isl g technology overview - greater...
TRANSCRIPT
Explore Every Alternative.
ISL G Technology Overview
The 3 E’s: There are three key reasons for using Natural Gas to power commercial vehicles.
Environmental Leadership
Energy Policy Economic Benefits
Simpler Cleaner Fuel
Complex Hydrocarbon
Simplest Hydrocarbon
High hydrogen-to-carbon ratio results in GHG advantage
Energy Policy: The U.S. is the world’s largest consumer of imported oil.
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EIA data for year 2007
Top 25 Petroleum Importers
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Large & Growing Natural Gas Opportunity Forecast: Delivered Energy Prices for Diesel & Natural Gas Transportation Fuels, 2010-2035
Source U.S. Energy Information Administration, Annual Energy Outlook 2010
2008 Equivalent U.S. Dollars Per Gallon Equivalent
Gas Shale Plays are an Industry Changing Breakthrough
North America Resource Estimates 2,119 Tcf of Total Resource 95+ Year Supply at 75 Bcf/d 70+ Year Supply at 100 Bcf/d
Energy Security
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Lower Fuel Costs-Historically 25-40%
Price difference to diesel is growing Natural gas price is lower with new supply
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Cummins Westport Inc. (CWI) is a Joint Venture of Westport & Cummins
Cummins Inc.
“CWI” Cummins Westport Inc.
50/50
Cummins Inc. Westport
Innovations Inc.
Over 30,000 Engines Delivered June 2011
Over 10,000 ISL Gs
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CWI: Fully integrated within Cummins. We are Cummins’ automotive natural gas engine company.
Product Engineering
Cummins Tech Center Cummins VPI Process
Cummins Account Teams & Distributors
Manufacturing
Warranty
Cummins Plants
Parts & Service Cummins Distributors
Sales
Cummins Warranty
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Why ISL G?
Environmental Leadership ISL G Met Regulated 2010 EPA/Euro EEV in 2007
20% Lower greenhouse gas emissions
Energy Security Reduced reliance on oil Biomethane capable
Economic Benefits Improved Reliability Improved Efficiency Lower total fuel costs
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ISL G Natural Gas Engine 8.9 Litre (540 cu. In.) In line 6 cylinder Charge Air Cooled (CAC) Spark ignition Peak Rating:
– HP-320 hp Torque -1000 lb-ft Certified to 2010 EPA and CARB NOx
and PM standards Three Way Catalyst Aftertreatment Manufactured by Cummins in Cummins
Engine Plant- Rocky Mount, North Carolina
Over 10,000 in service
• 2007 - 1st Heavy Duty Engine Certified
2010 EPA
• 2008 - # 1 Natural Gas Engine in
Transit
• 2009 - #1 Natural Gas Engine in
Refuse
• 2010 - #1 Natural Gas Engine in
Conventional Truck
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Cummins Westport - 30,000 Automotive Engines Delivered
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10,000 ISL Gs produced in 4
Years
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Evolution of Natural Gas Engine Technology Stoichiometric combustion is the ideal combustion process during which
fuel and oxygen are burned completely – Early HD natural gas engines were stoichiometric – Ideal air/fuel ratio - chemically correct mixing of fuel and air – Consumes all fuel & air without excess of either in exhaust – Three way catalyst (TWC) aftertreatment is highly effective at NOx reduction, but only if there is no
oxygen in exhaust stream Lean Burn combustion, adds air to the air fuel mixture so the air content
is higher than the stoichiometric ratio – Evolution from Stoichiometric to meet market demands – Lean burn in heavy duty NG enabled better efficiency, power density and durability than
conventional stoichiometric combustion – Excess air leads to reduced exhaust temperatures – Oxygen in exhaust enables oxidation catalyst, not TWC
Stoichiometric combustion with cooled EGR combines & improves the best attributes of both Stoichiometric & Lean Burn combustion.
– Cooled EGR (CEGR) replaces the additional air in Lean Burn combustion – CEGR reduces exhaust temperature similar to lean burn engines – Better efficiency and power density compared to Lean Burn and Stoichiometric technologies – Enables a TWC for NOx control.
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Cooled Exhaust Gas Recirculation (CEGR)
Stoichiometric Combustion
Three Way Catalyst (TWC)
Cummins
Cummins Emission Solutions
2010 ISL G - Three Key Emission Technologies
Cummins Westport
Stoich EGR Three Way
Catalyst Architecture
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T
Three Way Catalyst
O2 Sensor
EGR Cooler C
harg
e A
ir C
oole
r
O2 Sensor
Throttle
Fuel
CWI 2010 Technology
Spark Ignited Combustion
Spark Plug
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Benefits of Stoichiometric EGR Combustion
Increased power density – Torque curves are virtually the same as diesel – Diesel-like transient response/performance – More torque at idle (+34%)
Increased thermal efficiency – 5% fuel economy improvement vs. lean-burn natural gas engines – Lower methane emissions (GHG benefit)
Decreased emissions – Meets 2010 emission standards – Lower carbon (greenhouse gas) emissions – Quiet - ISL G is 9.9 decibels quieter than ISL9 at Idle/no load – Simple, passive, maintenance-free aftertreatment
Catalyst Inlet
NOX
CO
HC
Catalyst Outlet
N2
CO2
H2O ISL G TWC -‐ similar package size to current mufflers
Three Way Catalyst TWC reduces three harmful emissions: NOX, CO, HC
End products are: N2, CO2, H2O
Packaged as a replacement muffler
Simple, passive, maintenance-free
Consistent performance across all duty cycles
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NMHC NOx CO PM FTP EUR
O FTP EUR
O FTP EUR
O FTP EUR
O STD 0.14 0.14 0.2 0.2 15.5 15.5 0.01 0.01 CERT 0.13 0.04 0.13 0.01 1.2 0.4 0.002 0.000
California Air Resources Board - Executive Order Shows Emissions Results
ISL G is under 2010 NOx and PM regulations
FTP: Federal Test Procedure [ transient and steady state ]
EURO: Euro III European Steady-State Cycle
STD: standard or emissions test cap
CERT: certification level
Tough California Emissions Standards and Cummins Westport Engines
Further Reductions are Being Explored • Sub Ambient • “Zero” Emissions
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Up to 20% Lower Greenhouse Gas Emissions
As natural gas fuel economy improves, CO2 emissions are reduced
CH4 emissions, adjusted to consider GHG impact are less than 10% of total GHG emissions.
Well to Wheel (WTW) analysis with GHGenius modeling tool predicts over 20% WTW GHG emissions benefit for natural gas vs. diesel.
Using landfill gas or anaerobic gas as a biomethane fuel increases GHG difference to ~90%.
Cummins Westport approves the use of biomethane that meets fuel specifications.
Source: Presentation to AFVI convention by Don O’Conner (S&T)2 Consultants May 2008
GHG - Biomethane Fuel Impact
Natural Gas Vehicle has 20 - 22% Lower GHG with fossil gas
Source:http://www.nsca.org.uk/assets/biogas_ as_transport_fuel_june06.pdf
Biogas based fuel improves GHG
reduction by 75-200%
2012 Results (California)
Source: CEC-600-2007-004-REV
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Well-to-Wheel Greenhouse Gas Emissions GH
G em
issio
ns p
er kW
h on
the s
haft
CO2 equivalent / any greenhouse gas converted into same greenhouse effect as CO2
Source: Volvo Group – transit
732
240
66 26 11
0 100 200 300 400 500 600 700 800
Diesel, crude oil Ethanol, wheat Ethanol, enzyme wood
Ethanol, wood via black liquor
Biogas as CNG/LNG
How Big is a Ton of CO2?
One CNG Transit bus reduces CO2 by approx 97.6 trailers full per year.
Reduced Noise
ISL G is 5.5 decibels quieter at peak torque
and load
ISL G is 9.9 decibels quieter at Idle/no load
Communities notice the natural gas noise
advantage.
ONE Diesel engine idling is louder than TEN natural
gas engines idling together
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Technology What is the Same?
Major Engine Components – Block, crankshaft, main bearing,
piston rods, EGR – Over 80% parts commonality
500 hour Maintenance Interval Parts and Service
– Global Cummins Distributor Network
320, 300, 280, 260 and 250 HP ratings
Compatible with Cummins Diagnostic tools – Insite – Quickserve online
Manufactured in Cummins Engine Plant, North Carolina
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ISL G Warranty - Every Coverage
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Technology What is Different? Cylinder head
– 2 valve vs. 4 valve (diesel) Ignition
– Spark Ignition (SI) vs. Compression (diesel)
Fuel System – Intake manifold vs. Common rail
injection (diesel) Aftertreatment
– 3 way catalyst vs. Particulate Filter + Selective Catalytic Reduction (diesel)
Maintenance Cost – Incremental cost of maintenance
related to ignition and overhead valve adjustments adds up to $0.03 per mile ($0.02 per km) to ISL G
Lubricating Oil – Natural gas engines require a
specific oil that meets Cummins specification CES 20074
Noise – Natural gas engines are up to
10db quieter at idle
Compression Ratio – ISL G is 12:1 compression
ISL G Components
EGR Valve Fuel Module ECM ICM
EGR Cooler Wastegate Turbo Crankcase Breather EGR Crossover Tube
2 Valve Cylinder Head & Coil on Plug Ignition
Initial valve set at 1,000 hours, 2,000 hours thereafter Ignition coils mounted at 45 degree angle One coil per cylinder, left side of valve cover Spark Plug change interval is 1,500 hours
Turbocharger, Exhaust Manifold, EGR Cooler
Wastegated Turbocharger EGR Crossover Tube
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Three Way Catalyst Aftertreatment
Similar to catalyst on gasoline passenger cars Packaged as a muffler. Vertical or horizontal mount Weighs ~100 pounds Passive device Benefits:
– Maintenance-free – Reliable – No regeneration events – Easy to install in vehicle
2010 Engines Aftertreatment Comparison
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Cummins TWC
Heated DEFTank
DEF Dosing Control Unit
ECM
SCR Catalyst Particulate Filter
Estimated System Weight ~ 60 Gallons Fuel CNG – 1,000 lbs more LNG – 300 lbs more
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System Weights ISL9 Diesel ISL G Natural Gas Engine 1,695 lbs 1,625 lbs Aftertreatment 450 lbs 100 lbs Fuel Tanks - Diesel (60 Gal) 100 lbs (550 lbs Full) - CNG (60 DGE) 1,600 lbs (2,000 lbs Full) - LNG (68 DGE) 815 lbs (1,288 lbs Full) Total Weight (Full) 2,695 lbs CNG - 3,725 lb
LNG - 3,013 lb
Keys to Success Follow Cummins maintenance intervals and procedures outlined in Operation
and Maintenance manuals Use Cummins Authorized parts Set oil drain / service intervals based on average fleet speed Default interval is the hours stated.
– Interval is Defined by application and average speed – hours, miles or time, which ever comes first
Use only natural gas engine oil (CES 200074) Check air intake every 250 hours, and use only OEM approved air filters Perform Initial Overhead Valve adjustment at 1,000 hours or 15,000 miles
(24,000 km)
Example: Normal Duty - Oil Drain/Service Intervals
Average Vehicle Speed Kilometers Miles Hours Months Normal Duty -Truck 24,000 15,000 500 6 Transit Bus 10-15 mph 9,650 6,000 500 6 Refuse Truck 10-15 mph 9,650 6,000 500 6
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Use 15W-40 Natural Gas Engine Oil
Cummins Westport natural gas engines require special engine oil that is available from major oil suppliers.
Careful attention must be paid to engine oil specifications because natural gas engine oil has different properties than diesel engine oil. A sulfated ash limit of 0.6 percent has been placed on all engine lubricating oil recommended for use in Cummins Westport engines.
Higher ash oils can cause valve and/or piston damage and lead to excessive oil consumption and degradation of the catalyst.
Do not use diesel engine oil in a natural gas engine. If diesel engine oil is used, valve torching, piston scuffing, and reduction in spark plug life will occur.
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CES20074 Gas Engine Only (GEO) engine oil is available from most major oil companies
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ENGINE MODEL ADVERTISED HP(KW) @ RPM
PEAK TORQUE LB-FT @ RPM
GOVERNED SPEED
ISL G 320 320 (239) @ 2000 1000 (1356) @ 1300 2200 RPM
ISL G 300 300 (224) @ 2100 860 (1166) @ 1300 2200 RPM
ISL G 280 280 (209) @ 2000 900 (1220) @ 1300 2200 RPM
ISL G 260 260 (194) @ 2200 660 (895) @ 1300 2200 RPM
ISL G 250 250 (186) @ 2200 730 (990) @ 1300 2200 RPM
ISL G Ratings
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Fuel
Natural gas fuel must meet ISL G fuel specs per AEB 79.05 Minimum Methane Number (MN) is 75 Natural Gas fuel for the ISL G can be stored on the vehicle in either liquid
(LNG) or compressed (CNG) form. ISL G requires fuel to be regulated to max 150 psi, min 70 psi Cummins Westport approves the use of up to 100% biomethane that meets
Cummins published natural gas fuel specifications
CNG Delivery Chain
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Conventional Unconventional - Shale Renewable - BioMethane
Source Producer
CNG Fuel Station
Compress
CNG Fuel Stations
CNG Time Fill Station Overnight fueling Small compressor One storage vessel Dual hose or single hose posts
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CNG Fast Fill Station Rapid succession vehicle fueling Large compressor(s) Three or more storage vessels
CNG Time Fill
Fast Fill CNG Dispenser
LNG Delivery Chain
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Conventional Unconventional - Shale Renewable - BioMethane
Source Producer
LNG Fuel Station
Liquefy
Transport
LNG Fuel Stations LNG is trucked to refueling station in 10,000 gallon tanker
trailers – LNG source is typically a dedicated liquefaction plant for vehicle
LNG or utility company LNG peak-shaving plant – “Small-scale” liquefaction (i.e. smaller than industrial-scale
liquefaction plants) is expected to increase LNG availability
Requires on site LNG bulk storage tank, typically 13,000 to 16,000 gallons
LNG dispensed to vehicle tanks as a cryogenic liquid – Approx 50 gpm refueling rate
LNG stations cost less than CNG stations – Easier to pump a liquid than compress a gas
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Recent market activity points to “corridors” that support the on highway market for natural gas.
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Step 1: Serve Local/
Regional Trucking Hubs
Step 2: Serve Lanes that
Connect the Hubs
Note: Chesapeake $1 billion investment announcement (July 2011)
OEM Supplied Fuel System Components (Both CNG and LNG Systems)
Mounted on the vehicle Regulates storage pressure down to engine specification pressure (70-150 psi) Note drain on pre-filter has a drain requirement
Must be drained if there is 1 oz of liquid
CNG Fuel Storage Strong and safe - Carbon fiber wrapped CNG tanks
– 3,600 psi capability
Can be mounted vertically or horizontally Each tank carries approx.15 diesel equivalent gallons (DGE)
Shut off valve
Fuel fill connection
Fuel pressure gauges
LNG Fuel System
75 Diesel Gallon Equivalent Tank
LNG Economizer
• LNG tanks are designed with thermal properties to store natural gas as a liquid (-260 F). • The liquid leaves the tank to an economizer supplied with engine coolant to warm the gas to gaseous form. As it returns to gaseous state it expands and pressurizes the system. • A LNG fuel system is a low pressure system designed for normal operating pressure of 230 psi.
Established ISL G Applications
BUS REFUSE
CWI is available from leading urban bus and cab over refuse truck companies
Transit ISL G Availability
Top North American CNG Transit Fleets LAMTA, Los Angeles, CA OCTA, Orange County, CA Big Blue Bus, Santa Monica, CA
TransLink, Vancouver, BC NY / Long Island Transit, NY San Diego Transit, CA
Foothills Transit, San Gabriel Valley, CA
RTC Transit, Las Vegas, NV HSR, Hamilton, ONT
Fort Worth, TX Santa Clara, CA
Tacoma, WA St. Louis, MO
OEM New Flyer NABI Orion ElDorado MCI
Model 30/35/40 Low Floor 35/40 Low Floor 60 BRT
Orion V HF Orion VII LF
EZ Rider II Motor Coach
Fuel CNG CNG CNG LNG/CNG 40 and 45 ft
Engine ISLG 280 ISLG 280 ISL G 320
ISL G 280 ISLG 280 ISLG 320
Cab Over Refuse Truck Availability OEM AutoCar Mack Peterbilt American
Lafrance Crane Carrier
Model Xpeditor TerraPro LE Terra Pro CO
320 Condor LET
Fuel LNG/CNG LNG/CNG LNG/CNG LNG/CNG LNG/CNG
Engine ISLG 320 ISLG 320 ISL G 320 ISL G 320 ISLG 320
. OR North America Refuse Fleets
City of Los Angeles, CA City of Toronto Miller Waste, Ont
Republic Service City of Sacramento, CA EMI, Que
Specialty Solid Waste Long Island, NY City of Surrey, BC
City of New York Smithtown, NY
Denver, CO Waste Management (USA & Canada)
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Conventional Truck Availability OEM Freightliner Peterbilt Kenworth Volvo
Model M2 – 112 SD - 114
320 384 365
T800SH W900S T440 T470
VNM
Engine ISLG 320 ISL G 300
ISL G 320 ISLG 320 ISL G 320
Application 6x4 Tractor 4x2 Tractor 4x2 Truck 6x2 Truck Vocational
Tractor Vocational
Mixer
Tractor Vocational
Mixer
Tractor
OR
Automotive Natural Gas Truck Market
Cummins Westport Confidential 52
Other OEMs
OEM Thomas Blue Bird
Capacity Autocar
Application School Bus Yard Tractor Yard Tractor
Model Type D Capacity – TJ9000 Autocar - Xspotter
Engine ISLG 250 ISL G 250 ISLG 320
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OR
CWI Contact Information Bill Boyce, Eastern USA
– [email protected] – Office: (330) 534-8352 – Cell: (330) 720-9785
Jerry Johnson, Western USA – [email protected] – Cell: (303) 396-9821
Jeff Campbell, Canada – [email protected] – Office: (604) 718-2099 – Cell: (604) 318-4790
Gordon Exel, VP & General Manager, Americas – [email protected] – Office: (604) 718-8384 – Cell: (604) 764-9867
Gloria Stewart, Account Executive [email protected] Office: (812)-377-0481 Cell: (812)-350-2684
Brandon Davis, Technical Support Manager – [email protected] – Office: (562) 760-4537 – Cell: (562) 760-4537
www.cumminswestport.com
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