Natural Gas as a Transportation Fuel March 2013
GTI s Current NGV RD&D Program is Robust > Vehicles and On-Board Storage Develop/demonstrate new engines and vehicles > Cummins ISX12 G, other high-efficiency, lowemission engines New vehicle platforms (e.g., heavy-duty hybrids) Components: NGV storage advances (CNG, LNG, ANG) and related fuel delivery devices > Infrastructure Demonstrate and deploy new products and stations Components: new compressors, dispensing, fuel quality, small fleet and home fueling New solutions to reduce cost, position gas industry Cummins ISX 12 G Advanced Storage Navistar MaxxForce Infrastructure Advancements 2
ADVANCED NGV ENGINE Ultra-Low Emission, 12-Liter Heavy-Duty Natural Gas Engine Development Project Objectives > Design and develop an engine for Emission Solutions Inc., suited for a variety of applications in Class 7 and 8 vocational trucks > Demonstrate regulated emissions at/below EPA/CARB 2010 standards 0.20 g/bhp-hr NOx, 0.01 PM, 0.14 NMHC, 15.5 CO > Demonstrate peak rating of 400 hp, 1350 lb-ft torque > Demonstrate 5 to 10% improved fuel economy vs. existing spark-ignited natural gas engines in Class 8 truck duty cycles Pre-Alpha Engine Built at Jamestown Engine Plant > Quantify GHG reductions vs. existing spark-ignited natural gas and diesel engines in Class 8 truck duty cycles > Build Alpha engine and integrate into test vehicle 3
INDUSTRY-LEADING NGV ENGINE Cummins ISX12 G > Collaborative effort to meet strict heavy-duty emission requirements in CA > Higher horsepower (400 hp) and efficiency > Nearing culmination of over three-year, multi-million development GTI played key role in securing $3 million in government and industry funding GTI managed program plan and kick-off, technical input, field testing support > Continues highly successful 25-year relationship among GTI, Cummins, Cummins Westport Inc. (CWI) 4
INDUSTRY-LEADING NGV ENGINE Cummins ISX12 G > Critical next-generation engine Fits high-horsepower needs of key growth markets freight trucks, high GVW regional haulers, refuse collection, concrete mixers, regional haulers > Fills out product line above highly successful, world-leading ISL-G (8.9L) sold worldwide Engine Profile > 11.9L displacement > 400 hp / 1450 ft-lb rating > Spark ignited; stoichiometric with cooled EGR > Out-perform strict CARB emission standards > Maintenance-free after treatment > LNG / CNG / biomethane capable > New best-in-class product that exceeds customer expectations > Q1/2013 official launch > Could command significant market share over next 10 years 5
CWI ISX12 G Field Test Trucks 6
Advanced Heavy-Duty Vehicle Pre-Commercial Demonstrations Navistar Natural Gas MaxxForce 13-liter > Demonstrate12 Class 8 Tractors for goods movement Dual Fuel compression ignition, 430HP 1550 lb-ft torque US Hybrid Plug-in LNG Hybrid Truck > Demonstrate transport of cargo from ports 3 on-road drayage trucks CWI 8.9 ISLG + 320kW motor drive + 100kW Li-ion battery pack > Partners: GTI, US Hybrid, Freightliner, UC Riverside, Calko Transport 7
Low-Cost and Scalable CNG Cylinder > Assisted HyPerComp Engineering Inc. in product development and certification stages of: Type 4 all-composite cylinder Scalable design 13 to 15, 17, and 7 gge Targeting a market introduction price at $115 per gge 3 rd -party certification testing completed > Helped lead to collaboration by 3M and Chesapeake JV 8
Long-Haul Tractor Trailer Integrated Storage > Develop integrated solutions for CNG storage on regional and long-haul tractors and trailers > Target weight savings to minimize impact on payload capacity Boost driving range above 1,000 miles Enable time-fill at dock Explore potential for using cylinders as part of trailer frame to save weight 9
Advanced Storage Solutions > Develop advanced solid-state storage technology Proprietary program with industrial partner Metal-organic framework (MOF) adsorbents > Several additional efforts targeting CNG storage Including non-destructive evaluation techniques 10
Adsorbed Natural Gas (ANG) System for Light-Duty Vehicles Design and demonstrate a 10GGE commercial prototype Adsorbed Natural Gas (ANG) system that integrates the three essential features: novel sorbent materials, an active thermal management system, and a conformable Smart Tank. Due to the inherent non-linearities in the scale-up of gas flow in porous solids, heat conduction in packed beds, and stress distributions in tanks, a integrated systems approach that focuses on a full-scale prototype is essential to ensure correct design trade-offs among the critical components, going beyond ARPA-E requirements. Key Personnel > GTI (Prime): Overall PM, MOF adsorption isotherms testing, poisoning limitations, thermal management and system integration, and full-scale system testing > Argonne: Thermal modeling, POP material investigation > NW University/ NuMat: MOF screening, performance modeling, small-scale synthesis Technology Impact Project targets 9.2 MJ/l volumetric capacity at 35 bar (CNG @ 250 bar) and 12 MJ/kg gravimetric density (2 x s all steel tank) in a tank with a 90% conformability factor using a $10/kg material ($500 per 10GGE material cost). Achieving these goals should yield a 5 year payback for personal car. Similar range at reduced cost and lower operating pressure will dramatically improve the market adoption rate of NGVs. Challenges: Material identification, cost-effective synthesis, heat management design, poisoning of bed, tank conformability/cost tradeoffs, manufacturability of MOF-tank system, durability & longevity unknowns. TRL-3 to TRL-6 w/ working prototype system at full-scale. 11
Strategies to Shift Gas Industry Practices and Cost-Effectively Grow the NGV Market Goal: Achieve major impact on long-term NGV infrastructure investment by aligning utility operations and NGV fueling station needs to efficiently deploy capital. Address regulatory barriers. 1. Maintain high-pressure gas service downstream of city gate (bypass gate stations and take advantage of sunk cost in pipeline compression capacity). 2. Move micro/mini storage into LDC operations to supply NGV stations and integrate into utility peak demand management solution set. 3. Integrate LNG storage operations into vehicle fueling operations. 12
NGV Fueling Infrastructure > USDOE Clean Cities Program $15 million program awarded to City of Chicago, managed by GTI One of 25 Clean Cities awards Leveraging another $25 million in cost share > Major expansion of NGV fueling infrastructure 13
NGV Fueling Infrastructure > USDOE Clean Cities Program 16 fleets resulting in 16 CNG sharedaccess stations (public and private) 100+ EV chargers 230 NGVs and ~400 hybrids Waste Management and Groot refuse trucks CNG green taxi program at O Hare International Airport 14
Lake Michigan Corridor Alternative Fuel Implementation Initiative > Another DOE Clean Cities initiative > GTI is project lead, $764,000 funding > Includes southeastern Wisconsin, greater Chicago and northern Indiana > Make existing municipal fueling stations available to other fleets > Create vehicle conversion inspection criteria > Train and educate fuel retailers, first responders, vehicle mechanics, code officials, measurement agencies and fleet operators 15
NGV Station Modeling and Software Tools > GTI has developed several NGV software tools CASCADE software for NGV station sizing AccuFill dispenser filling algorithm, licensed to several manufacturers CHARGE model for cylinder filling 16
Compressed Gas Vehicle Fuel Dispensers > Dispenser design > Dispenser performance Fill time Fill level (i.e., % of full fill) > Including GTI-developed AccuFill technology > Safety and certification Weights and measure Compliance with industry standards 17
GTI AccuFill Algorithm > GTI developed and patented technology to address CNG temperature rise during mid-1990s helps compensate for heating effects, providing more complete and consistent fill performance over wide range of ambient conditions > Technology licensed to several worldwide manufacturers > Extended to hydrogen dispensers in mid 2000s; also applicable to ANG 18
GTI CNG AccuFill Algorithm Field Testing > Independent field testing (using PVT calculation) compared with dispenser measured mass 100% Percent of Full Fill 95% 90% 85% 3 data points 40 28 7 13 2 TYPE AVG Fill STD DEV Count Steel Type 2_1 100.4% 0.66 3 Steel Type 2_2 99.0% 1.96 40 Steel Type 2_3 99.5% 2.05 28 Aluminum Type 2 99.0% 1.06 7 Carbon Type 4 98.8% 0.94 13 Carbon Type 4 98.7% 0.96 2 Totals 99.2% 1.39 98 80% Steel Type 2 (A) Steel Type 2 (B) Steel Type 2 (C) Aluminum Type 2 Carbon Type 4 (A) Carbon Type 4 (B) 19
GTI CHARGE Model > First principle model of dynamic fast-fill process with real gas properties Uses multiple differential equations Filling of cylinders Discharge of ground storage (including isentropic cooling) > Assess cylinders of different size and construction > Various starting and ending conditions 20
GTI High-Pressure Compressed Gas Test Facility > Large-scale environmental chamber Three-bank, 5500 psig CNG cascade Three-bank, 7500 psig hydrogen cascade (with higher pressure if needed) Wide Temperature Capability > Minus 20 to 140 o F > Fully instrumented facility Precision scale, mass flow meters Temperature, pressure High-speed data acquisition 21
Fast-Fill Empirical Testing 22
Mobile NGV Fleet Fueling > Working with Ultimate CNG on Fuel Mule product > GTI-designed mobile CNG fueling Total delivery capacity of 650 DGE (diesel gallon equivalent) Fuel 15-40 vehicles per day @ 8 DGE/min > Various uses: starter station, temporary use, remote vehicles, others > System can be replenished off peak, enhances central station daily demand 23
Home Fueling Development > Working with natural gas industry and other stakeholders > Assess worldwide options > Target features 0.8-2 scfm (0.4-1 gallon/hour) 120 VAC, <15 amp 40 dba @ 20 feet Indoor/outdoor location Over 4000 hour service interval <$2000 24
Single-Piston, Four-Stage Linear Motor Compressor for Home Fueling > Free Piston Linear Motor Compressor (FPLMC) eliminates all but one moving part to improve durability and compressor system efficiency, while significantly decreasing overall system cost, installation, and maintenance for natural gas home refueling appliances > 4-stages of compression, ¼ psig to over 3,600 psig, flow rate of over 2 scfm (1 GGE per hour). 1,600 W motor load, 120 VAC, less than 20 amp demand 25
Single-Piston, Four-Stage Linear Motor Compressor for Home Fueling Key Partners > UT-CEM: Linear Motor design > GTI: Compressor and heat management designs > Argonne National Lab: Near-frictionless surface treatment and sealing technologies Technology Impact > Combines the functions of the compressor and motor into one device > Uses a single moving part, thus eliminating inefficiencies inherent in converting rotary motion into linear motion > Fewer wearing components, reduced parasitic friction, increased durability, reliability, and reduced maintenance > Decreased number of parts, allows for ease of manufacturing and reduced initial investment > Challenges: Cooling of windings and gas, non-lube sealing surfaces, overall heat management scheme > Conclude with working prototype achieving 1,000 hour test at scale in 30 months (TRL-3 to TRL-7) 26
Small-Scale Liquefaction Plant (Pipeline Gas, Australia) > 32,000 LNG gallon/day (50 MTPD) plant supplying LNG for large truck fleets in Tasmania, Australia region Uses GTI-licensed liquefaction technology > Producing remote LNG from pipeline natural gas Used for remote vehicles operated by forest products industry to substantially reduce diesel fuel use 27
Small-Scale Liquefaction Plant (Landfill Gas, USA) > World s largest landfill gas to LNG facility (Linde-Waste Management) > Altamont Landfill in California > 13,000 LNG gallons per day (32 MTPD) > Includes GTIlicensed liquefaction technology 28
Research Opportunities > GTI has a host of research projects that are open to the industry for participation and investment. Outsource all or part of your R&D activity to leverage your technology investment and choose from a menu of business arrangements. For More Information Tony Lindsay GTI R&D Director, End Use Solutions 847-768-0530 tony.lindsay@gastechnology.org 29