case study: lng conversions of heavy equipment in - HHP

CASE STUDY: LNG
CONVERSIONS OF HEAVY
EQUIPMENT IN USE AT
LANDFILLS / MRF’S
DAVID BOLDEROFF

Introduction
• Who we are
• Heavy Equipment LNG Conversion
Project
• Refueling Options / Issues
• Successes & Problems

Los Angeles County
Sanitation Districts
• LACSD consist of 23 independent special
districts serving about 5.4 million people in
Los Angeles County.
• Service area covers approximately 815
square miles and encompasses 78 cities
and unincorporated territory within the
county.
• Manage both wastewater and solid waste
disposal assets.

Los Angeles County
Sanitation Districts
• Wastewater: Approx.1,400 miles of main
trunk sewers, 50 pumping plants, and 11
wastewater treatment plants convey and
treat about half the wastewater in Los
Angeles County.

Los Angeles County
Sanitation Districts
• Solid Waste: Provide about one-third of
the countywide solid waste management
needs. LACSD operate:
‣ 3 X Sanitary Landfills
‣ 3 X Landfill Gas-to-Energy Facilities
‣ 3 X Materials Recovery/Transfer Facilities
‣ 2 X Refuse-to-Energy Facilities
‣ Developing Waste-by-Rail Project

LNG Conversion Project
Initial Pilot Project 2003:
• 1993 Caterpillar 966F II Wheel Loader
• Removed CAT 3306 Diesel Engine
• Installed CAT ACERT C10 Dual Fuel Engine
• Work completed by Quinn Company
(Local Caterpillar Dealership)
Clean Air - Electronic Control Unit
• Still in Operation Today (Approx. 9,000hrs)

Before Conversion

The Conversion Process

After Conversion
Table
CHART LNG
Tank (97 GAL)
260HP & 5.2 G/HR
Gas Detection
System
CAT C10
ACERT T2
Dual Fuel
Engine
New Engine
Cooling
Package

The Cost
TOTAL PROJECT COST: $154,200
SCAQMD GRANT FUNDING: - $137,800
COST TO LACSD: $16,400
FUEL SAVINGS OVER 9,000 HRS
~ $23,400 or 17%

Application (MRF)

Further Work
During 2004-05 sent the following
equipment through the Caterpillar
Certified Rebuild Program (CCRP), which
included repowering & conversion to LNG:
• 4 X CAT 966F Wheel Loaders and
• 2 X CAT 824C Wheel Dozers

NEXGEN LNG
Tank (150 GAL)
Gas Detection System
CAT C12
ACERT T2
Dual Fuel
Engine
CAT 824C Wheel Dozer
330HP & 12 G/HR

The Cost
Incremental Cost Difference
(in lieu of rebuilding existing engine)
CAT 966F Wheel Loaders $93,300
SCAQMD GRANT FUNDING: - $70,300
COST TO LACSD: $13,000
CAT 824C Wheel Dozers $102,300
SCAQMD GRANT FUNDING: - $ 95,500
COST TO LACSD: $ 6,800

LNG
2
Picture 1: LNG Dispenser
1
Picture 2: LNG tanks and LNG
conversion to CNG device
• Liquid Natural Gas (LNG) current price $2.66 DGE

CNG
• Compressed Natural Gas (CNG). These pictures
show the CNG side of the fueling facility. Current
price $2.20 GGE.

Secondary Refueling
Module with 4 X 150 GAL
Tanks
Total # Compact

Issues with Mobile Refueller
• Slow process as mobile refueller relied
on pressure differentials (no pump)
• Could not measure quantity of LNG
dispensed
• Venting of gas from equipment tanks
and mobile refueller (loss of $$$)
• Maintenance cost ($3,200 for
replacement hose and nozzle)

Maintenance Issues
• Overfilling LNG Tanks
• Moisture in System
• Cost of Components
• Still Utilized 20-50% Diesel Fuel for
Pilot Ignition (Need right application)
• LNG station reliability
• Availability of skilled & knowledgeable
technicians

Successes
• Good Public Relations
• Fuel Savings
• Credits with California Air Resource Board

Thank You.