HCNG Engine Powered Transit Buses Operating on Waste

HCNG Engine Powered Transit Buses Operating on Waste Hydrogen April 1, 2008 Westport Innovations Inc. , Trans. Link

Hydrogen Engines • Internal Combustion Engines are very well developed and increasingly sophisticated. – Engine power and efficiency are improving – Engines are getting much cleaner to meet emissions targets • Adapting high efficiency engines to operate on a mixture of hydrogen and natural gas (HCNG) could result in cost effective power plants. Some questions: – Can HCNG powered engines meet customer requirements on power density, efficiency and emissions? – How can one benefit from current progress in engine/emissions control technologies? • The overall goals of the current project are to develop HCNG powered commercial vehicles that would be part of a long term hydrogen roadmap while providing emissions benefits. Copyright © 2008, Westport Innovations Inc. 2

IWHUP Demonstration Overview • • • Integrated Waste Hydrogen Utilization Project (IWHUP). IWHUP is an $18, 000 initiative to harness waste hydrogen and promote its use as a fuel by demonstrating emerging clean fuel cell and transportation technologies. Comprised of nine sub-projects: 1. 2. 3. 4. 5. 6. 7. 8. 9. Waste Hydrogen Supply Compressed Hydrogen Distribution Light-duty Hydrogen Vehicle Fuelling Station Heavy-duty HCNG Vehicle Fuelling Station Light-duty H 2 -ICE Powered Vehicles Heavy-duty HCNG Powered Transit Buses Combined Heat & Power Fuel Cell Demonstration Education and Outreach Initiative Project Management Initiative Copyright © 2008, Westport Innovations Inc. 3

IWHUP: Specific Project Goals • An integrated approach to promoting: • the use of vented by-product hydrogen, and, • the necessary infrastructure, end use applications, regulatory framework and education • • Stimulate greenhouse gas (GHG) emission reduction. Further hydrogen usage from by-product streams. Explore economic performance of sub-project applications. Evolve current codes, standards and regulations of distribution and use of hydrogen fuel. • Provide education on hydrogen fuels, applications and safety issues. • North Vancouver “Node” of the BC Hydrogen Highway. TM. Copyright © 2008, Westport Innovations Inc. 4

IWHUP Partners and Funding Programs Industry/Other Partners • Sacré-Davey Group (Lead) • Westport Innovations • Powertech Labs • HTEC H 2 Energy & Tech. Corp. • Clean Energy Fuels • Dynetek Industries • Nuvera Fuel Cells • Questair Technologies • Easywash • Newalta • South Coast British Columbia Transportation Authority (Trans. Link) • Ford Motor Company of Canada Funding Programs • Industry Canada • Sustainable Development Technology Canada • Natural Resources Canada • US Do. D Climate Change Fuel Cell Program Copyright © 2008, Westport Innovations Inc. 5

By-product Hydrogen • IWHUP Source – North Vancouver electrochemical plants (Sodium Chlorate & Chlor-alkali) ~ enough by-product hydrogen to power a fleet of over 20, 000 vehicles • Over 50, 000 kg vented annually in Canada ~ enough to power almost 200, 000 vehicles ~ approximately 750 wind turbines (1 MW) would be required to produce this amount of hydrogen with electrolysers • Over 1000 sources of by-product hydrogen around the world Copyright © 2008, Westport Innovations Inc. 6

IWHUP Hydrogen Supply • Hydrogen captured from a by-product streams • HTEC’s pilot plant will purify & compress 20 kg/hr to 450 bar (6500 psig) at 99. 999% purity levels US-Do. D/ERDC-CERL Climate Change Fuel Cell Program Copyright © 2008, Westport Innovations Inc. 7

IWHUP - Hydrogen Distribution • Self Load/Unload compressed hydrogen distribution system • TC approved aluminum - carbon-fiber cylinders – 450 Bar • 89 kg of hydrogen per Power. Cube (6 total on trailer) US-Do. D/ERDC-CERL Climate Change Fuel Cell Program Copyright © 2008, Westport Innovations Inc. 8

Heavy-Duty HCNG Fuelling Station • Added to existing CNG Station • New H 2, HCNG, CNG Capability High Volume Dispenser • Located at Translink’s Port Coquitlam Transit Facility US-Do. D/ERDC-CERL Climate Change Fuel Cell Program Copyright © 2008, Westport Innovations Inc. 9

HCNG Transit Buses • HCNG mixture with 20 volume% H 2 and 80 volume% NG. • Builds on the technology developed on the 5. 9 L B Gas Plus lean burn spark ignition engine. • Upgrade of the 280 HP 8. 3 L C Gas Plus engine. • Re-calibration objectives: – Maintain engine torque, power and fuel economy. – Reduce NOx while keeping other emissions same or better. – No detrimental impact on drivability. Copyright © 2008, Westport Innovations Inc. 10

Cummins Westport – SI NG Engine Products HCNG Calibrations Available 5. 9 Liter 195– 230 hp 420– 500 lb-ft 8. 3 Liter 250 -280 hp 750 – 850 lb-ft 1. 8 NOx+NMHC 0. 01 PM Lean Burn SI (emissions are in g/bhp-hr) Copyright © 2008, Westport Innovations Inc. 8. 9 Liter 320 hp 1000 lb-ft 1. 4 NOx+NMHC 0. 01 PM 8. 9 Liter 250 -320 hp 660 -1000 lb-ft 0. 1 NOx 0. 01 PM Stochiometric +EGR+TWC 11

Engine Hardware Modification • Minimal changes to the engine hardware. • The hot-wire type mass flow meter unit on the engine measures the fuel flow rate. • Higher thermal conductivity of hydrogen in HCNG has a stronger cooling effect on the hot wire sensor. The output voltage of the original unit built for CNG service saturates when the engine is operated on HCNG. • Modifications to the mass flow meter were carried out to enable operation on the HCNG fuel. The process was: – – – Identification of a design solution System modeling to simulate the mass flow meter Mass flow meter bench tests and model validation Machining of modified parts based on model prediction Engine testing of the modified mass flow meter with HCNG Copyright © 2008, Westport Innovations Inc. 12

HCNG Engine Steady-state Torque and Emissions Post-catalyst Test Cell Results: • NOx, CH 4 and CO 2 emissions reduced. • Engine torque on HCNG same as CNG. Copyright © 2008, Westport Innovations Inc. 13

HCNG Bus Drivability and Acceleration Bus performance on HCNG was verified by conducting acceleration as well as hill climb tests. Buses were also tested on urban driving routes. • HCNG bus drivability was at par with CNG. Copyright © 2008, Westport Innovations Inc. • Driver feedback indicated no significant difference between HCNG and CNG bus operation. 14

Compliance and Regulatory Approval of the HCNG Buses • Components on-board the bus were assessed for their compatibility with HCNG fuel: – Bus fuel system: Fuel tanks, Piping, Gas leak detection and Fire Suppression system – Engine fuel supply components (metallic and non-metallic) coming into contact with HCNG • HCNG Bus was also inspected and assessed for its compatibility with appropriate code requirements by an independent laboratory (Powertech Labs). • Compatibility of the fuel tank and gas leak detection for HCNG service was verified with the system suppliers. • Bus inspection was also performed by an independent bus company to pass the commercial vehicle inspection program. • Regulatory approval from British Columbia Safety Authority and BC Ministry of Transportation also obtained before commencing the bus testing in regular service. Copyright © 2008, Westport Innovations Inc. 15

Bus Emissions Testing • Emissions testing was performed with two sets of onboard emissions measuring equipment. – PEMs (commercial equipment from SEMTECH) – DOES 2 (custom-built unit from Environment Canada) • Each unit could measure HC, CO, NOx and CO 2. In addition the DOES 2 system could also measure total particulate matter. Copyright © 2008, Westport Innovations Inc. 16

Bus Emissions Test Cycle • A bus driving cycle for on-road emissions testing was developed based on typical service on regular routes. • Tests tracks were set up on the runway of a closed airport in Delta, British Columbia. Copyright © 2008, Westport Innovations Inc. 17

HCNG vs. CNG Bus Emissions in Steady State Operation Copyright © 2008, Westport Innovations Inc. 18

HCNG vs. CNG Bus Emissions in Transient Operation Copyright © 2008, Westport Innovations Inc. 19

HCNG Buses on Regular Service Routes 0. 708 average 0. 734 average • Currently 4 HCNG buses and 2 CNG control buses are operating in the Greater Vancouver region in regular service. Copyright © 2008, Westport Innovations Inc. 20

Summary • • • Engine test cell steady-state testing indicated 30% reduction in NOx+NMHC without sacrificing engine torque or fuel economy. Field testing verified that the HCNG bus acceleration and drivability were at par with CNG. Emissions testing of HCNG and CNG buses under transient operation on a test track indicated following emissions benefits: – – • NOx emissions on HCNG were 38% lower. THC emissions on HCNG were 20% lower. CO 2 emissions were 9% lower. Fuel consumption expressed in terms of diesel-equivalent-liters/km was similar on either fuel. HCNG demonstration buses have similar performance characteristics to the CNG control buses in regular passenger service. Copyright © 2008, Westport Innovations Inc. 21