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1 GE LOCOMOTIVE PROJECT 2 Engineering Design 100 Submitted to: Mr. Wallace Catanach Sec. 004 Group 7: Fantastic Four Group Members: Gabriel [email protected] Ziyang [email protected] Hongbo [email protected] Ruixi [email protected]
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GE LOCOMOTIVE PROJECT 2 - Pennsylvania State … GE LOCOMOTIVE PROJECT 2 Engineering Design 100 Submitted to: Mr. Wallace Catanach Sec. 004 Group 7: Fantastic Four Group Members: Gabriel

Mar 20, 2018

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Page 1: GE LOCOMOTIVE PROJECT 2 - Pennsylvania State … GE LOCOMOTIVE PROJECT 2 Engineering Design 100 Submitted to: Mr. Wallace Catanach Sec. 004 Group 7: Fantastic Four Group Members: Gabriel

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GE LOCOMOTIVE PROJECT 2 Engineering Design 100

Submitted to: Mr. Wallace Catanach

Sec. 004

Group 7: Fantastic Four

Group Members:

Gabriel [email protected]

Ziyang [email protected]

Hongbo [email protected]

Ruixi [email protected]

Page 2: GE LOCOMOTIVE PROJECT 2 - Pennsylvania State … GE LOCOMOTIVE PROJECT 2 Engineering Design 100 Submitted to: Mr. Wallace Catanach Sec. 004 Group 7: Fantastic Four Group Members: Gabriel

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Table of Contents

Executive Summary……………………………………………..…………. 3

Introduction…………………………………………………..……………….. 4

Needs………………………………………………………………………………. 4,5

Research……………………….…………………………..……………………. 5-9

Concept Generation………………………………………………………...9,10

Concept Selection……………………………………………………………11

Cost Model………………………………………………………………………..12

Design……………………………………………………………………………….14,15

Model………………………………………………………………………………..15

Conclusion…………………………………………………………………………16

References………………………………………………………………………..16

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Executive Summary

Pittsadelphia has a need for the design of a cost-effective transportation solution that reduces emission and meets the new EPA requirements. It’s going to maintain or increase transportation ability between the port cities. Every day approximately 165,000 tons of raw materials travel via rail into and out of the Pittsadelphia. The train emissions generated from engine-emitted NOx is a key complaint of city residents. Tier 2 locomotives used to haul freight are approaching age for overhaul, at which investments will be required to meet EPA Tier 3 (or higher) requirements.

We are going to upgrade the locomotive fleet to meet more recent emissions guidelines set by the EPA. A few options may exist to meet the new standards. We are implementing a combination of methods to reduce the locomotive’s emissions and its effect on smog in the city. Using a combination of a an ammonia based after treatment and exhaust gas recirculation we successfully reduce the amount of NOx produced and hydrocarbons emitted into the atmosphere.

GE Transportation is going to be our Sponsor. GE Transportation, is a unit of GE (NYSE: GE), they solve the world’s toughest transportation challenges. GE Transportation builds equipment that moves the rail, mining, and marine industries. GE designs and builds fuel-efficient and reduced-emission freight and passenger locomotives; diesel engines for rail; marine and stationary power applications; signaling and software solutions; drive systems for mining trucks; and value-added services to help customers grow. GE Transportation is headquartered in Chicago, IL, and employs approximately 13,000 employees worldwide.

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Introduction

In today’s society, the government is enforcing stricter and

stricter regulations on companies to control their emissions. The

automobile industry was hit first but now the locomotive industry is

getting the attention. The locomotive industry is no exception to this

problem. The industry is constantly developing new ways to reduce

their carbon footprint and develop new ways to cut down on the

harmful emissions produced from their locomotives. Specifically,

General Electric has tasked us to develop a model for a new locomotive

to add to their fleet. It must meet the new EPA requirements for NOx

emissions and must also reduce the emissions that contribute to the

smog in the urban area. This can be achieved through a number of

different methods such as after treatment, upgraded combustion

design etc.

Needs

Customer Statement Needs Statement Smog from locomotive is a key complaint

of city residence

Reduce smog emissions within Pittsdelphia

Smog is generated from engine emitted NOx

Decrease NOx emissions from engines of locomotive

Tier 2 locomotives used to haul freight are approaching age of overhaul

Upgrade the locomotive fleet

EPA requires locomotive to reach tier three requirements

Meet EPA requires for NOx

Page 5: GE LOCOMOTIVE PROJECT 2 - Pennsylvania State … GE LOCOMOTIVE PROJECT 2 Engineering Design 100 Submitted to: Mr. Wallace Catanach Sec. 004 Group 7: Fantastic Four Group Members: Gabriel

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Needs metrics

Upgrade locomotives from tier 2 to tier 2+, or even higher

Add after treatment on locomotive engines

Add emissions recirculation

Use alternative fuels

Pick the comparative low cost solution

Reduce smog emissions within the

city

x x

Decrease NOx

emissions from engines

x x x

Upgrade the locomotive

x

Meet EPA requirements

NOx

x x x x

Cost efficient design

x X

Research

Freight

15 Freight trains/day 2 Locomotives/freight trains Coal

5 Minerial trains/day 3 Locomotives/coal train

45 Locomotives/day 50 total locomotives in fleet

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Mileage for Teir 2 locomotive 1 Ton freight 470 miles/gallon Diesel 165000 Tons/day

Emmissions for Teir II Locomotive 0.2 g/hp-hr Particulates 5.5 NOx/hp-hr NOx

Assumptions

500 miles/trip into the city 50 mph average speed 143 tons tons/loaded coal car 117 tons Weight of coal 26 tons Weight of coal car

215000 lbs Freight Lading Capacity 30 tons Freight car weight empty 110 tons Freight Lading Capacity

$2.50 $/gallon Diesel fuel 500 miles One way trip

Coal train full

12000 gallons need 12000 gallons to go 470 miles 470 miles need 12000 gallons to go 470 miles 500 miles Miles per trip to city

Page 7: GE LOCOMOTIVE PROJECT 2 - Pennsylvania State … GE LOCOMOTIVE PROJECT 2 Engineering Design 100 Submitted to: Mr. Wallace Catanach Sec. 004 Group 7: Fantastic Four Group Members: Gabriel

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Coal Train In

Coal Train Out

Freight Train In

Freight Train Out

Coal/freight into city (tons)

(tons) 12,000 0 7,000 5,000

Total # of cars in a train

103 103 64 64

Weight of empty cars

(tons) 2,678 2,678 1,920 1,920

Weight of locomotives

(tons) 648 648 432 432

Total weight of loaded train

(tons) 15,326 3,326 9,352 7,352

Total power @50 mph level grade

(hp) 10,230 2,220 6,242 4,907

Power fraction 0.76 0.16 0.69 0.55

Fuel used per train (gal) 10,883 2,362 6,641 5,221 Fuel cost per train ($) 27,208 5,905 16,602 13,052

Particulate emissions per train

(kg) 20 4.4 12 10

NOx emissions per train

(kg) 563 122 343 270

ANNUAL TOTALS GRAND

TOTAL Fuel used (kgal) 19,862 4,310 36,359 28,583 89,114 Fuel cost (M$) 49.7 10.8 90.9 71.5 223

Particulate emissions (tonnes) 18.7 4.1 34.2 26.9 83.8 NOx emissions (tonnes) 513 111 940 739 2,304

Page 8: GE LOCOMOTIVE PROJECT 2 - Pennsylvania State … GE LOCOMOTIVE PROJECT 2 Engineering Design 100 Submitted to: Mr. Wallace Catanach Sec. 004 Group 7: Fantastic Four Group Members: Gabriel

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Alternative Fuel Emissions:

NOx(g/mile) CO(g/mile) HC(g/mile) PM(g/mile)

D1 32 9.7 2.6 0.96 D2 31.8 16.5 2.1 1.48 NG 30 15.3 14.8 0.03

M100 14.7 19.9 14.7 0.26 E85 18.2 31.9 10.5 0.49

Alternative Fuel Price

D1 D2 NG M100 E85 Price(d/gal) 2.498 2.331 2.512 1.89

Locomotive Diagram (Size Relativity):

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Exhaust gas recirculation (EGR) is a technique of reducing nitrogen

oxide emissions in petrol/gasoline and diesel engines. It works by

recirculating a portion of an engine's exhaust gas back to the

engine cylinders. This dilutes the Oxygen in the incoming air stream and

provides gases inert to combustion to act as absorbents of combustion

heat to reduce

peak in-cylinder

temperatures. NOx

is produced in a

narrow band of

high cylinder

temperatures and

pressures.

Picture from www.aa1car.com

A High Pressure Injection Pump is the device pumps diesel (as the fuel)

into cylinders of a diesel engine. Traditional injection pump is driven

indirectly from the crankshaft by gears, chains or a toothed belt (often

the timing belt) that also drives the camshaft. It rotates at half

crankshaft speed in a conventional four-stroke diesel engine. Its timing

is such that the fuel is injected only very slightly before top dead

center of that cylinder's compression stroke. It is also common for the

pump belt on gasoline engines to be driven directly from the camshaft.

Page 10: GE LOCOMOTIVE PROJECT 2 - Pennsylvania State … GE LOCOMOTIVE PROJECT 2 Engineering Design 100 Submitted to: Mr. Wallace Catanach Sec. 004 Group 7: Fantastic Four Group Members: Gabriel

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Picture from www.enginebuildermag.com

A diesel particulate filter is the device designed to remove diesel particular matter or soot from exhaust gas of a diesel engine. Usually its type varies in cordierite wall flow filter, Silicon carbide wall flow filter, Ceramic Fiber Filters,

Metal fiber flow-through filters, and paper filter.

Picture from http://www.ironmanparts.com/?id=emi3&sub=products

Page 11: GE LOCOMOTIVE PROJECT 2 - Pennsylvania State … GE LOCOMOTIVE PROJECT 2 Engineering Design 100 Submitted to: Mr. Wallace Catanach Sec. 004 Group 7: Fantastic Four Group Members: Gabriel

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Ammonia based after-treatment is a technique of converting nitrogen

oxides, with a catalyst into diatomic nitrogen, and water. A

gaseous reductant, typically anhydrous ammonia, aqueous

ammonia or urea, is added to a stream of flue or exhaust gas and is

adsorbed onto a catalyst. Carbon dioxide, is a reaction product when

urea is used as the reductant.

Picture form http://www.mathworks.com/company/newsletters/articles/optimizing-a-diesel-engine-aftertreatment-

system-with-matlab-and-gt-suite.html

Concept Generation

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Page 13: GE LOCOMOTIVE PROJECT 2 - Pennsylvania State … GE LOCOMOTIVE PROJECT 2 Engineering Design 100 Submitted to: Mr. Wallace Catanach Sec. 004 Group 7: Fantastic Four Group Members: Gabriel

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Concept Selection

WEIGHING UPGRADE ENGINE

EXHAUST GAS RECIRCULATION

PISTON DESIGN

HIGH PRESSURE INJECTION

DIESEL PARTICULATE FILTER

AMMONIA BASED

USE ALTERNATIVE FUEL

REACH EPA REQUIREMENTS

35% 5 5 4 4 5 5 5

REDUCE HARMFUL EMISSIONS WITHIN THE CITY

25% 5 5 3 3 5 5 4

ECONOMICAL 25% 3 3 4 3 4 4 4 LOW MAINTENANCE

15% 4 5 5 5 3 3 5

SUM 4.35 4.5 3.65 3.65 4.45 5.5 4.5 CONINUE? YES YES NO NO NO YES NO

REACH EPA REQUIREMENTS

REDUCE HARMFUL EMISSION

ECONOMICAL LOW MAINTENANCE

SUM OF + CONTINUE?

UPGRADE ENGINE

+ + _ 0 2 Yes

EXHAUST GAS RECIRCULATION

+ + 0 + 3 Yes

PISTON DESIGN 0 0 + + 2 Yes

HIGH PRESSURE INJECTION

0 0 0 0 0 Yes

DIESEL PARTICULATE FILTER

+ + + - 3 Yes

AMMONIA BASED + + + - 3 Yes

USE ALTERNATIVE FUEL

0 + - + 2 yes

Page 14: GE LOCOMOTIVE PROJECT 2 - Pennsylvania State … GE LOCOMOTIVE PROJECT 2 Engineering Design 100 Submitted to: Mr. Wallace Catanach Sec. 004 Group 7: Fantastic Four Group Members: Gabriel

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Cost Model

Design

TierII to Tier III locomotive upgrade

After Treatment Cost

Exhausted Gas Recirculation

total cost

cost 750k 100k 100k

Number of locomotives

50 50 50

upgrade cost

37,500,000 5,000,000 5,000,000 47,500,000

Page 15: GE LOCOMOTIVE PROJECT 2 - Pennsylvania State … GE LOCOMOTIVE PROJECT 2 Engineering Design 100 Submitted to: Mr. Wallace Catanach Sec. 004 Group 7: Fantastic Four Group Members: Gabriel

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Our designed entailed upgrading each locomotive from tier II to

tier III. We added an after treatment system to each locomotive. The

ammonia based after treatment will significantly reduce the amount of

NOx emitted into the atmosphere. To combat against the

carbohydrates not burned in the combustion process we also

implemented an exhaust gas recirculation. Both of these solutions will

significantly reduce the harmful emissions of the locomotive and

reduce smog in Pittsdelphia.

Model

Page 16: GE LOCOMOTIVE PROJECT 2 - Pennsylvania State … GE LOCOMOTIVE PROJECT 2 Engineering Design 100 Submitted to: Mr. Wallace Catanach Sec. 004 Group 7: Fantastic Four Group Members: Gabriel

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Conclusion

Modern technology is constantly being advanced. Society

is demanding for bigger and better machines. Our use of

technology does have negative effects that are not always

accounted for economically. This is why the EPA sets these

regulations. The locomotive industry is behind the curve when

it comes to these regulations. These advanced designs need to

be implemented into the new locomotives being produced.

These new locomotives are just another stepping stone to

reducing our carbon footprint and our impact on our planet.

References

http://www.mathworks.com/company/newsletters/articles/optimizing-a-diesel-engine-aftertreatment-system-with-

matlab-and-gt-suite.html

http://www.ironmanparts.com/?id=emi3&sub=products

www.aa1car.com

www.enginebuildermag.com