Optimization of combustion and higher efficiency: Provides improved fuel economy, which results in faster payback compared with Westport's first generation HPDI product and compared to spark-ignited natural gas engines. Westport HPDI engine efficiency under highway operations is approximately 44 percent compared with spark ignited natural gas engines at approximately 37 percent. This means approximately 15 percent to 20 percent fuel economy improvement compared to spark ignited natural gas engines under typical operating conditions.
Proprietary HPDI 2.0 dual common rail fuel injector: Designed for adaptability and multiple OEM engines ranging from 10 liter to 100-liter displacement (typically, over 50 kW per cylinder output) featuring higher performance and controllability, greater reliability, and longer life, and much lower cost. Unique concentric dual-needle design with electro-hydraulic actuation and control.
Proprietary on-engine gas fuel conditioning module: Designed for more precise pressure control for even lower engine emissions and better fuel economy. New sealing designed for longer durability. Smaller size for ease of packaging on the engine.
Redesigned electronic control systems: Allows full integration with existing engine and vehicle controls.
Improved components: Completely reorganized supply chain allows for reduced production costs and increased scalability for manufacturing alongside existing diesel-based components for multiple OEMs. For example, the new gas control module (GCM) has been reduced in cost by approximately 60 percent.
System performance: High transient performance with integrated fuel storage and delivery systems that ensure proper fuel flow under all driving conditions, improving performance, driveability, and safety at lower cost.
Got brakes? By using the same high compression ratio as diesel engines, Westport HPDI engines deliver engine braking power equivalent to that of diesel engines which is critical in many trucking applications. The reduced compression ratio used in SI engines results in an approximately equivalent reduction in engine braking performance.
Compatibility: Westport HPDI 2.0 is designed for complete compatibility with state of the art commercial vehicles today. For example, by injecting fuel precisely into each cylinder, HPDI provides the same responsiveness and fast torque achievement as diesel engines, resulting in benefits such as an easier ability to be matched to automated manual transmissions (AMT).
Improved emissions profile: Westport HPDI 2.0 is designed to meet the latest in stringent emission regulations including Euro VI and EPA 2014 and is the only natural gas technology that can control methane emissions in-cylinder avoiding costly methane aftertreatment. As an added benefit, the significant increase in efficiency of HPDI over traditional SI engines affords Westport HPDI 2.0 dramatically lower greenhouse gas (GHG) emissions than conventional natural gas or diesel engines.
Compliance and certification: In addition to the emissions certification for HPDI 2.0 engines, OEM's vehicles built with Westport HPDI 2.0 technology will comply with applicable safety standards in North America—such as relevant Federal Motor Vehicle Safety Standards (FMVSS), National Fire Protection Association (NFPA), and Society of Automotive Engineers (SAE) standards—and their equivalents in Europe such as Regulation No. 110 of the Economic Commission for Europe of the United Nations (UN/ECE).
Heat rejection: while the higher compression of Westport HPDI 2.0 engines provide the heat necessary to auto-ignite their fuel, combustion in the Diesel thermodynamic cycle is more efficient, with more power and less heat produced than with the Otto thermodynamic cycle prevalent in SI engines. Westport HPDI engines operate at similar engine temperatures as diesel engines, reducing cooling challenges and reducing stress related reliability and durability challenges for other SI-based engine systems including turbochargers and exhaust treatment systems.
Proprietary liquefied natural gas (LNG) tanks: Westport HPDI 2.0 LNG tank solutions range from 70 to 150 US gallons and up to 20,000 gallons for off road applications. The new tank configurations feature lower costs, high-quality testing and validation, and new designs for structures enabling several vehicle-mounting configurations including behind-the-cab gantry and frame-rail packages to simplify vehicle design and production. Westport has invested over $1 million in HPDI 2.0 LNG tank testing and validation under extreme conditions to simulate the toughest environments for natural gas products.
New proprietary intelligent LNG fuel pump: Our redesigned cryogenic fuel pump is hydraulically driven and uses a single-stage, slow reciprocating architecture. This provides significantly lower cost, higher performance, and longer life and allows the use of fuel stations that deliver cold LNG, which improves vehicle range, and reduces station cost. The HPDI 2.0 fuel system is rated for delivering warm high pressure gas to truck engines with ratings up to 600 hp and to large off-highway engines up to 4,500 hp. Unlike traditional LNG systems, the full maximum flow rate is sustainable from the moment the truck is refilled to the moment the tank is empty. Because the pump is integrated into the tank module, there is no pump cool down time.
CNG capability: Every natural gas engine burns compressed natural gas (CNG). Ultimately, the customer will decide which form of natural gas they wish to carry—either high pressure CNG or cold cryogenic LNG—based on a number of variables including but not limited to: weight of the load; weight of the fuel storage system; range required by the vehicle; and availability of CNG and LNG. The HPDI 2.0 system is architected to be compatible with LNG and CNG allowing the market to decide which storage method it prefers. Given the energy density of LNG compared with CNG, and Westport HPDI's ability to haul heavier loads over longer distances as compared with traditional natural gas engines, in most cases we expect HPDI applications will select LNG fuel storage.
Overall, Westport HPDI 2.0 will provide a compelling combination of diesel-like power, torque, fuel efficiency, and engine braking performance in a natural gas engine—making it ideal for almost all commercial freight applications.
Migration Path for HPDI 1.0
Westport first generation HPDI systems have been delivered on more than 1,200 Peterbilt and Kenworth trucks since its first wide-scale introduction in 2010. As noted in previous news releases and customer communication, Westport is committed to the continuation of its class-leading support for all our existing customers with the first generation of HPDI.
In partnership with Peterbilt and Kenworth dealers, Westport will be able to offer compatible next generation system features to our existing customers, as some HPDI 2.0 components are applicable to first generation HPDI. The benefits are expected to be reduced costs, improved components, and increased durability and performance. For customers, further information is available from your Westport representative.
Westport HPDI 2.0 has been designed for simplicity, performance and a reduction in overall system costs. For the first time, Westport expects OEM Westport HPDI vehicles to be competitively priced with SI-based systems. The increased performance in torque and related power in Westport HPDI, combined with the best fuel economy and related emissions profile and the fully integrated engineered Westport HPDI 2.0 products will give OEMs and their customers the ultimate natural gas engine and vehicle performance and reliability, and strong economic value particularly in high fuel use applications.
Westport HPDI 2.0 is in development now with a number of global OEMs and Westport anticipates first availability of customer products in late 2014 and 2015.
Market Opportunity for HPDI Natural Gas Vehicles
According to the International Energy Agency, world oil demand for commercial road freight and other heavy-duty transport modes, including rail, totalled approximately 273 billion gallons in 2012. The U.S. Energy Information Association predicts that the price of LNG will remain below the price of petroleum diesel for at least the next two decades and be approximately 33 percent below in 2035, with a gallon of diesel expected to be selling for $4.55 compared to a diesel gallon equivalent of LNG at $3.05. At these rates, if the world changes the way it moves goods by shifting to natural gas, these transport modes could save over $400 billion per year. The market for natural gas in transportation in China is bourgeoning. According to the International Energy Agency, natural gas demand in China's commercial road transport sector will reach around three times higher than today's levels by 2035.
Company has earned 40 percent market share of the commercial truck natural gas market.