BOARD MEETING DATE: April 2, 2004
AGENDA NO. 4

Execute Contract to Cosponsor Development and Demonstration of Hydraulic-Hybrid Heavy-Duty Vehicles

SYNOPSIS:

Hybrid-electric passenger cars have been commercialized by Honda and Toyota which capture braking energy, store it electrically, and re-use it in propulsion with the use of electric motors. Hydraulic-hybrid systems are now under development which store braking energy as compressed gas and re-use this energy for propulsion through the use of special pumps in the drivetrain. CALSTART, in association with Permo-Drive Technologies Limited and the U.S. Army National Automotive Center, has proposed the development and demonstration of a hydraulic-hybrid technology on heavy-duty vehicles. The total cost of this project is estimated to be $1,358,476 with AQMD funding not to exceed $250,000.

COMMITTEE:

Technology, February 27, 2004, Recommended for Approval

RECOMMENDED ACTION:

Authorize the Executive Officer to execute a contract with CALSTART to develop and demonstrate a hydraulic-hybrid system on heavy-duty vehicles in an amount not to exceed $250,000 from the Clean Fuels Fund.

Barry R. Wallerstein, D.Env.
Executive Officer

Background

Over 60 percent of the Basin’s NOx emissions inventory can be attributed to mobile sources with heavy-duty trucks and buses accounting for approximately 20 percent of the NOx inventory. Low emission, alternative fuel heavy-duty engines have one-half or less the NOx emissions of their diesel counterparts and only a fraction of the particulate emissions. With these low emissions, natural gas engines have successfully been commercialized in the heavy-duty sector. Nonetheless, further reductions in NOx emissions and particulate are needed in the Basin to achieve the federal ambient air quality standards.

Hybrid technologies represent a method to further reduce emissions from existing low emission engines. Hybrid technologies use a combination of energy sources to propel vehicles, generally an internal combustion engine with another source. Both Honda and Toyota have commercialized hybrid-electric passenger cars, the Hybrid Civic and the Prius. During braking, these hybrid-electric vehicles capture energy normally lost as heat in conventional brake systems. An electric motor/alternator is used to slow the vehicle and generate electricity which is stored in a battery or capacitor pack. During propulsion, the stored electricity is used to power the electric motor and help propel the vehicle. Fuel economy and emissions can be improved by up to 25 percent. Wear and tear on the braking system is also reduced, further lowering operating costs.

In recent years, new types of non-electric, mechanical hybrid systems have been under development. One such technology is the hydraulic-hybrid system, which uses a special hydraulic pump installed in the vehicle drivetrain, usually between the transmission and drive shaft. During braking, the pump slows the vehicle through pumping hydraulic fluid and compressing gas in a pressure tank. During propulsion, the process is reversed, pressure is released, and the hydraulic pump helps propel the vehicle. As with hybrid-electric systems, microprocessors control the energy collection and release based on the vehicle speed, brake pedal position, throttle position, and other factors.

Proposal

CALSTART, in association with Permo-Drive Technologies Limited and the U.S. Army National Automotive Center (NAC), has proposed to develop and demonstrate a hydraulic-hybrid system on heavy-duty trucks. The advantages are lower emissions, lower fuel consumption, and reduced brake maintenance.

In Task 1, NAC will test the Permo-Drive system in several U.S. Army diesel vehicles called "FMTVs" and obtain performance data under various operations. Under Task 2, computer simulations will be performed based upon the data collected by NAC. These simulations will then be used to develop the base microprocessor calibration for a refuse collection truck. In Task 3, the Permo-Drive system will be fully integrated into a natural gas refuse truck. Initial road testing will be performed and the vehicle configuration and system calibration will be optimized. Emission testing will then be performed under Task 4 using a heavy-duty chassis dynamometer system. Finally, in Task 5 the natural gas hydraulic-hybrid refuse truck will be demonstrated up to 12 months in actual refuse collection service.

Benefits to AQMD

The proposed project is included in the March 2004 update of the Technology Advancement Plan under the project entitled, "Develop and Evaluate Heavy-Duty Hybrid Vehicles." The AQMP relies upon the expedited implementation of advanced technologies in Southern California to achieve air quality standards and to continue reductions in air toxic exposure.

The use of hydraulic-hybrid technology in refuse collection trucks is expected to reduce emissions by at least 25 percent. When applied to refuse trucks with modern natural gas engines (1.8 g/bhp-hr NOx), NOx emissions are reduced by about 0.1 ton per year per truck. If this technology is applied to refuse collection trucks with modern diesel engines (2.5 g/bhp-hr NOx), NOx emissions are reduced about 0.14 tons per year per truck. Emission reductions would be even greater if this technology were retrofitted to older trucks. Beyond this, fuel is expected to be reduced by at least 25 percent and brake maintenance reduced by more than 50 percent. Cost reductions with less fuel used and longer brake life could enable the hydraulic-hybrid technology to pay for itself in about 2-3 years; the life of refuse trucks in the Basin is about 12 years.

Sole Source Justification

Section VIII.B.2 of the Procurement Policy and Procedure identifies four major provisions under which a sole source award may be justified. This request for a sole source award is made under provision B.2.d.: Other circumstances exist which in the determination of the Executive Officer require such waiver in the best interest of the AQMD. Specifically, these circumstances are: B.2.d.(1) Project involving cost sharing by multiple sponsors.

This program is cosponsored by several entities, where AQMD’s contribution will be leveraged at a ratio of approximately 1 to 5. Project funding will be supplied by Dana Systems, Permo-Drive Technologies, U.S. Army NAC, Mack Trucks, Waste Management, Federal Refuse Truck, and others. Dana Systems is a manufacturer of heavy-duty truck transmissions, axles and differentials. Permo-Drive Technologies is an Australian company which has developed their hydraulic-hybrid system and hold proprietary rights. The U.S. Army NAC is developing new technology for military vehicles which, mainly, will reduce fuel consumption. Mack Trucks is a major manufacturer of heavy-duty trucks and is one of four manufacturers of heavy-duty natural-gas engines. Waste Management is part of the largest refuse collection business in the United States. Federal Refuse Truck is a manufacturer of refuse truck bodies.

Resource Impacts

Total cost for the proposed project is approximately $1,358,476. AQMD’s contribution from the Clean Fuels Fund shall not exceed $250,000. The total estimated cost-share for this proposed project is:
 

Sufficient AQMD funds are available in the Clean Fuels Fund, which is established as special revenue from the state-mandated Clean Fuels Program. The Clean Fuels Program, under Health and Safety Code Sections 40448.5 and 40512 and Vehicle Code Section 9250.11, establishes mechanisms to collect revenues from mobile sources to support projects to increase the utilization of clean fuels, including the development of the necessary advanced enabling technologies. Funds collected from motor vehicles are restricted, by statute, to be used for projects and program activities related to mobile sources that support the objectives of the Clean Fuels Program.

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