Session 1 at NAFA, presented by Bill Van Amburg, April 24, 2013
Alternative Fuels and High-Efficiency Vehicles – Update for Fleets
Wednesday, April 24 10:15 – 11:45 am
The landscape of alternative fuels and advanced vehicles is rapidly changing, capabilities are improving and it is hard for fleets to keep up. This session will provide a valuable 10-thousand foot overview of the latest products available today, the technology emerging in the near term and what these technologies and fuels can mean to fleet operations. This is a valuable session both for fleets just trying to get up to speed on this arena, and as an update for fleets already active but wanting to stay current.
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Alt fuels and hi efficiency vehicles update calstart - 4-24-13
1. Alternative Fuels and High-
Efficiency Vehicles
Update For Fleets
Bill Van Amburg, CALSTART
1
Fleet Sustainability Track
Presented by CALSTART
2. SUSTAINABILITY TRACK
Advanced Fuels, Vehicles and Strategies
for Fleets – Making Sustainability Work
4 Session Track for 2013 Presented by
CALSTART
2
Myths, Facts &
Misperceptions: The
Straight Scoop on New
Fuels & Tech
April 25 10:00 – 11:30 am
Smart Alt Fuels & Tech
Workshop: Making it
Work for You
April 25 3:30 – 5:00 pm
Fleet Sustainability/
Greening: The Key
Steps to Plan Your Path
April 26 9:30 – 10:45 am
Fleet Sustainability Track
Presented by CALSTART
Alt Fuels & High
Efficiency Vehicles:
Update for Fleets
April 24 10:15 – 11:45 am
4. Agenda
CALSTART Background
The Pace of Change – Why so Fast?
The Options Landscape for Fleets
Ethanol
Natural Gas (gaseous fuel)
Biodiesel
Electric
Hybrid (including Plug in)
Hydrogen
Fleet Impacts – Dealing with Change
Conclusions
4
5. CALSTART is a national, non-profit,
clean transportation organization.
Mission:
Support and
expand clean
transportation
technology
industry
Tech and fuel
neutral
Goals:
• Create high-quality jobs;
• Clean the air;
• Reduce dependence on foreign oil; and
• Reduce global warming emissions
6. What CALSTART Does
Mission:
Support and
expand clean
transportation
industry
Role:
Speed
development,
validation and
use of clean
transportation
systems
Activities:
TECH: Help partners
structure, manage and
validate technology
projects
POLICY: Develop policies
supporting clean
transportation development
and use
USE: Help fleets and others
choose and use clean
transportation
SUPPORT: Provide
members access to
opportunities, connections,
info, trends
9. More Choices than Ever for Fleets!
Light-duty (cars and light trucks) OEM-
produced natural gas (dedicated and bi-fuel),
hybrid, plug in hybrid, electric and other fuel
vehicles
Medium and heavy-duty OEM and small
manufacturer natural gas, propane, hybrid
and electric vehicles and plug in technology
for work site engine-off operations
Hybrid construction equipment entering
market
9
10. Why the Rapid Change?
ENERGY SECURITY: FUEL SUPPLY AND COSTS –
Traditional fuel supplies more expensive
The need for alt and biofuels is increasing
Huge supply of low cost NA natural gas from new production (hydrofracturing)
Regional fuel variation and choice becoming more prevalent
GLOBAL WARMING – Push to reduce GHGs intensifying and
pushing fuel economy –
CAFÉ revised to match CA CO2 rules: CAFÉ for med & heavy trucks heads to
phase 2
Energy efficiency reduces GHG impact; Fuel switching and blending reduces GHG
impact; Modal split (transit and rail) has long term role
EMISSIONS REDUCTIONS – World population increasingly
urban and world emission standards increasingly move to CA/Euro
standards
Fine particulates (nano particles) will be of increasing concern from combustion
Diesel fuel still challenged in dirtiest regions (ports, Southern California)
11. Efficiency is Huge Driver
Big move in light duty to add improved
combustion, turbocharging, multi-speed
transmissions, aerodynamic features to cars and
trucks – partly based on new Fed CAFE
In big rigs, tractor and trailer aerodynamics, low
rolling resistance tires are current focus – but
next gen includes turbo-compounding, thermal
energy recovery, idle reduction
In vocational trucks, some hybrid and electric
options, big interest in natural gas (for price
rather than efficiency)
Current truck FE standards not tough but new
and more stringent standard under development11
12. Options Landscape: Examples
Fuels Technologies
Ethanol: avail now; regional;
process and feedstock
improving; small CO2 gain but
growing
Propane: vehicle models
available; special fueling;
small CO2 gains
Biodiesel: feedstock
concerns; CO2 gains; NOx
issue
Renewable diesel:
emerging option
Plug-in hybrid: first LD products
available; first pilot products in
M/HD; business case varies based
on fuel prices; strong policy support
Hydrogen: longer term
option; transit; blending
Electric: LD products expanding,
multiple makers; MD products
emerging for delivery/ urban niche
Fuel Cell: still early demos; limited
testing; some deployments 2015?
Hybrid: models of ALL types
including start-stop expanding in
LD; OEM production in MD/HD and
prices dropping; 20-50%
carbon/fuel reduction
Strategies
Platform/engine
size reduction:
“right-sizing”
platforms
Dispatch
changes, work
changes to
reduce/optimize
vehicle use
Routing
efficiencies:
VMT reduction
Natural gas: low price, high
production/jobs; controversy on
production; limited
infrastructure but expanding;
CO2 benefits; Biomethane
Adv. Engine/Powertrain: cylinder
on demand; improved combustion;;
turbocharging; transmissions
13. Chrysler MD Ram
ProMaster
Ford MD Transit
Redesigned
Transit Connect
Nissan NV
OEMs Go Aero, Efficient
14. Ethanol
Growth in production slowing, fuel price dropping
Drought, loss of incentives, ~40% of US corn crop
goes to ethanol – but it is off setting oil today;
required by Renewable Fuel Standard (RFS)
Clear limits seen on corn-only based production
Other feedstocks and advanced production (such as
cellulosic) are in active development – second
generation production methods have already started
Lower in energy than gasoline, price a bit lower
Lower GHG impact than gasoline; lower for most
(not all) emissions – low % blends an emissions
concern in some areas
Infrastructure growing quickly but still limited; most
flex fuel vehicles still do not use E-85!
16. Natural Gas
Renaissance, growth of natural gas continues
Large surge in domestic supply has meant low price
relative to diesel and gasoline, due to expansion of
hydrofracturing – “fracking” – though controversial
Fleets now have several options in light trucks and
vans; only one OEM car (Honda Civic GX), but can get
upfits for several passenger car models
ALL medium and heavy-duty OEMs now offer natural
gas (Freightliner, Mack, Volvo, Kenworth, Peterbilt,
Navistar)
Additional engine families now available (6, 8.9, 12,
13, 15 liter)
Domestic and lower carbon – particularly biomethane
Niches remain strong: transit, refuse, now ports
Infrastructure still barrier, though fuel partners
available and corridors are growing; strongest growth
in regions with good infrastructure
17. Four LD Natural Gas OEM Products
Honda Civic NG
Dodge Ram 2500
Chevy Silverado
Ford F-250
Ford’s Transit will be
shipping with
gaseous fuel-ready
engines
17
18. Bi-fuel is Back! CNG and Gasoline
18
17 GGE NG fuel tank
36 GGE gasoline tank
NG-ready engine (hardened valves, valve
seats)
19. NG Upfitters/QVMs-QCMs
19
Ford uses QVMs for alt fuels
– provides gaseous fuel
ready engine
Clean Energy Fuels-BAF
Altech-Eco
Impco Automotive
Landi Renzo USA with
Leggett and Platt
Venchurs Vehicle Systems
Westport LD
Roush CleanTech
20. Excitement Over Engines
8.9 liter CW ISL G
15 liter Westport HPDI
NEW: 12 liter CW ISX 12 G
Volvo developing own 13L
20
21. Freightliner Natural Gas
Cascadia NG –
ISX12G
M2 112 NG (LNG
& CNG) ISL 6 G
114SD NG ISL G
8.9
FCCC NG
chassis
21
24. Volvo Natural Gas
Developing OWN 13 liter
D13 LNG engine for 2014
Adding natural gas option
for VNL tractor (ISX12 G)
ISL G engine in VNM
Has unique diesel-methane
bi/dual-fuel trucks in Europe
FM 460, 13 liter engine
Can operate up to 75%
methane, 25% diesel
Global partnership with
Shell Oil on LNG marketing 24
25. Mack Natural Gas
Adding Mack Pinnacle
on highway NG truck,
using ISX 12 G; NG
Granite in late 2013
UPS buying 700 LNG
tractors
Have TerraPro low
entry and cab-over NG
for refuse
25
26. Navistar Natural Gas – Still Coming
TransStar, ISL G
Had hoped to
launch in Fall 2012;
aiming for limited
production in 2013
Had originally
planned own
engine partnership
but that did not
succeed, delayed
entry
26
27. Renewable Natural Gas –
Lowest Carbon Fuel
Trucks driving on natural
gas produced from dairy
manure operating in San
Joaquin Valley
Ohio becoming big leader
Process produces and
refines manure biogas to
“biomethane” – essentially
renewable natural gas
Lowest carbon emission fuel
according to CARB scoring Dairy partners – Hilarides
Dairy, Hilmar Cheese
28. Why Are Fleets Paying Attention?
28
Courtesy: CNGPrices.Com
29. NG Prices Down with Fracking Up
29
US Energy Information Agency, 2013
Factors moderating this: Big increase in power
plant demand, LNG export and fracking
restrictions may increase prices but still stable
compared to petroleum
30. Ultra Low Emitting Engines
California needs even lower NOx emissions
than current EPA engine standards – 80%
lower by 2030!
Has proposed a voluntary low emission
standard to allow engine makers to certify up
to 80% below EPA 2010 levels
Natural gas looks like the leader to be able to
meet new lower levels – several development
projects underway
30
31. Biodiesel and Renewable Diesel
Volumes still low but production and use
jumped in 2012 though incentives lapsed – some
impact from feedstock switching to produce
ethanol, drought
Most OEMs accepting increased biodiesel use –
fuel spec has now been developed for B1-B20
levels
Fuel quality improving but still varies
Little or no performance drop off from
conventional diesel; some operating concerns
(such as cold weather)
Reduced greenhouse gases and particulates
from diesel, but increased NOx for biodiesel
remains issue
32. Electric Technology – Many Options
Plug in vehicles expanding – multiple Electric Vehicles
now available
GM sales highest with Volt extended range EV (or is it a
plug in hybrid?) and now Spark EV; Nissan Leaf expands
markets; Ford, Toyota, Honda, Mitsubishi, Tesla selling;
Chrysler, VW, BMW products coming
Medium-duty all-electric trucks available in North
America from Smith Trucks, EVI (FCCC partnership),
Boulder - but Navistar drops out
Improving battery technology partly thanks to hybrids
(lithium ion)
Still expensive, range limited but energy storage costs
dropping steadily
Increased petroleum prices makes an improving
business case in right applications
Criteria and GHG emissions very low; varies depending
on fuel source of power plants, each region different
However: powerplant emissions improving over time
everywhere
34. EVs: Growth Continues
~50,000 PEVs sold in
2012
Most popular? GM Volt
EREV: Extended Range
Electric Vehicle - Electric
drive system with a small
gasoline engine generator
when batteries get low
Roughly half of PEV sales
were Volts (~23,000)
Plug in Prius #2, ~13,000
Nissan Leaf EV drops to
#3, ~10,000
35. Do You Know What’s Available?
Honda Fit EV
Ford Focus EV
Mitsubishi i
Toyota iQ
Tesla Model S
RAV 4 EV
Chevy Spark EV
110 kw motor
35
36. Did You Know What’s Coming?
BMW i3
Carbon fiber
body, dedicated
EV platform
Fiat 500 e
87 miles range
108 mpge
Free loaner for
long trips
36
37. Do You Know What’s Coming?
VW E-Up
VW E-Golf
Smart for Two EV
Top speed 78
~$26,000 w/o incentives
37
38. Nissan Beyond the Leaf
Nissan e-NV200
concept
Near future
production
24 kwh battery
Base vehicle is basis
of NYC cabs
In testing in
Singapore
38
39. Workplace Charging:
Employer EV Initiative
Fills a critical gap in PEV
Infrastructure needs
Extends the range of PEVs
and builds the market
Creates local ‘PEV
showrooms’ for info
sharing on vehicles
EV’s can act as ‘employee
pool cars’ for day trips
www.evworkplace.org
40. Electric Truck Sales Improving
EVI delivering first 100 to
UPS
Smith redesign entering
service featuring
redesigned driveline and
modular battery packs
43. EVI – FCCC E-Truck
» Closer relationship between
EVI and Freightliner
Custom Chassis
» EVI truck in FCCC booth
» Support to EVI for “glider”
purchase
44. Battery Swap System
» 100 buses operating in Beijing since 2008;
similar system also in Shanghai
» Automated system provided by Dianba
Technology, funded by State Grid
44
45. Battery Swap System
» Buses swap packs several times per day
» 240 9kw charging units
» When not needed for buses, batteries also provide grid
support 45
46. Fast Charge Buses
» 30 buses operating in Chongqing Transit
» State Grid facility refueling Hengtong buses with
Microvast batteries
» 10 minute fast charge gives ~50 kwh of storage 46
47. Best Uses for E-Truck Business Case
To get sufficient payback, need to
drive maximum miles possible (or
maximum use of energy)
• Dedicated, return-to-base routes with
known daily mileage highly valuable
High Utilization/Daily miles (5-7 days
a week) seems important
70-100 miles/day seems like an
initial “sweet spot” for fuel savings
payback (sufficient miles to
generate fuel savings needed)
48. Best General Use/ Duty Cycles
1. Fixed route applications - 70%
• Stop and go
• Localized, dedicated routes
• Short haul
• Limited range
• ‘Spoke and hub’
• Urban Delivery, Refuse, Mail trucks, Transit Buses
2. Facility vehicles – 19%
• Airports, seaports, railyards, military bases, parks, resorts
• Warehouse support and maintenance
• Cargo handling
3. High idle, work site applications – 11%
• Aerial devices
• PTO
• Utility vehicles
50. Full Battery Electric
Balqon drayage trucks
in demonstration at port
Proterra all-electric bus
operating with Foothill
transit
Reduced battery pack
size augmented with
fast charge
51. Road-Connected Power
Well known in transit
industry (electric trolley-
bus)
Used widely in mining with
extremely heavy
equipment
Now beginning testing in
Europe (Siemens) for
heavy-haul trucks
Other tests looking at in-
road power alternative
Siemens eHighways Concept (from
2/17/11 CalHEAT Forum briefing)
52. Hybrid Technology
Platform types expanding, incremental cost in cars
dropping, multiple models now available
Over a decade experience in cars: decent and
growing market penetration (3%); automaker
competition growing (Toyota, Ford, Honda)
Products in market for medium- and heavy-duty
vehicles and new products coming (Hino, BAE,
Volvo, Parker, Rexroth)
First focus is urban work trucks: Class 4-8 refuse,
utility, delivery; class 8 drayage, line-haul and
construction equipment are in demonstration
Hybrids multiply benefits when combined with low
carbon fuels (biofuels, NG, electricity – plug-in)
53. Plug-in Hybrid Electric Vehicles
They’re here! Limited production and high
cost, but expanding choice, multiple OEMs in
market, more coming
Until recently most PHEVs were conversions
from small firms – very few on road
Benefits: increased fuel economy, GHG
reductions, possible zero emission driving
Cost and life cycle of energy storage
(batteries) are prime limiter: but, infrastructure
less of an issue (can plug in off 110 V at home,
do not need high rate charging)
Most focus is on passenger cars – however
while trucks offer additional challenges, there
may be possible business case benefits
before cars
57. Start-Stop – Mild Hybrids
GM offering a
mild hybrid
called “eAssist”
Belt driven
starter
alternator
Saves fuel by
turning off
engine at stops
Chevy,Buick
57
58. Ford Develops PHEV Architecture
Fusion
hybrid,
Fusion
Energi
(PHEV)
C-Max
Energi
(PHEV)
58
59. New PHEV (E-REV) Options Coming
Cadillac ELR
Volt driveline
Mitsubishi
Outlander PHEV
2 liter gas
engine, twin 60
kw e-motors
20-25 mile EV
range in US?
Honda Accord
PHEV
59
60. Volvo Diesel PHEV
V60 PHEV
Coming to US?
Decision in 2013
Diesel electric; 70 hp
e-motor
31 mile EV range 60
61. Fisker Karma
PHEV with high
performance
(Not a fleet
vehicle!)
Pushing the
market place and
technology, but
facing production
challenges – did
it miss its
market?
61
62. Light PHEV or Extended Range E-Trucks
VIA; ALT-e REEP;
Quantum
Chevy Silvarado; F-150
Class (4 cylinder 2 liter
engine 25 kwh pack; 52
mile EV range; 32 mpg
possible FE
Many fleets interested in
this capability but OEMs
not yet responding
62
64. Hybrid Sales Picking Up
Hino Class 5 Cab-over
highly competitive for price
and selling well
Eaton new battery system
showing 4-5% increased
fuel economy over
previous design, better
business case
65. Allison Hybrid H 3000
» Parallel electric hybrid
» 100 kw motor, scalable
battery pack (1.7 kwh
modules)
» Fits in same space as
3000 transmission
66. Hydraulic Hybrid – Class 6
Parker Hannifin, Freightliner Custom Chassis,
Morgan Olson moving into production of a
series hydraulic hybrid for delivery cycles
Just starting field validation testing – have seen
40-60% fuel economy improvement
Major delivery fleets in first deployments
66
67. Hydraulic Hybrid: Autocar-Parker
E3 Hydraulic hybrid
refuse truck uses Parker
“Runwise” system
Up to 30-50% reduction
in fuel use
High cost – but good
business case in intense
duty cycles
Now in early production
after pre-production
validation in Florida
68. DSNY/Bosch Rexroth HRB Hybrid
HRB pre-production deployed
(15- MY2011 Mack LEU 613)
First
HRB/DSNY
cooperation
HRB retrofits
deployed
(2- Mack LEU 613)
First HRBs deployed
(3- Crane Carrier LET2)
HRB full production
deployed
(32- MY2012 Mack LEU 613)
20122008 2009 2010 2011 20132007
ConceptProduction
20062005
HTUF Refuse
Working Group
Formed
68
69. XL Hybrid
Hybrid retrofit start up
Targeting Class 2b
Post transmission,
simple upfit
In testing
69
70. New Hybrid Offering: BAE
Focus on heavy-duty
vocational truck (Class 6-8)
segment
Adapts their system to
parallel design with
Caterpillar transmission
Long experience in transit
market (over 3,000
systems) with series
design
In field demonstration
71. Dual-Mode Hybrids (w/ ZE Mode)
• Meritor – Navistar testing advanced
dual-mode hybrid design
• Electric drive at lower speeds (up to
48 mph), blended mode at higher
speeds
• Can greatly reduce fuel use, cut idle
emissions, provide partial zero
emissions
• Eaton also testing a dual mode
hybrid – zero emission driving for
short range, low speed driving
• Dual mode systems already exist in
transit
72. CALSTART Success Stories
Early field deployment helped CAT move
hydraulic hybrid to market as much as 1 year
earlier
Caterpillar employs hydraulic hybrid technology that is 98%
common with the conventional 336E excavator to boost fuel
efficiency of the 336EH hybrid 50%. Connected Caterpillar with
73. Commercial Construction
Equipment
• HTUF/TARDEC Hybrid-Electric
Bulldozer – Data Collection,
Evaluation and Verification
– Goals are to verify fuel savings &
productivity gains
– CAT D7E diesel-electric track-type
bulldozer w/down-sized 9.3L engine
– Conventional D7R & D6T tested at the
same time as baseline
– Results: up to 22% improvement in
productivity, 60% improvement in fuel
consumption
– Partners: U.S. Army, U.S. Navy,
Caterpillar
74. Plug In Work Trucks - Odyne
Commercial work trucks show
potential for PHEV
functionality
Extra energy storage boosts
idle reduction/work site
engine-off
Odyne first into market; Good
partners in Johnson Controls,
Allison
Several models
Plug-in hybrid utility bucket
trucks
PHEV “digger-derrick”
version 6/08, a higher
power-demand work truck
PHEV underground
compressor truck
75. Plug-in Energy Storage Bodies
Growing interest from fleets if
fuel saving not needed from
driving cycle
Altec, Terex, Time, Azure and
others with systems
Stored energy to operate lift,
tools at work site
Separate from and does not
change conventional driveline
Fuel savings and idle
reduction benefits
76. Series Electric/Hybrid –
Range Extender
Artisan – Parker prototype
electric drive system with
turbine extender (multi-fuel
turbine)
Much development in
turbines, focus on NG
Vision Industries prototype
series electric with fuel cell
range extender
77. Hydrogen / Fuel Cell Technology
Longer term technology for vehicles – still
developmental
US DOE had halted vehicle-based fuel cell development
funding – but has now started re-investing
US DOT still investing in technology for transit buses,
costs have reduced by about half
In medium term, good applications in stationary/
distributed generation; fork lifts; Auxiliary power units
(APUs) for system power, idle reduction, range extension
on some vehicles/equipment
A few hundred vehicles built worldwide for technical
assessment to date - Still could be a launch of small
volumes in 2015
Costs still very high, though significant technical
advancement has occurred in cost, reliability, durability,
size
Benefit in near term from blending hydrogen with natural
gas (NOx reductions)
78. FCEVs
Honda has been a
leader in fuel cell and
vehicle integration,
along with Daimler
GM and Toyota active
but silent – FC fits
GM’s Volt architecture
Most OEMs
researching to some
extent
2015 will see a small
number offered
78
79. FC Commercial Vehicles
Investment and
demonstration continue
for zero-emission transit
buses
Emerging business
case for forklifts and
other industrial vehicles
Many companies
incorporating in
warehouses
79
80. Significant Improvements
On-road durability growth at AC Transit > 12,000 hrs
Significant increase in life cycle nearing life of bus
Availability >83%
Reduced cost >40%, size >50%
80
Latest
PC 58
Early
PC40
Former UTC Power design, now Clear Edge
82. Commercialization Vision for HD
82
HD Fuel Cells
Fuel Cell
APUs (Delphi)
LD Fuel Cells
HD Propulsion
Fuel Cells
Range
Extender
Fuel Cells
83. Develop a Strategic Fleet Plan:
We Can Help You Do ItTechnology/Fuel/Operational
Application/ Region
LD Urban
Support
LD Regional
Vehicle
Reduce vehicle count
through process
improvement
Right size platforms
to job needs
NEVs for on-site
transport
Mix of natural gas
or propane vehicles
in regions with
infrastructure
Hybrids for urban
driving Some hybrids for
stop and go driving
E85/Flexfuel for
longer distance if fuel
available
Right size platforms
to job needs
MD Work
Vehicle - Urban
Mix of hybrids for
urban, stop-go or
high idle work
Right size platforms
dispatched for job
needs
Natural gas or
propane vehicles in
cities with
infrastructure
Biodiesel blends
(check spec and
source)
MD Work
Vehicle - Rural
Right size platforms
dispatched for job
needs
Biodiesel blends
(check spec and
source)
Chassis energy
storage for work
site idle
Natural gas or
propane vehicles in
cities with
infrastructure
85. Regional Meetings
First Regional HTUF Meeting – Birmingham, AL
Barber Motor Sports Park
Date: May 22, 2013
Interest in California Regional Meeting(s) from
several organizations
Timing: SoCal – July, NoCal - TBD
New York Regional Meeting
Timing: Aug/Sep 2013
Co-Host & Sponsorship opportunities still available!
86. Summary
Rapid pace of change, driven by efficiency
and energy security, is changing the vehicle
landscape for fleets
More options today than ever – in multiple
platforms and technology
Not every option works best in every
application – fleets need to look at how they
use their vehicles, match use, infrastructure
to options that fit their need
Three more sessions to help you walk that
path
86
87. SUSTAINABILITY TRACK
Next Session in Track: Myths, Facts &
Misperceptions
Visit CALSTART in Booth 724
87
Alt Fuels & High
Efficiency Vehicles:
Update for Fleets
April 24 10:15 – 11:45 am
Smart Alt Fuels & Tech
Workshop: Making it
Work for You
April 25 3:30 – 5:00 pm
Fleet Sustainability/
Greening: The Key
Steps to Plan Your Path
April 26 9:30 – 10:45 am
Fleet Sustainability Track
Presented by CALSTART
Myths, Facts &
Misperceptions: The
Straight Scoop on New
Fuels & Tech
April 25 10:00 – 11:30 am