team 13 Karl Bratt Jonathan Haines Brandon Koster NATURAFILL 2013, TEAM 13, CALVIN COLLEGE LAST UPDATED: 5/15/2014 i 2014, Karl Bratt, Jonathan Haines,