Diesel locomotives are the backbone of the global transportation network, powering freight and passenger trains across vast distances. These engines are known for their high torque, endurance, and ability to haul massive loads. However, like most diesel engines, they are inefficient, burning only a portion of the fuel they consume and wasting the rest as heat and emissions. This inefficiency leads to high fuel consumption, significant operational costs, and increased environmental impact.

To address these challenges, Diesel-Hydrogen Assist Technology (D-HAT™) offers a game-changing solution that enhances diesel combustion efficiency, resulting in substantial fuel savings and emission reductions. In this case study, we explore how the implementation of D-HAT™ on a locomotive led to a remarkable 24% reduction in fuel consumption, demonstrating the potential of hydrogen-assisted combustion to transform the efficiency and sustainability of diesel-powered fleets.

The Challenge: High Fuel Consumption and Emissions in Diesel Locomotives

Diesel locomotives are vital for moving goods over long distances, but they come with significant fuel consumption. A typical locomotive consumes thousands of gallons of diesel fuel per day, contributing to high operational costs and considerable environmental emissions. Several factors contribute to this inefficiency:

• Incomplete combustion: Locomotives, like all diesel engines, operate with a combustion efficiency of around 70%, meaning that 30% of the diesel fuel remains unburned. This leads to wasted fuel, carbon buildup in the engine, and higher emissions.
• Heavy loads: Diesel locomotives must haul tons of freight across challenging terrain, placing a heavy strain on the engine and requiring more fuel to maintain power and speed.
• Fuel price volatility: Diesel prices can fluctuate significantly, and even small increases in fuel prices can dramatically impact the profitability of rail operations.

The company operating the locomotive faced the dual challenge of controlling fuel costs and reducing its environmental footprint while maintaining performance and reliability. They needed a solution that could reduce fuel consumption without sacrificing the power and endurance required for heavy freight operations.

The Solution: Diesel-Hydrogen Assist Technology (D-HAT™)

Diesel-Hydrogen Assist Technology (D-HAT™) was identified as a solution to address the locomotive’s fuel inefficiency and emissions challenges. D-HAT™ improves combustion efficiency by injecting a small amount of hydrogen into the engine’s air intake system, which enhances the burn rate of diesel fuel.

Here’s how D-HAT™ works:

1. Hydrogen Generation: The D-HAT™ system generates pure hydrogen gas through an onboard Proton Exchange Membrane (PEM) cell that uses steam distilled water and electricity from the engine’s alternator. Hydrogen is produced on-demand, meaning there is no need for storage, minimizing safety risks.
2. Hydrogen Infusion: The hydrogen gas is introduced into the engine’s air intake, where it mixes with the diesel fuel. Because hydrogen burns more quickly and completely than diesel, it helps the fuel combust more efficiently.
3. Increased Combustion Efficiency: By promoting a more complete burn of the diesel fuel, D-HAT™ increases the combustion efficiency from around 70% to 93%, significantly reducing fuel waste and improving power output.

The company installed the D-HAT™ 6000 unit on a large, two-stroke diesel locomotive. This unit is specifically designed for high-displacement engines used in railroad applications and is capable of producing up to 4 liters of hydrogen per minute. The installation was completed in under 8 hours, and the locomotive was tested under normal operating conditions over several months.

Results: A 24% Reduction in Fuel Consumption

The results of the D-HAT™ implementation on the locomotive were both immediate and impressive. Over the course of the test period, the locomotive’s fuel consumption was reduced by 24%. This substantial fuel savings was achieved without any reduction in performance or power output.

Key Benefits of the D-HAT™ Installation:

1. Significant Fuel Savings
   • 24% reduction in fuel consumption: The locomotive used significantly less diesel fuel to perform the same work, resulting in considerable cost savings for the company. Given the high fuel usage of locomotives, this reduction translated into thousands of gallons of fuel saved over the test period.
   • Lower operational costs: With less fuel required to power the locomotive, the company reduced its overall fuel expenses, improving profitability even as fuel prices fluctuated.
2. Improved Engine Performance
   • Increased torque: The D-HAT™ system increased the torque output of the locomotive’s engine, allowing it to haul heavy loads more efficiently. The locomotive experienced better acceleration and power at lower RPMs, reducing strain on the engine.
   • Extended engine life: With more complete combustion, the D-HAT™ system minimized carbon buildup inside the engine. This reduced wear and tear on the engine components, extending the life of the locomotive’s engine and reducing the need for frequent maintenance.
3. Reduced Environmental Impact
   • Fewer emissions: The hydrogen-assisted combustion process reduced the locomotive’s emissions of carbon dioxide (CO2), nitrogen oxides (NOx), and particulate matter (PM). By burning more of the diesel fuel completely, the D-HAT™ system cut down on the pollutants released into the atmosphere.
   • Lower carbon footprint: The fuel savings achieved with D-HAT™ translated into a direct reduction in CO2 emissions, helping the company meet its environmental goals and comply with stricter emissions regulations.

Quantifying the Savings: A Closer Look

To better understand the financial and environmental impact of the D-HAT™ installation, let’s break down the numbers:

• Fuel savings: Prior to D-HAT™, a locomotive consumes approximately 4,500 gallons of diesel per day. With a 24% reduction, a locomotive saves 1,080 gallons of diesel per day.
  • Over the course of a year (assuming 300 days of operation), this results in a savings of 324,000 gallons of diesel.
  • At an average diesel price of $4 per gallon, the company saved approximately $1.3 million annually on fuel costs alone.
• Emission reductions: For every gallon of diesel saved, approximately 22.4 pounds of CO2 are avoided. With 324,000 gallons of diesel saved annually, a company reduces its CO2 emissions by over 7.2 million pounds per year. This is a significant reduction in a company’s carbon footprint, contributing to its sustainability goals and compliance with environmental regulations.

Operational Impact and Feedback

The success of the D-HAT™ installation on the locomotive was not limited to fuel savings and emission reductions. The company’s fleet operators and engineers provided positive feedback on several operational improvements:

• Consistent performance: The D-HAT™ system had no negative impact on the locomotive’s power or reliability. In fact, the increased torque and faster acceleration allowed for more efficient operations, particularly when hauling heavy loads.
• Ease of maintenance: With reduced carbon buildup inside the engine, the company found that the locomotive required less frequent maintenance. Engine components experienced less wear and tear, extending the intervals between oil changes, filter replacements, and other maintenance tasks.

Why D-HAT™ is Ideal for Locomotives and Heavy-Duty Applications

The success of D-HAT™ in reducing fuel consumption in locomotives demonstrates its potential across a wide range of diesel-powered applications. For fleet operators, particularly in industries where diesel engines are essential for moving heavy loads, D-HAT™ offers several key advantages:

• Scalable technology: D-HAT™ can be installed on a variety of diesel engines, from locomotives and marine vessels to trucks and off-road equipment. The system is designed to scale with engine size and displacement, making it suitable for high-demand applications.
• Immediate fuel savings: The fuel savings achieved with D-HAT™ are immediate and measurable, providing a clear return on investment (ROI) for fleet operators.
• Environmental compliance: With emissions regulations tightening around the world, D-HAT™ helps companies reduce their environmental impact without requiring a complete overhaul of their fleet.

Conclusion: A Fuel-Efficient Future with D-HAT™

The case study of the locomotive equipped with D-HAT™ highlights the significant fuel savings and performance improvements that hydrogen-assisted combustion can deliver. By reducing fuel consumption by 24%, the company not only lowered its operational costs but also reduced its environmental impact, paving the way for a more sustainable and profitable future.

For fleet operators looking to improve efficiency, reduce fuel costs, and meet emissions standards, D-HAT™ offers a practical, scalable solution. Whether applied to locomotives, marine vessels, or other heavy-duty diesel engines, D-HAT™ redefines diesel efficiency, helping businesses achieve measurable savings and a cleaner environmental footprint.