Natural Gas as a Transportation Fuel

March 2013

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GTI’s Current NGV RD&D Program is Robust

> Vehicles and On-Board Storage─ Develop/demonstrate new engines and vehicles

> Cummins ISX12 G and other high-efficiency, low-emission 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 Navistar MaxxForce

Advanced Storage

Infrastructure Advancements

3

Cummins Westport Inc. (CWI) 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 > Commercially available

> Critical next-generation NGV engine is a major new product in market─ Nearing culmination of over three-year,

multi-million development─ GTI played key role in securing $3 million

in government and industry funding─ Program managed by GTI, continuation

of over 25-year relationship with Cummins and CWI

> 400 hp for larger vehicles─ Perfect fit for heavy-duty trucks—

refuse collection, concrete mixers, regional haulers

─ Fills out product line above highly successful, world-leading ISL-G (8.9L) sold worldwide

INDUSTRY-LEADING NGV ENGINE

Cummins ISX12 G

4

CWI ISX12 G Field Test Trucks

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CWI 6.7L Ultra-Low Emission Medium-Duty Natural Gas EngineNew GTI Project > Recently announced $1 million award on RD&D project to support Cummins

Westport in the development of a 6.7-liter dedicated natural gas engine

Benefits/Value> Perfect fit for school bus, package delivery,

class 5-7 trucks> Fills out product line below ISL-G (8.9L)

sold worldwide and new 11.9 liter engine

Goals and Targets> 260 hp / 660 ft-lb rating > Spark ignited; stoichiometric with cooled EGR > Out-perform strict CARB 2013 emission standards> Maintenance-free aftertreatment > CNG / LNG / biomethane capable > Commercial launch targeted for early 2015

5

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Advanced Heavy-Duty VehiclePre-Commercial DemonstrationsClean Air Power (CAP)/Volvo 13-Liter Engine Demo> Demonstrate12 Class 8 Tractors for

goods movement ─ Dual fuel compression ignition,

430hp 1550 lb-ft torque

US Hybrid Demo> Demonstrate hybrid truck transport of

cargo from ports─ 3 on-road drayage trucks ─ CWI 8.9 ISLG + 320kW motor drive +

100kW Li-ion battery pack

> Partners: US Hybrid, Freightliner, UC Riverside, Calko Transport, SoCal Gas

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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─ 3rd-party certification testing completed

> Helped lead to collaboration by 3M and Chesapeake JV

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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

9

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.

Technology ImpactProject 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.

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

10

Strategies to Shift Gas Industry Practices and Cost-Effectively Grow the NGV Market

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.

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.

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.

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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 alternative fueling infrastructure─ 16 fleets resulting in 16 CNG shared-access 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

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Lake Michigan Corridor Alternative Fuel Implementation Initiative

> Another DOE Clean Cities initiative with GTI as project lead

> 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

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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

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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

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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

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Fast-Fill Empirical Testing

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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

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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

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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

2020

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 technologiesTechnology 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)

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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

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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 GTI-licensed liquefaction technology

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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 InformationTony Lindsay GTI R&D Director, End Use Solutions 847-768-0530 tony.lindsay@gastechnology.org