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EPA ‘10 & EU VI Experience & Approach Dr. Uwe Zink Director, Emerging Industry Technologies Corning Incorporated April 4, 2011
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2 Agenda Regulatory framework Engine technology & calibration approaches System designs Certification examples Enabling framework Experience to-date Outlook –future regulations
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3 Regulatory Landscape EPA’10 required an 83% NOx reduction compared to 2007 OBD phases in Daimler Truck, MTZ Heavy Duty Conference 2009
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4 Observed Engine Technology Approaches High pressure flexible injection systems Unit injector Common rail Cooled EGR Fixed/WG or VG Turbo Single stage Dual stage Turbocompounding
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5 EPA’10 – EUVI General Calibration & Emission Control Approaches EPA’10 Approach: EPA’07 baseline with DPF Add DeNOx (SCR) system EUVI Approach EUV baseline with SCR Increased EGR Add DPF system US-FTP, NTE, PN Implicit and very stringent compliance requirements DOCDOCDOCDPF(*)DPF(*)DPF(*) No/min DeNOx DeNOxDeNOx (*): Observe wall flow filter in all EPA’10 systems
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EPA’10 / EUVI Systems Designs and Design Considerations
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7 Example of an EPA’10 Emission control system: -MD & HD application - DOC + DPF + SCR Cummins, SAE GOT 9/2010 Example of actual design as on vehicle
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8 SCR add-on to a 2007 system http://www.tectrucks.com/assets/carbslideshow_volvo_scr.pdf
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9 http://www.detroitdiesel.com/emissions/epa2010/economy.aspxhttp://www.detroitdiesel.com/emissions/epa2010/economy.aspx, DAG MTZ Heavy Duty Conf 11/2009 DTNA “One Box” Design & Vehicle Integration -compact design
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10 System Design and components selection for reduced system back pressure Daimler Truck, MTZ Heavy Duty Conference 2009
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11 Fuel consumption and AdBlue Trade-off -Optimum provides benefit compared to EPA’07 systems Daimler Truck, MTZ Heavy Duty Conference 2009
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12 -Optimum provides benefit compared to EPA’07 systems -Example shown at ~ 2.5 g/HPh NOx Cummins, SAE GOT 9/2010
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13 Thermal Management approach to ensure SCR efficiency over cert & operating cycle Cummins, MinNOx 6/2010, SAE GOT 9/2010
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14 Examples of published EUVI Design Iveco, ATA Conference 2006 ww.scania.com/Images/P11301EN%20Euro%206%20engines%20ready%20for%20the%20market_240653.pdf, 2011, 13l 440 and 480 HP rating.
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EPA’10 Certification Examples
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16 Some examples of EPA 2010 NOx Certifications, various OEs -against Standard of 0.2 g/HPh and individual FELs NOx(g/BHPh) Displ. (l) 810121416 0.1 Std: 0.2 0.3 0.4 0.5 Family Emission Limit Cert against US FTP Cert against RMC/SET http://www.arb.ca.gov/msprog/onroad/cert/mdehdehdv/2011/2011.php
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Enabling Framework Urea/NH 3 Delivery
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18 DEF Logistics Building in the US http://www.factsaboutscr.com –SCR101: Getting Ready for EPA2010 Dealer / Distributor IBC, 55-gallon drum, 2 gallon jug Home Terminal Intermediate Bulk Container (IBCs) or 2-2.5 gallon Jugs Truck Stop Fuel island filling
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19 DEF Infrastructure -evolving across North America -currently ~ 3,000 stations Diesel Exhaust Fluid will soon be sold at over 2,500 locations all over North America. http://www.detroitdiesel.com/emissions/epa2010/availability.aspx
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20 AdBlue/DEF Logistics grown substantially in Europe http://www.findadblue.com/ Stations in Europe (3/29/11): 3587 w/Pumps, 7333 w/Canisters
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Emerging NH 3 Systems
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22 New mixer allows urea injection at T>180C -Key for thermal management and/or space mitigation Mixer has low pressure drop and high surface area. 4.8% max pressure drop in ESC (0.25 kPa) Inj>220C Inj>180C SwRI, SAE 2010-01-1185 The new mixer with revised calibration shows higher efficiency than without at all points. Point E is 181C; F is 225C.
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23 Update on ammonia adsorption SCR First commercial contract -production trial in 2011. Amminex, CTI SCR Conf, 7-10
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DPF Aspects
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25 DPF Maintenance Aspects -addressed already for the EPA’07 systems Assume low sulfur diesel (<50 ppm) is available Filter cleaning/service –several concepts On-vehicle-air assisted Off-vehicle-air/liquid In workshop Centrally Lube oil: Low SAPS (<1%) oil CJ-4 recommended by OEs Still CI-4 (<1.4% SAPS) in use Filter cleaning intervals depend on duty cycle Experience: Several applications exceed min. design of 150,000 miles SAPS: Sulphated Ash Phosphorus Sulphur
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26 Maintenance & Inspection Guidelines
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EPA’10 Experiences Generally 5-7% fuel consumption benefits
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28 Observe long DPF regeneration intervals with high NOx/Low PM -some advertise “no active regeneration” http://www.tectrucks.com/assets/carbslideshow_volvo_scr.pdf
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29 Customer feedback on 2010 Systems –positive throughout the industry (Example shown from Volvo) http://www.volvotrucks.com/SiteCollectionDocuments/VTNA_Tree/ILF/Products/2010/09-VTM095_testimonials_041509.pdf
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Outlook 2014+ CO 2 Regulations emerging
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31 HD CO 2 /Fuel Consumption Reduction: Different approaches JP: Fuel consumption, EU: CO 2 focus(?), EPA: GHG focus New EU Regs CO 2 (assumption) 20112012201420132015201620172018201920212020202220232024 EPA CO 2 e (CO 2 ; N 2 O, CH 4 caps; BC) JP: Fuel cons. -12% vs 2002Tighter JP Regs (assumption) (*): www.Daimler.com, MTZ 1-’09, http://www.cat.com/sd2009, http://www.deere.com/en_US/globalcitizenship/stewardship/metrics.htmlwww.Daimler.comhttp://www.cat.com/sd2009 DoE SuperTruck Vehicle fuel eco demo ACEA: 20% reduction goal (*) DoE: +50% freight efficiency Prototype demo CO 2 /Fuel Eco - Government / OE Initiatives DAG’s “Shaping Future Transportation” (*) “Road to Emission Free Mobility (LD & HD)”(*) Tighter EPA Regs
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32 HD CO 2 /Fuel Consumption Reduction: Different approaches JP: Fuel consumption, EU: CO 2 focus(?), EPA: CO2 w/cap on GHG EU Regs CO 2 (assumption) 20112012201420132015201620172018201920212020202220232024 JP: Fuel cons. -12% vs 2002JP Regs + (assumption) CO 2 /Fuel Eco - Regulatory Landscape / Assumptions On-Road EPA CO 2 e (*) EPA Regs + (assumption) EPA Baseline: 2009 Total: 11-16%30-40% Vehicle: 5 -10%15-20% Engine: 6%15-20% (*) expect cap on N 2 O, CH 4, BC
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33 CO 2 & fuel consumptions measures -Aerodynamics, vehicle weight, engine, tires, drivetrain Ref.: Technologies and Approaches to Reducing the Fuel Consumption of Medium- and Heavy-Duty Vehicles, April 2010; http://www.nap.edu/catalog/12845.html
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34 Summary EPA’10 represents tightest emission regulation for commercial vehicle engines today Typically met by advanced engine technology and DPF plus SCR systems While meeting the regulations, OEs offered value to end user via reduced fuel consumption compared to 2007 engines Typically higher NOx calibration with SCR DeNOx Other engine based approaches observed as well Urea infrastructure in US is rapidly building Expect similar system designs for EUVI Expect wall flow filter to meet PN regs across the board Outlook OBD next in US 2013 CO 2 regulations coming in 2014 (US), assume EU will follow with CO 2 Expect next round of engine/aftertreatment system evolution
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Thank you for your kind attention! Questions are welcome!
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