Alternative Fuels and High-

Efficiency Vehicles

Update For Fleets

Bill Van Amburg, CALSTART

1

Fleet Sustainability Track

Presented by CALSTART

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

VISIT OUR BOOTH TO FOLLOW UP

CALSTART – Booth 724

3

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

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

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

Title is here

7

CALSTART National Offices

CALSTART HQ

Nor Cal Office Colorado Office

Midwest Office

Planned NE Office

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

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)

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 development 11

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

Chrysler MD Ram

ProMaster

Ford MD Transit

Redesigned

Transit Connect

Nissan NV

OEMs Go Aero, Efficient

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!

Ethanol Prices, Production Down

15

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

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

Bi-fuel is Back! CNG and Gasoline

18

17 GGE NG fuel tank

36 GGE gasoline tank

NG-ready engine (hardened valves, valve

seats)

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

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

Freightliner Natural Gas

Cascadia NG –

ISX12G

M2 112 NG (LNG

& CNG) ISL 6 G

114SD NG ISL G

8.9

FCCC NG

chassis

21

Kenworth Natural Gas

T 800 (LNG)

T 440, T470,

W900S – CNG

or LNG

22

Peterbilt Natural Gas

Models 384, 365

and 320 in

natural gas

ISL G; adding

ISX 12 G

23

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

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

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

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

Why Are Fleets Paying Attention?

28

Courtesy: CNGPrices.Com

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

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

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

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

Plug in market growth chart

33

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

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

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

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

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

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

Electric Truck Sales Improving

EVI delivering first 100 to

UPS

Smith redesign entering

service featuring

redesigned driveline and

modular battery packs

Electric Trucks

Smith EVI

Boulder DV 500

E-Trucks

US Hybrid

Zero Truck

Balqon

Vision Industries

Capacity

EVI – FCCC E-Truck

» Closer relationship between

EVI and Freightliner

Custom Chassis

» EVI truck in FCCC booth

» Support to EVI for “glider”

purchase

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

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

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

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)

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

www.calstart.org/Projects/E-Truck-Project.aspx

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

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)

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)

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

Still the Hybrid Leader

54

Toyota Expands Variants of Prius

Plug in Prius

55

New Challengers

Ford offers dedicated hybrid platform (C-Max), redesigns Fusion hybrid

Honda maintains Civic and Accord hybrid, adds Accord PHEV

GM expanding options

Hyundai

Nissan

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

Ford Develops PHEV Architecture

Fusion

hybrid,

Fusion

Energi

(PHEV)

C-Max

Energi

(PHEV)

58

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

Volvo Diesel PHEV

V60 PHEV

Coming to US?

Decision in 2013

Diesel electric; 70 hp

e-motor

31 mile EV range 60

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

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

Hybrid electric, hybrid

hydraulic, plug-in, all-

electric and advanced

systems – 75% of

these trucks are in

production!

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

Allison Hybrid H 3000

» Parallel electric hybrid

» 100 kw motor, scalable battery pack (1.7 kwh modules)

» Fits in same space as 3000 transmission

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

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

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)

2012 2008 2009 2010 2011 2013 2007

Co

nce

pt

Pro

du

cti

on

2006 2005

HTUF Refuse Working Group

Formed

68

XL Hybrid

Hybrid retrofit start up

Targeting Class 2b

Post transmission,

simple upfit

In testing

69

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

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

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

military combat engineering for military assessment.

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

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

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

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

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)

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

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

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

FC Durability in CALSTART Testing

81

Commercialization Vision for HD

82

HD Fuel Cells

Fuel Cell APUs (Delphi)

LD Fuel Cells

HD Propulsion Fuel Cells

Range Extender Fuel Cells

Develop a Strategic Fleet Plan: We Can Help You Do It

Te

ch

no

logy/

Fuel/ O

pera

tional

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

QUESTIONS?

Before my last thoughts….

84

bvanamburg@calstart.org

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!

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

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

Thank you

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