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An Evaluation of Natural Gas-Fueled Locomotives

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An Evaluation of Natural Gas-Fueled Locomotives An Evaluation of Natural Gas-fueled Locomotives November 2007 Report prepared by: BNSF Railway Company Union Pacific Railroad Company The Association of American Railroads California Environmental Associates Contributors The following individuals developed this paper. Larry Caretto Former Dean of Engineering and Computer Science and Professor of Mechanical Engineering California State University, Northridge Steve Fritz Manager, Medium-Speed Diesel Engines Southwest Research Institute John Hedrick Senior Research Engineer Southwest Research Institute Mike Iden General Director Car & Locomotive Engineering Union Pacific Railroad Lanny Schmid Director of Environmental Field Operations Union Pacific Railroad Mark Stehly Assistant Vice President for Environment and Research & Development BNSF Railway Andrew Trump Consultant to California Environmental Associates and the Association of American Railroads Darcy Wheeles Senior Associate California Environmental Associates Sarah Weldon Research Associate California Environmental Associates Questions about this report may be directed to: Sarah Weldon Research Associate California Environmental Associates 423 Washington Street, 3rd Floor San Francisco, CA 94111 [email protected] 415-421-4213, ext 34 Table of Contents Tables and Figures ...................................................................................................................................... iii Abbreviations and Selected Terms ............................................................................................................ iv 1. Executive Summary.................................................................................................................................. 1 Findings and Conclusions ......................................................................................................................... 2 The Railroads’ position on natural gas ..................................................................................................... 3 2. Evaluating Natural Gas-fueled Locomotives ........................................................................................ 7 Locomotive Type........................................................................................................................................ 7 Locomotive Utilization............................................................................................................................... 7 Basis and Means of Comparison ............................................................................................................... 8 Reductions from Fuel Shift v. Mode Shift .................................................................................................. 9 Potential Future EPA Requirements and Engine Builder Strategies......................................................... 9 Other Considerations............................................................................................................................... 10 3. Initial Efforts in Evaluating Alternative Fuels by California Air Resources Board (CARB).......... 13 4. Methods for Using Natural Gas as a Locomotive Fuel........................................................................ 15 5. Railroad Interest in Alternative Fuels .................................................................................................. 17 6. Railroad Efficiency Improvements ....................................................................................................... 19 7. EPA Emission Standards and Certification Test Standards for Locomotive Engines ..................... 21 Proper Evaluation Methodology ............................................................................................................. 23 8. Later Rail Industry Research, Test, and Demonstration Efforts using Alternative Fuels............... 25 Burlington Northern CNG Effort (1983-1987) ........................................................................................ 25 SwRI Two Cylinder Research Engine Test (1986)................................................................................... 26 Burlington Northern Effort with ECI and Air Products (1987 - 1992).................................................... 27 Burlington Northern Operations with Natural Gas-fueled Locomotives (1992-1995)............................ 28 MK Rail LNG Switch Locomotives (1993 - present)................................................................................ 29 UPRR R&D Program with Engine Builders (1992-1995)....................................................................... 30 GasRail Initiative (1993-1998)................................................................................................................ 32 Southern California LNG Line-haul Locomotive Project (2004) ............................................................ 33 ECI Conversion Kit for the EMD 645 Engine (2006).............................................................................. 35 Other Efforts Using ECI Products........................................................................................................... 36 9. Recent Innovations & Investment......................................................................................................... 39 EPA Certified Tier 2 Line-haul Locomotives........................................................................................... 39 GE Diesel-battery Road Hybrid Locomotive........................................................................................... 39 Page i Railpower Technologies Corporation “Green Goat” Diesel-battery Hybrid ......................................... 40 National Railway Equipment “Gen Set Switcher” .................................................................................. 41 Railpower Technologies “Gen Set Switcher”.......................................................................................... 41 Clean Engine Technology Investments .................................................................................................... 43 10. Comparison of Exhaust Measurements from Different Locomotives.............................................. 45 11. Exhaust Emissions Evaluation of the ECI Product versus a New Locomotive Meeting EPA Tier 2 Certification Standards.............................................................................................................................. 51 Results of SwRI’s Exhaust Emissions Test............................................................................................... 51 Emissions Comparison with Tier 2 Locomotives..................................................................................... 52 Toxic Pollutant Emissions ....................................................................................................................... 53 Summary of ECI Test Data ...................................................................................................................... 54 12. Natural Gas vs. Diesel Fuel Economics............................................................................................... 57 Recent Price Experience with Natural Gas and Diesel ........................................................................... 57 13. Conclusions ........................................................................................................................................... 61 Findings and Conclusions ....................................................................................................................... 62 The Railroads’ position on natural gas ................................................................................................... 63 Appendix 1 – Additional Measures to be Evaluated According to Section 8(c) of the MOU on Rail Yards ............................................................................................................................................................. 1 Appendix 2 – Internal GE Memo, UPRR R&D Effort.............................................................................. 3 Appendix 3 – Comments of GE and EMD ................................................................................................. 5 Appendix 4 – U.S. EPA Document References .......................................................................................... 7 Appendix 5 – Calculation Details for Exhaust Emissions Data................................................................ 9 Appendix 6 – Railroad Responses to Questions and Issues Raised by the Bay Area Air Quality Management District.................................................................................................................................. 11 Appendix 7– Railroad Responses to Questions and Issues Raised by the South Coast Air Quality Management District.................................................................................................................................. 15 Page ii Tables and Figures FIGURE 1: TIMELINE OF RAILROAD RESEARCH ACTIVITIES ............................................................................ 4 TABLE 1: COMPARING NATURAL GAS-FUELED LINE-HAUL LOCOMOTIVE CONVERSION AND CERTIFIED TIER 2 DIESEL LINE-HAUL LOCOMOTIVES (G/BHP-HR)................................................................................... 5 FIGURE 2: NORTH AMERICAN NEW LOCOMOTIVE SALES VOLUME: 1972- 2007 (EST) ................................ 10 TABLE 2: NEW LOCOMOTIVE PURCHASES BY THE CLASS
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