GE LOCOMOTIVE PROJECT 2
Engineering Design 100
Submitted to: Mr. Wallace Catanach
Sec. 004
Group 7: Fantastic Four
Group Members:
Gabriel Shope---------------------------gds5164@psu.edu
Ziyang Fang------------------------------zkf5009@psu.edu
Hongbo Li--------------------------------hfl5026@psu.edu
Ruixi Sun---------------------------------rms5921@psu.edu
1
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
2
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.
3
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
Smog is generated from engine emitted
NOx
Tier 2 locomotives used to haul freight are
approaching age of overhaul
EPA requires locomotive to reach tier
three requirements
Reduce smog emissions within Pittsdelphia
Decrease NOx emissions from engines of
locomotive
Upgrade the locomotive fleet
Meet EPA requires for NOx
4
Needs Upgrade
metrics locomotives
from tier 2
to tier 2+, or
even higher
Reduce smog
emissions
within the
city
Decrease x
NOx
emissions
from engines
Upgrade the x
locomotive
Meet EPA x
requirements
NOx
Cost efficient
design
Add after
treatment
on
locomotive
engines
Add
Use
emissions
alternative
recirculation fuels
x
x
x
x
x
Pick the
comparative
low cost
solution
x
x
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
5
Mileage for Teir 2 locomotive
1 Ton freight
470 miles/gallon
165000 Tons/day
Emmissions for Teir II Locomotive
0.2 g/hp-hr
5.5 NOx/hp-hr
Diesel
Particulates
NOx
Assumptions
500
50
143
117
26
miles/trip into the city
mph
tons
tons
tons
215000 lbs
30 tons
110 tons
average speed
tons/loaded coal car
Weight of coal
Weight of coal car
Freight Lading Capacity
Freight car weight empty
Freight Lading Capacity
$2.50 $/gallon
500 miles
Diesel fuel
One way trip
12000 gallons
470 miles
500 miles
need 12000 gallons to go 470 miles
need 12000 gallons to go 470 miles
Miles per trip to city
Coal train full
6
Coal/freight into city
(tons)
Total # of cars in a
train
Weight of empty
cars
Weight of
locomotives
Total weight of
loaded train
Total power @50
mph level grade
Power fraction
(tons)
Fuel used per train
Fuel cost per train
Particulate emissions
per train
NOx emissions per
train
Coal Train Coal Train Freight
Freight
In
Out
Train In Train Out
12,000
0
7,000
5,000
103
103
64
64
(tons)
2,678
2,678
1,920
1,920
(tons)
648
648
432
432
(tons)
15,326
3,326
9,352
7,352
(hp)
10,230
2,220
6,242
4,907
0.76
0.16
0.69
0.55
(gal)
($)
(kg)
10,883
27,208
20
2,362
5,905
4.4
6,641
16,602
12
5,221
13,052
10
(kg)
563
122
343
270
ANNUAL TOTALS
Fuel used
Fuel cost
Particulate emissions
NOx emissions
(kgal)
(M$)
(tonnes)
(tonnes)
19,862
49.7
18.7
513
4,310
10.8
4.1
111
36,359
90.9
34.2
940
28,583
71.5
26.9
739
GRAND
TOTAL
89,114
223
83.8
2,304
7
Alternative Fuel Emissions:
D1
D2
NG
M100
E85
NOx(g/mile)
32
31.8
30
14.7
18.2
CO(g/mile)
9.7
16.5
15.3
19.9
31.9
HC(g/mile)
2.6
2.1
14.8
14.7
10.5
PM(g/mile)
0.96
1.48
0.03
0.26
0.49
D2
2.498
NG
2.331
M100
2.512
Alternative Fuel Price
D1
Price(d/gal)
E85
1.89
Locomotive Diagram (Size Relativity):
8
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.
9
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
10
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-aftertreatmentsystem-with-matlab-and-gt-suite.html
Concept Generation
11
12
Concept Selection
REACH EPA
REQUIREMENTS
REDUCE
HARMFUL
EMISSION
ECONOMICAL
LOW
MAINTENAN
CE
SUM OF +
CONTINUE?
UPGRADE
ENGINE
EXHAUST GAS
RECIRCULATION
PISTON DESIGN
+
+
_
0
2
Yes
+
+
0
+
3
Yes
0
0
+
+
2
Yes
HIGH PRESSURE
INJECTION
0
0
0
0
0
Yes
DIESEL
PARTICULATE
FILTER
AMMONIA BASED
+
+
+
-
3
Yes
+
+
+
-
3
Yes
USE ALTERNATIVE
FUEL
0
+
-
+
2
yes
WEIGHING
REACH EPA
REQUIREMENTS
REDUCE
HARMFUL
EMISSIONS
WITHIN THE
CITY
ECONOMICAL
LOW
MAINTENANCE
SUM
CONINUE?
35%
UPGRADE EXHAUST GAS
PISTON HIGH
ENGINE
RECIRCULATION DESIGN PRESSURE
INJECTION
5
5
4
4
DIESEL
AMMONIA USE
PARTICULATE BASED
ALTERNATIVE
FILTER
FUEL
5
5
5
25%
5
5
3
3
5
5
4
25%
15%
3
4
3
5
4
5
3
5
4
3
4
3
4
5
4.35
YES
4.5
YES
3.65
NO
3.65
NO
4.45
NO
5.5
YES
4.5
NO
13
Cost Model
TierII to Tier III
locomotive upgrade
cost
Number of
locomotives
upgrade
cost
750k
After
Treatment
Cost
100k
Exhausted
Gas
Recirculation
100k
50
50
50
37,500,000
5,000,000
5,000,000
total cost
47,500,000
Design
14
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
15
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-withmatlab-and-gt-suite.html
http://www.ironmanparts.com/?id=emi3&sub=products
www.aa1car.com
www.enginebuildermag.com
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