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Natural Gas Charges Into the Future

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Natural Gas Charges Into the Future POWERTRAIN SYSTEM: CNG & LNG ENGINES arge U.S. reserves and the ability to use existing engine technology make natural gas attractive. In fact, natural Natural gas charges gas price projections are significantly lower than historical averages as more information becomes available on mas- Lsive shale gas reserves. into the future Engine and fuel availability continue to by Curt Bennink expand. “We are in the stage of investment in Explore natural gas options when designing new vehicles. both infrastructure build-out and product devel- opment,” says Paul Blomerus, Senior Director, High Horsepower Corporate Development, Westport Innovations Inc., Vancouver, BC, Canada. “Where those two meet is a perfect storm of new products to meet demand and available cheap fuel. Then we will see an inflec- tion point.” In the push to transition from petroleum-based vehicles to an affordable domestic alternative, natural gas is quickly gaining favor. Any vehi- cle traditionally powered by gasoline or die- sel can be converted to natural gas. Although natural gas does produce greenhouse gases, it is much cleaner than either gasoline or diesel. It is an odorless, nontoxic, gaseous mixture of hydrocarbons—predominantly methane (CH4) and it possesses the lowest carbon con- tent of any hydrocarbon fuel. A side benefit is that compressed natural gas (CNG) fuel sys- CNG refueling of refuse trucks in Livermore, CA. NGVAMERICA OEM Off-Highway | JANUARY/FEBRUARY 2013 www.oemoffhighway.com 7 POWERTRAIN SYSTEM: CNG & LNG ENGINES tems are completely sealed, so there are no evaporative emissions. But the economic business case remains strong. “There are so many different angles and they are all predicated on economics,” says Richard Kolodziej, President of Natural Gas Vehicles for America (NGVAmerica). “The more fuel you burn, the greater the potential savings.” There is also customer familiarity. Natural gas Cryogenic LNG refueling. already accounts for a quarter of the energy used WESTPORT INNOVATIONS in the U.S. But a couple of hurdles need to be overcome. First is development of the distribu- enough stations you can go after other fleets, tion channel. “There are two million miles of the ones that don’t return to a depot every night. natural gas pipeline delivering gas to almost After these natural gas fueling communities (the every city and town,” says Kolodziej. “You have Refueling an LNG storage tank on a Class 8 heavy-duty truck. hubs) develop, the next step is to place fueling sta- to get it from the underground pipeline to the WESTPORT INNOVATIONS tions along the interstate highways that connect vehicle, so fueling stations need to be built.” them (the spokes). Through this hub-and-spoke There are about 1,100 CNG fueling sta- the country, with most stations popping up approach, a national CNG fueling network is tions around the country with 20 to in heavily populated areas. “The four counties being created.” 25 new stations coming online around L.A., for example, have 100 stations,” says Fuel availability is critical to the speed of every month. But they are Kolodziej. Salt Lake City has quite a few stations growth. “A number of options can be employed Vertical LNG storage tanks. WESTPORT INNOVATIONS not equally distrib- and growth is now occurring in Oklahoma City, in key market segments, from on-site delivery in uted around Tulsa and other key cities. “The industry’s strat- the case of liquefied natural gas (LNG) for key egy has been to go after return-to-home fleets machines, or strategic fueling locations nation- through this business value stream.” first, where one public station can serve sev- wide in the case of rail,” says Scott Fiveland, GAS The other hurdle is the availability of the eral fleets in an industrial park. Once there are New Technology Manager, Caterpillar Inc., engines. Finding the perfect size engine for Peoria, IL. “The successful deployment of LNG many applications can be difficult. There are Westport high-pressure direct injection solutions will require the economics through the gaps in the natural gas engine range – including (HPDI) injector for heavy-duty engines. value stream from fuel to infrastructure to fuel a critical gap between 9 and 15 liters. Numerous WESTPORT INNOVATIONS use. We expect the economics to look attractive companies use the 9-liter natural gas engine on OEM Off-Highway | JANUARY/FEBRUARY 2013 www.oemoffhighway.com 8 POWERTRAIN SYSTEM: CNG & LNG ENGINES a Class 8 truck. “That only works if you are working on flat ter- Actually, engine manufacturing capacity isn’t as much of an rain. Even there you are working that engine pretty hard,” says issue. “Our business model has always been to leverage existing Kolodziej. manufacturing capacity wherever possible,” says Blomerus. “We He explains, “That is why the 12-liter Cummins Westport engine will utilize engine manufacturers or existing supply chains. We that is supposed to come out in April is exciting for so many really don’t see supply or capacity as an issue. If anything, as the people. In many cases the 8.9-liter is too small and the 15-liter is share of gas increases the capacity will switch from supporting too big.” A 12-liter natural gas engine hits a sweet spot for many diesel fuel to supporting gas fuel.” in the Class 8 truck market. Currently there is a 9-liter engine from Cummins Westport Engine types and use Inc., Vancouver, BC, Canada, and the 15-liter Westport HD engine. Three types of engine technologies are currently employed for More choices will be coming in the future that will help further natural gas engines used on mobile equipment – spark ignited, Fueling an LNG powered refuse truck. fill in the gaps. dual fuel and high pressure direct injection (HPDI). The technol- NGVAMERICA Economics drive natural gas vehicles “Natural gas supply has skyrocketed because of the shale gas,” “Fuel selection is driven by economics and availability, among other Who Says Gears Can’t Be Fun? Gears for today’s off-highway applications must operate smoothly, says Richard Kolodziej, President of Natural Gas Vehicles for America factors,” says Scott Fiveland, GAS New Technology Manager, Caterpillar quietly and around the clock in the harshest environments – and reliability is paramount. Forest City Gear helps design, develop and (NGVAmerica). “Demand is growing, but slowly. That puts huge downward Inc. “Since natural gas offers savings to customers, due to lower fuel manufacture the highest quality gears for some of the leading OEMs. pressure on price.” The price at the time of this writing was under $4/ operating costs, Caterpillar expects natural gas growth to explode. The Let’s have some fun together. million BTUs. “When natural gas is $5.60/million BTUs, that translates economic savings, depending on the natural gas to diesel fuel delta, Visit: www.forestcitygear.com. to .70 cents a gallon gasoline equivalent (GGE) in the field. You have to can translate to more than a 50% savings to the customer in operating 11715 Main Street move it and you have to compress it.” But even if this adds $1.50/million fuel costs.” Roscoe, IL 61073 815-623-2168 BTUs to the cost, the consumer price is around $2.00 per GGE. “There Demand is being driven by high fuel use customers, including railroads are eight gallons equivalent in a million BTUs. There are seven gallons and mine truck operators. “A locomotive will consume 300,000 gallons diesel equivalent in a million BTUs.” per year,” explains Paul Blomerus, Senior Director, High Horsepower This pricing makes natural gas attractive. “In duty cycles that use a Corporate Development, Westport Innovations Inc. The biggest mine lot of fuel, there are customers that can pay back their vehicle in a year trucks can more than double that. The economic motive is extreme. The [or] a year and a half,” notes Kolodziej. In addition, natural gas exhibits business is growing where the volume is large (Class 8 or smaller truck- many positive attributes. “It is cleaner burning so the engine oil stays ing) or where the fuel burns are large. The middle will fill in and it will cleaner longer.” There is less carbon buildup in the engine. benefit from the new engine technologies developed.” OEM Off-Highway | JANUARY/FEBRUARY 2013 www.oemoffhighway.com 9 POWERTRAIN SYSTEM: CNG & LNG ENGINES How an LNG station operates. GRAPHIC BY CHART INDUSTRIES engine has a flatter torque curve which gives that nice low-end response.” Westport uses spark ignition on light-duty (1- to 5-liter) and Cummins Westport cur- rently uses SI on medium-duty (5.9- to 9-liter) engines. Many light-duty engines used on pas- senger cars and light-duty trucks are configured for bi-fuel operation. In medium-duty vehicles natural gas can also be cost effective with a ogy deployed depends on the application. “But spark-ignited engine. [for] the largest and most demanding engines An upside of the spark-ignited engine is that where efficiency and power response are core it is much quieter than a diesel compression- requirements, the HPDI is more suitable,” says ignition engine. The downside of a spark-ignited Blomerus. natural gas engine is it typically provides 85 Natural gas needs an ignition source to make it to 90% of the power of a diesel and 80% of the work. It will not ignite by compression alone like torque of a diesel. diesel fuel. This ignition source is usually a spark But the spark ignited engines also have emis- plug in a spark-ignited engine or a small mixture sions benefits. “On the Cummins Westport of diesel in a compression-ignited engine. But engines you don’t have a particulate filter and you do lose a little torque and cooling require- you don’t need urea to control the NOx,” says ments are increased.
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