Tier 4, Farm Incentives Move Irrigation from Diesel to Propane

Tier 4 emission standards are now fully implemented by the Environmental Protection Agency (EPA) and put the most stringent restrictions yet on diesel engines that require deep reductions in pollutants and particulate matter. With Tier 3 diesel engines now illegal, there are many options involving propane that allow farmers to cost-effectively continue with important farm processes such as irrigation.

The Propane Education & Research Council (PERC) started to work with engine manufacturers nine years ago as it became clear Tier 4 emission standards would make diesel engines much more expensive. From dual-fuel systems to engines designed and optimized for industrial applications, PERC has helped fund research and development involving several companies to help ensure alternatives to the Tier 4 diesel engine would be available in the marketplace. PERC has also implemented a Propane Farm Incentive Program that provides up to $5000 for qualifying farmers who purchase propane-powered farm equipment in exchange for sharing their propane equipment’s real-world performance data.

Michael Newland recently joined PERC as director of agriculture business development (see sidebar). “Many in the agriculture world are very familiar with using propane, as it has been a staple in rural communities for years,” Newland said. “Nonetheless, with Tier 4 standards taking effect, many rural consumers are just now learning about the clean and green aspects of propane and how that can help them save money while protecting the environment.” Newland believes propane’s use continues to become more common as more and more farmers see the benefits of propane versus diesel and other fuels. “I especially see potential in California where standards are elevated and more rigid than those of the federal government,” he said.

In California, Greg Gilbert of Autumn Wind Associates agrees. Gilbert, a consultant to the Western Propane Gas Association widely regarded as having a wealth of knowledge about California’s air quality regulations, believes propane has a lot of potential to expand market share. “I know we will see a lot of new propane engines at the 2019 Farm Show,” Gilbert said, referring to the World Ag Expo. Touted as the “World’s largest outdoor annual agriculture exhibition,” this event will be held Feb. 12-14 in Tulare, Calif.

While Gilbert sees many strong benefits from propane and its environmental friendliness, he warns against counting diesel out. “Large sums of money will be directed to improving diesel systems to make them more user-friendly and lower their cost per unit,” Gilbert said. “They have dramatically lowered their NOx emissions as a result already. I’m thankful that PERC recognizes that ‘the best never rest’ by continuing to fund ongoing improvements in propane engine technology, reduced emissions, and greater durability, all while helping to get the message out to growers and regulators in California and across the country.”

A retrofit system that mixes propane in with an engine’s diesel fuel is one solution backed by research and development from PERC. The 2Fuel dual-fuel system manufactured by 2Fuel Technologies (New Braunfels, Texas) allows growers and producers to bring diesel engines into compliance with even more stringent emissions standards without purchasing new expensive engine replacements.

“Engines that run on clean, American-made propane produce fewer emissions and meet Tier 4 standards, yet PERC realizes that not all operations are ready to replace their current diesel engines,” said Newland. “The dual-fuel system is an effective way for farmers to utilize propane on their farms for fuel savings, lower emissions, and energy independence, all while continuing to use the equipment they already own.”

The dual-fuel system is the first that is CARB certified, it has achieved “OEM” EPA certification, and 2Fuel Technologies is the only dual-fuel system manufacturer commercialized as a Tier 1 supplier.

A new 11.8-liter engine designed and optimized for industrial applications, including irrigation and power generation, was developed when PERC partnered with Zenith Power Products (Abingdon, Va.). This revolutionary technology earned Zenith honors as a runner-up for the WLPGA Innovation Award presented by the World LPG Association at the 2018 Global Technology Conference. The spark-ignited industrial engine is the first of a series of high-output stationary engines designed for standby and prime power applications by Zenith. The heavy-duty engine maintains high thermal efficiencies and low exhaust temperatures, while producing best-in-class low emissions and maintaining the environmental efficiency of all propane-powered engines.

“We were excited to team up with PERC to develop this engine to meet customer demands for a larger engine and help fill a gap in the market,” Bryan Memmott, president of Zenith Power Products, said. “Our goal is to give our customers not only initial cost savings and package efficiencies, but also lower operating costs. We’ve completed initial durability testing and are very pleased with the results.”

The engine meets both U.S. EPA stationary and standby emissions standards and is extremely powerful, producing 321 horsepower at 1800 rpm and 937 foot-pounds of torque.

“New propane-powered engines are highly efficient, cost-effective, and easily meet increasing environmental standards,” said Newland. “As we continue to build our portfolio of propane-powered engines, we work directly with manufacturers to ensure we are creating engines that provide an optimal solution to the challenge of today’s producers. This engine offers reduced operating costs due to lower fuel consumption, higher reliability, and less maintenance, on top of lower engine costs, weight, and emissions.”

A setup that synchronizes two 8.8-liter propane irrigation engines to run on one pump is an innovation developed by Husker Power Products (Hastings, Neb.) when it partnered with PERC. The idea came after a Missouri farmer contacted the company, looking for a more affordable option than electric for his center pivot irrigation project. The response was the idea of “dual-input power units” combining the two engines for double the power and benefits.

“We worked closely with our customer to develop a single controller that operates both power units and has the optional features of telematics to allow the user to monitor and control the units from any web-based device,” said Bill Heese, sales account manager at Husker Power Products. “The added convenience and cost savings of this setup are unparalleled.”

Heese noted that more and more engines, many bigger and more industrial, are being offered. “With Tier 4 diesel engines being the alternative, they are 50% to 100% higher in cost,” Heese said. “The newer propane engines are much less expensive, but are more robust, very durable, and have better longer-term value.”

An expanded portfolio of propane-powered engines offered by Industrial-Irrigation Services (IIS; Hastings, Neb.) was another development helped by a partnership with PERC. “Propane marketers need to recognize that propane engines for irrigation represent a growing market with a lot of opportunity, especially for summer gallons,” said Jay Canada, director of sales for Industrial-Irrigation Services. “IIS has been in the spark-ignited/propane engine business for over 60 years, so we’ve seen the trends change in this market. Right now market share for propane is really growing in the agriculture sector.”

“With our partnership with PERC, we have been able to improve and modernize our complete line of propane engines for irrigation, generator sets, and other ag-based appliances. Our new ‘Reliable Horsepower’ engine line ranges from 20-200HP and will be EPA certified and available in early 2019. These engines provide many advantages to the end user customer,” Canada said. “The new fuel system we have available is really a game changer for the industry — increased fuel efficiency, remote monitors and control capabilities, and a complete electronic control system.”

—Pat Thornton