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 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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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
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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 $/gallon Diesel fuel 500 miles One way trip
Coal train full
12000 gallons need 12000 gallons to go 470 miles 470 miles need 12000 gallons to go 470 miles 500 miles Miles per trip to city
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Coal Train In
Coal Train Out
Freight Train In
Freight Train Out
Coal/freight into city (tons)
(tons) 12,000 0 7,000 5,000
Total # of cars in a train
103 103 64 64
Weight of empty cars
(tons) 2,678 2,678 1,920 1,920
Weight of locomotives
(tons) 648 648 432 432
Total weight of loaded train
(tons) 15,326 3,326 9,352 7,352
Total power @50 mph level grade
(hp) 10,230 2,220 6,242 4,907
Power fraction 0.76 0.16 0.69 0.55
Fuel used per train (gal) 10,883 2,362 6,641 5,221 Fuel cost per train ($) 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
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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.
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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
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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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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
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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
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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
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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