Proposal:

Execute Contract with ISE Research to Develop and Demonstrate Heavy-Duty Hybrid-Electric Truck Fueled with Compressed Natural Gas

Synopsis:

The AQMD has received a proposal from ISE Research to develop and demonstrate a heavy-duty hybrid-electric truck fueled with compressed natural gas. Hybrid-electric drivetrains, using electric motors and engine-alternators called auxiliary power units (APUs), have demonstrated low NO_x and particulate emissions. This occurs because the APU operates at high efficiency and may use a clean fuel for very low emissions. Total project cost is $971,700. AQMD cost-sharing is $200,000.

Committee:

Technology, February 28, 1997, Recommended for Approval

Recommended Action:

Authorize the Chairman to execute a contract with ISE Research to develop and demonstrate a heavy-duty hybrid-electric truck fueled with compressed natural gas, for an amount not to exceed $200,000.

James M. Lents, Ph.D.
Executive Officer

Background

Heavy-duty trucks represent 4% of the vehicle population in California, but contribute nearly 50% of the NO_x and over 80% of the on-road particulate (as estimated by the ARB for 2000). Each heavy-duty truck emits approximately 34 times more NOx than a passenger car on a per-mile basis.

The high NO_x emissions from conventional diesel trucks result from the heavy loads transported. Nearly full engine power is needed to accelerate from a stop up to road speed as well as to travel up grades. NO_x and particulate emissions are extremely high during these modes. Through the use of alternative fuels such as natural gas, methanol or propane, NO_x emissions can be reduced by at least 50%, and particulate emissions by 90% due to fuel properties and combustion characteristics.

Another potential control technology for heavy-duty trucks is the use of hybrid-electric drives. Such systems consist of an electric propulsion system (electric motor, controller and battery pack) and an on-board engine alternator called an auxiliary power unit (APU). The electric propulsion motor provides good acceleration at high efficiency. In addition, electric propulsion systems can be designed to recover the energy normally lost during vehicle braking and return that energy to the battery pack (regenerative braking). The battery pack, together with the APU, provide short-term high power to accelerate, pass and climb hills. The APU, by itself, provides limited electrical power to recharge the battery during steady, low-power driving. This extends the overall range of the hybrid-electric truck, which would otherwise be limited by the battery pack's capacity.

The emissions from a heavy-duty hybrid-electric system should be much lower than a conventional diesel engine. This occurs because the APU engine is smaller and operates at a constant speed and load to recharge the battery pack. The APU can be switched off for quiet truck operation when desired. Through the use of an alternative fuel, APU emissions can be reduced even further. Overall, hybrid-electric systems have the potential to substantially reduce emissions, energy costs, maintenance costs, operational noise, and visible smoke.

Proposal

Staff has received a proposal from ISE Research to develop and demonstrate a heavy-duty hybrid-electric truck fueled with compressed natural gas (CNG). The project is supported by the Defense Advanced Research Projects Agency (DARPA) through CALSTART, the California Office of Strategic Technology, Kenworth Truck Company, and Crown Disposal.

This project involves the design, fabrication, and testing of a hybrid-electric drivetrain in a heavy-duty Kenworth truck tractor. The hybrid truck will be constructed at the CALSTART facility in Burbank. Reuland Electric of the City of Industry will be involved in developing the new electric propulsion motor. Asea Brown Boveri-USA (ABB) and Soft Switching Technologies (SST) will develop the motor controller. UC Riverside/CE-CERT will test and optimize the APU emissions. After achieving satisfactory emissions and operational performance, the truck will be demonstrated by Crown Disposal to service large refuse bins such as those used at construction sites.

The proposed truck will have an alternating current (AC) induction motor with 386 peak horsepower, an energy management system, regenerative braking, a lead-acid battery pack (768 volts), and a CNG-fueled APU (Clean Air Partners Vortec V-6 CNG engine with 147 peak horsepower [GM 4.3-liter base engine]). CNG was selected as the fuel for the APU because of low emissions demonstrated in several heavy-duty truck and bus projects. As a result of the low APU emissions and intermittent battery-only operations, the hybrid-electric truck is expected to produce 80-90% lower NO_x and particulate emissions than a modern diesel engine.

With the proposed hybrid-electric system, the demonstration refuse truck will begin its daily operation with the battery pack fully charged from the electrical grid. The APU will be used to maximize the battery charge level and assist during peak power requirements. By the end of the shift, the battery pack will be depleted and ready for recharging overnight. The truck will be designed to provide 300 miles range on a combination of power from the batteries and CNG-fueled APU. Its battery-powered range will be 50 miles.

This project should help expedite the commercial development of such low-emission systems and their introduction into the Basin. In addition to reducing emissions, these vehicles have the potential for reducing fuel consumption, reducing maintenance costs, and improving the aesthetics of heavy-duty truck operation (smoke, odor, noise). The developed technology could also have application to other trucks and buses used in the Basin.

The proposed project is included in the Technology Advancement Plan, approved on October 11, 1996, as Project M1-4. "Development and Demonstration of Low Emission, Alternative Fuel Technologies for On-Road Applications." The major benefit of this project is to assist truck and engine manufacturers in developing hybrid-electric propulsion technology. This will result in significant reductions of NO_x and particulate emissions with the potential for reduced operating costs and quieter operation.

Sole-Source Justification

Section II, Step 3(C) of the Consultant Selection Policy identifies four provisions under which the Governing Board may execute a sole-source contract: (1) cost to prepare documents exceeds the cost for consultants, (2) delay would result in the endangerment of public health, (3) services are only available from sole-source, (4) other circumstances exist identifying sole-source as in the best interest of the AQMD. This request for sole-source award is being made under provision (4).

ISE Research will be the contractor and manager for this project. ISE Research is a California-based small business with its main offices in San Diego and its main assembly facilities in Burbank. As a relatively new company, it has had experience in developing large AC-induction motors, electric heavy-duty trucks, and electric airport ground-service equipment. Engineering and technical staff experience includes work at General Dynamics Convair and Space Systems, Allied-Signal Aerospace, Garrett Corporation, Sandia National Laboratory and AT&T. ISE Research is well suited for this project.

ISE Research has completed a 13-month Medium- and Heavy-Duty Hybrid Truck Feasibility Study. This $350,000 study was funded jointly by ISE Research and the Mobile Source Emission Reduction Committee. It concluded that a hybrid drive system can meet the power and total energy needs of heavy-duty trucks in a broad variety of applications, and provide substantial economic and environmental benefits.

ISE Research has developed an innovative, and unique clean-fuels project. This involves the design, fabrication, testing and inaugural demonstration of a CNG-fueled hybrid-electric drivetrain and truck system. Besides reducing criteria pollutants, this technology will reduce visible smoke, noxious fumes, toxic emissions, and operational noise.

ISE Research has assembled an exceptionally qualified team capable of developing and demonstrating a CNG-fueled hybrid-electric truck for near-term implementation and air-quality benefits. The team includes: 1) Kenworth Truck Company - An original-equipment truck manufacturer who specializes customized truck tractors. Kenworth intends to offer a commercial hybrid-electric drivetrain as an option for a conventional diesel engine; 2) Reuland Electric - A firm located in the City of Industry which develops and manufactures AC induction motors; 3) ABB/SST - Developers of electronics and software for motor controllers and battery-control systems; 4) UC Riverside/CE-CERT - An emissions and engine testing facility located in Riverside; and 5) Crown Disposal - A refuse collection firm based in Burbank.

For these reasons, it is in the best interest of the AQMD to award a sole-source contract to ISE Research.

Resource Impacts

The total cost to the AQMD will not exceed $200,000. The total aggregate, shared cost of this project is expected to be $971,700. The funding breakdown is as follows:

	Direct	In-Kind
Defense Advanced Research Projects Agency	$250,000	-
California Office of Strategic Technology	180,000	-
ISE Research	127,250	$89,450
Kenworth Truck Company	75,000	25,000
Crown Disposal	-	25,000
AQMD	200,000	-
Totals	$832,250	$139,450	$971,700

Sufficient funds for this project are available in the FY 1996-97 Budget.

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