OptiFuel Systems is set to test a 5600 hp Total-Zero™ Renewable Natural Gas Line Haul Locomotive and a 2500 hp Total-Zero™ Powered Tender with 7500 DGE capacity starting January 2025. The RNG-powered locomotive utilizes Cummins RNG engines for continuous 5100 hp, employing OptiFuel’s Quick-Power™ technology. With a standard LFP battery pack, it reaches a peak power of 5600 hp. Prioritizing sustainability, OptiFuel’s Total-Zero™ RNG-Electric Locomotive aims for zero Well-to-Wheel (WTW) nitrogen oxides (NOx) and particulate matter (PM) emissions, achieving Negative Carbon Intensity (CI) and enhancing fuel cost efficiency and operating range by 25%.
OptiFuel Systems is pioneering a transformative initiative to eliminate harmful pollutants from diesel and renewable diesel engines, addressing critical concerns for air quality and public health. This innovative project, partially funded by a Department of Energy (DOE) grant, will undergo pre-production testing at the Federal Railroad Administration’s (FRA) Transportation Technology Center (TTC) over 12 months.
In 2026, OptiFuel is set to launch a two-year, one-million-mile test program featuring ten pre-production 5600 hp RNG line haul locomotives and five 10,000 DGE RNG tenders, operating across the United States. Upon successful completion, full-scale production is slated for 2028, with an estimated price tag of approximately $5.5 million for the RNG line-haul locomotive, available for purchase or lease.
OptiFuel’s President, Scott Myers, emphasizes the company’s expertise in fuel cell, hydrogen storage, and battery modules, citing their unique qualifications in designing Sierra Northern Railway’s hydrogen hybrid switcher locomotives. Myers contends that RNG is the optimal path for achieving zero-emission line haul locomotives and tenders due to considerations such as energy storage, operating costs, risks, and fuel availability over the next two decades.
OptiFuel’s commitment to sustainability extends beyond locomotive designs, incorporating modularity with standardized Quick Disconnect (QD) modules using ISO corner locks. Myers highlights that approximately 90% of components are shared across various RNG or hydrogen switchers, line haul locomotives, and RNG standard and powered tenders, enabling cost-effective high-volume production.
With a focus on customer-centric solutions, OptiFuel introduces a comprehensive refueling services and fuel station infrastructure plan. This plan not only addresses capital expenditure challenges related to refueling but also streamlines logistics for combined diesel-RNG fleets. OptiFuel’s Refueling Solutions Plan facilitates smooth fleet transitions, allowing line haul operators to run trains seamlessly with both old (diesel) and new (RNG) locomotives without disruptions.
OptiFuel plans to provide an estimated 3,000 RNG tenders and 60 RNG locomotive and tender refueling stations at no cost to Class 1 locomotives in the US, offsetting an estimated $8.5 billion in infrastructure expenses. This approach is based on railroads purchasing RNG over ten years at approximately $2.00 per Diesel Gallon Equivalent (DGE) through long-term contracts connected to specific RNG production sites.
OptiFuel’s innovative approach empowers railroad customers to enhance operations, regain competitive advantages, and reclaim market share from trucking by offering reliable and improved services. The company’s robust and sustainable rail network contributes to the integrity of the US supply chain, facilitates efficient goods transportation, and serves as a key driver of economic health.
OptiFuel Systems leads the technical front in collaboration with GTI Energy, the formal applicant to the Department of Energy, and other technical partners, including Cummins, BAE Systems, Luxfer Gas Cylinders, TMV Control Systems Inc., ENSCO, CAF Group, New York Air Brake, and Powerhouse, a Marmon Rail Company.
This material is based upon work supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) under the Vehicles Technology Office Award Number DE-EE0009215.The views expressed herein do not necessarily represent the views of the U.S. Department of Energy or the United States Government.
About OptiFuel Systems LLC:
OptiFuel Systems is a solution provider designing and manufacturing Total-Zero™ emission products and services in the hard-to-abate transportation and industrial markets, specifically in rail, marine and power generation. OptiFuel works as a systems integrator with strategic partners to engineer innovative technology that is low-risk and modular with flexible fuel options consisting of affordable renewable natural gas (RNG) and hydrogen fuels. Products include switcher and line haul freight locomotives, RNG and hydrogen tenders, stationary and mobile refueling systems, and mobile and stationary standby and emergency generators. Services include sales, leasing, long-term maintenance, and refueling services. Customers are expected to achieve increased reliability, reduced lifetime maintenance costs, minimized downtime, greater sustainability, and an impressive up to 30% enhancement in fuel economy. OptiFuel’s Total-Zero™ RNG-electric locomotives and hydrogen-electric locomotives are EPA certified as zero NOx and PM emissions and have achieved FRA concurrence. Recently, OptiFuel announced a $30 million Series A2 fundraising round to further scale business operations and strategic opportunities rapidly developing across key markets.