LNG Tech 101: Overview of Cooling, Storage
and Fleet Fueling
Your Speaker:
Your Host:
Dave Dixon, PE
Amy Little
Director of Engineering
Marketing & Training Coordinator
NorthStar Inc.
IMW Industries
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About IMW
IMW has been manufacturing industrial machinery since 1912, and has evolved to be a leading
manufacturer of natural gas compression systems, serving all major markets Globally. Equipment
is currently operating mid-east to North of the Arctic Circle.
•
Quality Products, Leader in CNG Compression & LNG Fueling Solutions
•
Provide full range of LNG solutions from NorthStar LNG
A variety of configurations for all applications
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A Clean Energy Company
IMW operates as a wholly owned subsidiary of Clean Energy Fuels Corp. (NASDAQ: CLNE).
Clean Energy is the largest provider of natural gas fuel for transportation in North America and a
global leader in the expanding natural gas vehicle market.
Clean Energy has operations in CNG and LNG vehicle fueling, construction and operation of
CNG and LNG fueling stations, biomethane production, and compressor technology.
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Continuing Education Credit
1 hr Technical Informal
More CPD Info or Board Room Attendance:
•
Name
•
Job title
•
Company
•
Email
Email to: webinars@imw.ca
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Join the Discussion!
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Your Speaker
David Dixon, PE
Director of Engineering,
NorthStar Inc.
Mr. Dixon has 13 years of experience in the LNG vehicle industry with
NorthStar, Inc. of Evanston, WY, now part of Clean Energy Fuels. Dave
has been responsible for the engineering on over 100 LNG vehicle fueling
facilities for municipal bus and waste hauling industries, and public LNG
fueling stations.
Dave holds a BS in Mechanical Engineering from the University of
Wisconsin-Madison and an MBA from St. Cloud State University.
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LNG Tech 101
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Introduction





David Dixon, P.E., Director of Engineering, NorthStar, Inc.
13 years with NorthStar, all focused on building LNG fueling
stations.
Also designed and built many LCNG stations.
Previous experience: 5 years at Minnesota Valley Engineering,
which later became Chart Industries, designing cryogenic
storage tanks and equipment.
Career focus: Design of LNG fueling facilities, less experienced
with truck engines and vehicle fuel systems.
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NorthStar History

Delivering turnkey LNG solutions since 1994.

Started as a family-owned business.

Our 20 years of experience gives us a great advantage with
our knowledge of LNG fuel and LNG stations.

Built over 30 turnkey LNG and LNCG fueling facilities.

Acquired by Clean Energy Fuels Dec. 2010.

Manufactured equipment for over 100 LNG and LCNG facilities
for Clean Energy Fuels since the acquisition.
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Clean Energy Fuels History



Started as Pickens Fuel Corporation by T. Boone Pickens and
Andrew J. Littlefair, Clean Energy President and CEO in 1997,
and now the largest natural gas fueling provider in the US.
Clean Energy is committed to delivering the benefits of natural
gas fuel to fleet operators across America.
Provides natural gas vehicle infrastructure and fuel:

LNG and CNG fueling stations.

LNG and CNG fuel sales.


Assistance with grant funding, vehicle leasing, and
financial incentives.
Vehicle Facility Modifications to allow vehicle maintenance.
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Agenda:

Basics of LNG

LNG Fueling Station Technology

LNG Vehicle Fueling

CNG Vehicle Fueling

Other LNG Applications
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Basics of LNG - What is LNG 1

LNG is natural gas that has been refrigerated to -260 Deg. F.

Liquefaction reduces the volume by 600:1.



Density of LNG is approximately 3.5 lb/gal at 0 psi, roughly
half the density of diesel fuel.
LNG is stored at the liquefaction plant in multi-million gallon
storage tanks (typically). The liquefier might be a dedicated
facility for LNG vehicles (Clean Energy two, Boron, CA and
Willis, TX) or might be peak shavers which sell excess LNG
into the LNG vehicle market.
LNG is predominately methane (typically >98%) with trace
amounts of ethane, propane, etc.
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Basics of LNG - What is LNG 2

LNG is colorless, odorless, and non-toxic.

When vaporized and mixed with air LNG is flammable.


Cold methane vapor is denser than air and can settle in
enclosed areas, while warm methane vapor is lighter than air
and disperses.
LNG can also be made from landfill gas, therefore is a
renewable, more carbon-neutral fuel.
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Basics of LNG - LNG Hazards

Methane is flammable in air in concentrations of 5% to 15%.
– Below 5% the mixture is too lean to burn.
– Above 15% the mixture to rich to burn.

Potential for frostbite and freezing due to low temperatures.
– Eyes especially vulnerable to sprayed or splashed LNG.

Potential for asphyxiation due to displacement of oxygen,
especially in enclosed areas.
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Basics of LNG - LNG Safety and Hazard
Prevention

Recommended Personnel Protective Equipment:
–
–
–
–

Cryogenic Gloves
Face shield
Closed shoes or boots
Long sleeve shirt and long pants recommended.
Hazard Prevention:
–
–
–
–
–
–
Follow recommended operating and maintenance procedures.
Use Personnel Protective Equipment
If there is a leak, avoid direct contact.
Don’t handle cold hoses and piping without proposer gloves.
Keep ignition sources away for tank and piping. No smoking.
Perform vehicle maintenance in proper area.
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Basics of LNG - First Aid

First Aid:
– Treat methane burns as other types of burns – cool affected area,
bandage if necessary, and seek medical assistance.
– Treat frostbite by warming slowly (do not run) and seek medical
assistance.
– Treat asphyxia by providing fresh air, rescue breathing if necessary, and
seek medical assistance.
– Seek medical assistance for eye injury caused by LNG.
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LNG Station Technology

Main Components of an LNG Station:
–
–
–
–
–
–
LNG Storage Tank
LNG Dispense Pump
LNG Dispenser
LNG Offload System
Safety System
PLC Control System
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LNG Station Technology – LNG Storage Tank



Most Clean Energy stations have single
18,000 gallon storage tank, 175 psi
working pressure
Clean Energy stations have provision to
add second tank.
Considerations
–
–
–
–
–
Daily amount dispensed
Spill containment size
Set back to property line
Desired on-site days of storage
Vertical vs. horizontal
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LNG Station Technology – LNG Dispensing Pump





ACD TC-34 most commonly used
dispense pump.
Installed in ASME sump adjacent to
tank.
Designed for 40 LNG gpm flow rate per
dispenser, one or two dispensers.
Second pump commonly in place for
redundancy.
Pump speed varied by control system
to optimize filling.
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LNG Station Technology – LNG Dispensers





Newest dispensers have integral card
reader and receipt printer (Gilbarco
frame and electronics with NorthStar
LNG piping).
Weights and Measures design type
approval.
Unit of measure is DGE, 6.06 lb/DGE.
Vehicle venting, when necessary, can
be through fill nozzle for Westport
HPDI or separate vent hose for other
types.
Designed for automatic operation.
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LNG Station Technology – LNG Offload System





NorthStar has been using same type of
pump as dispense pump.
Allows faster cooldown, easy priming,
and commonality of parts.
Other types of pumps available.
Offload connection located on back of
station to allow dispensing while
offloading is occurring.
Typical pumping time is 70 minutes,
approx. 1-1/2 hours start to finish.
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LNG Station Technology – Safety System

Emergency Shut Down System, manual reset only

Fire Detectors

Methane Detectors

Emergency Stop Buttons

Emergency Shutdown Valves

Remove electrical power from all LNG equipment

Spill containment wall sized for entire tank contents

Auto dialer or fire alarm control panel

Dispenser flow limits
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LNG Station Technology – PLC Control System

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
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Integrated PLC control system to minimize operator input.
PLC monitors and operates LNG tanks, LNG pumps, and
dispensers.
CE stations include web server for remote access through
VPN.
PLC programmed to automatically recover from many faults.
Some conditions may require technician assistance, such as
sensor failure. Auto dialer calls out to technician.
PLC contains adjustable operating parameters, normally only
adjusted at commissioning, or to optimize operation.
PLC also performs data collection that can be used for
optimization or alarm analysis.
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LNG Station Technology – Considerations

Fuel at existing public station, or build private station?

Public stations:
– Maintenance and operations handled by station owner
– Are stations on common routes or near fleet yard?

Private back lot stations:
–
–
–
–
–
Maintenance and operation by fleet owner, or contracted out.
Capital cost, or is grant funding available?
Start with small mobile fueler?
Sizing station for initial plus future expansion.
Is space available at fleet yard?
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LNG Station Technology – Sizing

Select number of dispensers based on number of vehicles to
be fueled per day
– 2 LNG dispensers minimum recommended for redundancy
– Rule of thumb 50 vehicles per dispenser per day, but every situation is
different.

Select number of dispense pumps based on number of
dispensers
– 1 pump can feed 2 dispensers.
– Consider second pump for redundancy

Size storage tank for throughput
– One 10,000 gallon delivery every 3 or 4 days or so is comfortable;
consider larger tanks or multiple tanks if throughput is higher than a
delivery every 2 days.

General recommendation: Do not over-size tanks or
dispensers; adds cost and adds heat load on station
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LNG Vehicle Fueling
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LNG Vehicle Fueling - Basics

Heavy-duty vehicles
– >50 DGE/truck/day

Pipeline gas cooled to -260 F

Store 2x (energy)/volume as CNG


Produced at LNG plants & delivered to
LNG station & stored in cryogenic trailers
Dispensed at 15+ DGE/minute
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LNG Vehicle Fueling - OEM Trucks Available
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LNG Vehicle Fueling - LNG Fuel Tanks
LNG Common Tanks
LNG Tank
Nominal Size
Effective Size
Effective Size
Dry Weight
Wet Weight
(Gal)
(Gal)
(DGE)
(lbs)
(lbs)
119
102
60
495
870
150
128
75
620
1,093
Westport GX 119
94
58
785
1,155
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LNG Vehicle Fueling – High Pressure/Low
Pressure Engine Systems

Westport HPDI
– HPDI now out of production, but included an onboard high pressure
pump.
• Uses colder, low pressure LNG than spark ignited system.

For Saturated Systems for Spark Ignited Engines:
– Spark ignited engines traditionally need low pressure at engine 50 to 80
psi is typical.
– LNG warmed in station to provide suitable pressure
– Recently Chart Industries and Westport have introduced pumping and
pressure building systems (Chart Charger and IcePak).
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LNG Vehicle Fueling - Infrastructure
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LNG – Advantages and Considerations
Advantages




Fuel costs less than diesel
Lower GHG emissions than
diesel


LNG composition is 97% CH4

No diesel fuel or exhaust aftertreatment to manage (SI
engines)


Diesel-like fueling

Greater fuel density/volume
–
–

Considerations
Greater range than CNG, per volume
Substantially lower weight of
storage
Less expensive tanks vs. CNG
equivalent


Cryogenic tanks
Special handling when fueling
(PPE)
Pressure and temperature
management of fuel to engine
Potential boil off (use it or lose
it) if vehicles are parked for
extended period (typically 7 to
10 hold time, depending on
tank design and liquid level)
Building modifications for
indoor maintenance
Fueling station availability
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LNG Vehicle Fueling – Clean Energy
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LNG Vehicle Fueling – Clean Energy
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CNG Vehicle Fueling
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CNG Vehicle Fueling - Common CNG Applications

Taxis

Light duty vehicles (pickup trucks, cars, vans)

Buses

Refuse trucks

Over-the-road tractor trailers
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CNG Vehicle Fueling - CNG Basics



Light, medium, and heavy duty vehicles
– Heavy > than 50 DGE/Day
NG delivered by pipeline to fueling station
Dried, compressed & stored at 4,500 psi and
dispensed at 3,600 psi

Dispensed at 3-11 gge/minute

Stored in several cylinders onboard the vehicle
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CNG Vehicle Fueling - LCNG





Many CE stations have LCNG fueling (Liquid LNG to CNG)
Can be used to provide CNG fueling where natural gas pipeline
is not available.
Much lower electrical consumption than CNG compressors of
same throughput (approx. 1:10)
LCNG composition typically more consistent and higher
methane than pipeline gas.
LCNG typically more expensive to produce due to cost of
trucked-in LNG.
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CNG Vehicle Fueling - Stations
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CNG Fuel Tanks
CNG Common Tanks
Nominal Size
Effective Size
Dry Weight
Wet Weight
(DGE)
(DGE)
(lbs)
(lbs)
4 Tanks BOC
60
45
1,150
1,450
5 Tanks BOC
75
55
1,650
2,025
2 Tanks Side Rail
82
60
1,200
1,650
Configuration
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CNG Vehicle Fueling– Advantages and
Considerations
Advantages

Greater infrastructure than LNG
Considerations

–
– Light and medium duty
especially

–
Simple fuel systems


–
–
–
No diesel fuel or aftertreatment to manage (SI
engines)
Gas/Vapor instead of cryogenic
No fuel loss if parked for an
extended period of time
Heat of compression (loss of
storage capacity on fast-fill)
Weigh more than LNG
•
– Easy to fuel like gasoline

Fuel storage tanks

Range limitations
More expensive than LNG
Takes 2x to 5x longer to fill than
LNG
Cost of compression
–

Potential impact to payloads and
revenue
Energy and maintenance with a
compression station
LDC inconsistencies in NG
composition (Methane # <75)
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CNG Vehicle Fueling - Station Availability




CNG stations more widespread than LNG stations.
Clean Energy owns and operates 400+ CNG stations and 120+
LNG stations, most public access but others private.
Either LNG or CNG stations can also be constructed on
backlots for private dedicated fleet fueling.
Grant availability also a consideration to defray capital
expense.
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Other LNG Applications
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Other LNG Applications

LNG Rail Locomotives
–
–
–
–
–
Initial trials underway with several rail carriers
Locomotives may be retrofitted with dual fuel diesel/LNG system
New locomotives may be dedicated LNG.
LNG carried in 20,000 gallon or larger tender car with on-board pumps
Regulatory environment evolving for other-the-rail operation.
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Other LNG Applications

Off Highway High Horsepower, such as Mining
– Initial trials underway with heavy-haul mining trucks.
– Likely to be retrofitted with dual-fuel diesel/LNG systems.
– Less onerous regulatory requirements than rail.
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Other LNG Applications

Marine
– Initial US projects underway for LNG powered shipping.
– More commonly used in Europe already.
– Requires additional infrastructure development in US for further
implementation (dedicated liquefiers, for example).
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Other LNG Applications

Power Generation
– LNG can be used as replacement for propane or oil in many applications
– Goal is reduced fuel costs, balanced against infrastructure cost to switch
to LNG.
– Stranded islands with no local energy source investigating LNG.

Storage and Vaporization
– Can be used as temporary replacement for pipeline natural gas.
– Replacement for propane for heat (eg asphalt plants).
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Conclusion
-
Tremendous Opportunities in LNG
-
Let’s work together to take advantage
-
Questions?
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john smith
d: +1 604.233.4567
m:+1 604.233.6789
e: johnsmith@imw.ca
43676 Progress Way • Chilliwack, BC • Canada V2R 0C3
imw.ca
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p +1 604.795.9491
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e info@imw.ca
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