epa ‘10 & eu vi experience & approach dr. uwe zink director, emerging industry...

EPA ‘10 & EU VIEPA ‘10 & EU VIExperience & Approach Experience & Approach

Dr. Uwe ZinkDr. Uwe Zink

Director, Emerging Industry TechnologiesDirector, Emerging Industry Technologies

Corning Incorporated Corning Incorporated

April 4, 2011April 4, 2011

2

AgendaRegulatory framework Regulatory framework

Engine technology & calibration approachesEngine technology & calibration approaches

System designsSystem designs

Certification examplesCertification examples

Enabling frameworkEnabling framework

Experience to-dateExperience to-date

Outlook –future regulationsOutlook –future regulations

3

Regulatory LandscapeEPA’10 required an 83% NOx reduction compared to 2007

OBD phases in

Daimler Truck, MTZ Heavy Duty Conference 2009

4

Observed Engine Technology Approaches

High pressure flexible injection systemsHigh pressure flexible injection systems

Unit injectorUnit injector

Common railCommon rail

Cooled EGRCooled EGR

Fixed/WG or VG TurboFixed/WG or VG Turbo

Single stageSingle stage

Dual stageDual stage

TurbocompoundingTurbocompounding

5

EPA’10 – EUVI General Calibration & Emission Control Approaches

EPA’10 Approach:EPA’10 Approach:

EPA’07 baseline with DPFEPA’07 baseline with DPF

Add DeNOx (SCR) systemAdd DeNOx (SCR) system

EUVI ApproachEUVI Approach

EUV baseline with SCREUV baseline with SCR

Increased EGRIncreased EGR

Add DPF systemAdd DPF system

US-FTP, NTE, US-FTP, NTE, PNPN

Implicit and very stringent compliance Implicit and very stringent compliance requirementsrequirements

DOCDOC DOCDOC DOCDOC

DPF(*)DPF(*) DPF(*)DPF(*) DPF(*)DPF(*)

No/min DeNOxNo/min DeNOx DeNOxDeNOx DeNOxDeNOx

(*): Observe wall flow filter in all EPA’10 systems

EPA’10 / EUVI SystemsEPA’10 / EUVI SystemsDesigns and Design Designs and Design

ConsiderationsConsiderations

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

8

SCR add-on to a 2007 system

http://www.tectrucks.com/assets/carbslideshow_volvo_scr.pdf

9http://www.detroitdiesel.com/emissions/epa2010/economy.aspx, DAG MTZ Heavy Duty Conf 11/2009

DTNA “One Box” Design & Vehicle Integration-compact design

10

System Design and components selection for reduced system back pressure

Daimler Truck, MTZ Heavy Duty Conference 2009

11

Fuel consumption and AdBlue Trade-off-Optimum provides benefit compared to EPA’07 systems

Daimler Truck, MTZ Heavy Duty Conference 2009

12

-Optimum provides benefit compared to EPA’07 systems-Example shown at ~ 2.5 g/HPh NOx

Cummins, SAE GOT 9/2010

13

Thermal Management approach to ensure SCR efficiency over cert & operating cycle

Cummins, MinNOx 6/2010, SAE GOT 9/2010

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.

EPA’10 Certification EPA’10 Certification ExamplesExamples

16

Some examples of EPA 2010 NOx Certifications, various OEs-against Standard of 0.2 g/HPh and individual FELs

NOx NOx

(g/BHPh)(g/BHPh)

Displ. (l)Displ. (l) 88 1010 1212 1414 1616

0.1

Std: 0.2

0.3

0.4

0.5

Family Emission Limit Cert against US FTP Cert against RMC/SEThttp://www.arb.ca.gov/msprog/onroad/cert/mdehdehdv/2011/2011.php

Enabling FrameworkEnabling Framework Urea/NHUrea/NH33 Delivery Delivery

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

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

20

AdBlue/DEF Logistics grown substantially in Europe

http://www.findadblue.com/

Stations in Europe (3/29/11):3587 w/Pumps,

7333 w/Canisters

Emerging NHEmerging NH33 Systems Systems

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.

23

Update on ammonia adsorption SCRFirst commercial contract -production trial in 2011.

Amminex, CTI SCR Conf, 7-10

DPF AspectsDPF Aspects

25

DPF Maintenance Aspects-addressed already for the EPA’07 systems

Assume low sulfur diesel (<50 ppm) is availableAssume low sulfur diesel (<50 ppm) is available

Filter cleaning/service –several conceptsFilter cleaning/service –several concepts

On-vehicleOn-vehicle -air assisted-air assisted

Off-vehicleOff-vehicle -air/liquid-air/liquid In workshopIn workshop

CentrallyCentrally

Lube oil: Low SAPS (<1%) oil CJ-4 recommended by OEsLube oil: Low SAPS (<1%) oil CJ-4 recommended by OEs

Still CI-4 (<1.4% SAPS) in useStill CI-4 (<1.4% SAPS) in use

Filter cleaning intervals depend on duty cycleFilter cleaning intervals depend on duty cycle

Experience:Experience: Several applications exceed min. design of 150,000 miles Several applications exceed min. design of 150,000 miles

SAPS: Sulphated Ash Phosphorus SulphurSAPS: Sulphated Ash Phosphorus Sulphur

26

Maintenance & Inspection Guidelines

EPA’10 ExperiencesEPA’10 Experiences

Generally 5-7% fuel consumption benefitsGenerally 5-7% fuel consumption benefits

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

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

Outlook 2014+Outlook 2014+COCO22 Regulations emerging Regulations emerging

31

HD CO2/Fuel Consumption Reduction: Different approaches JP: Fuel consumption, EU: CO2 focus(?), EPA: GHG focus

New EU Regs CO2 (assumption)

2011 2012 20142013 2015 2016 2017 2018 2019 20212020 2022 2023 2024

EPA CO2e (CO2; N2O, CH4 caps; BC)

JP: Fuel cons. -12% vs 2002 Tighter JP Regs (assumption)

(*): www.Daimler.com, MTZ 1-’09, http://www.cat.com/sd2009, http://www.deere.com/en_US/globalcitizenship/stewardship/metrics.html

DoE SuperTruck

Vehicle fuel eco demo

ACEA: 20% reduction goal (*)

DoE: +50% freight efficiencyPrototype demo

CO2/Fuel Eco - Government / OE Initiatives

DAG’s “Shaping Future Transportation” (*)

“Road to Emission Free Mobility (LD & HD)”(*)

Tighter EPA Regs

32

HD CO2/Fuel Consumption Reduction: Different approaches JP: Fuel consumption, EU: CO2 focus(?), EPA: CO2 w/cap on GHG

EU Regs CO2 (assumption)

2011 2012 20142013 2015 2016 2017 2018 2019 20212020 2022 2023 2024

JP: Fuel cons. -12% vs 2002 JP Regs + (assumption)

CO2/Fuel Eco - Regulatory Landscape / Assumptions On-Road

EPA CO2e (*) EPA Regs + (assumption) EPABaseline: 2009

Total: 11-16% 30-40%

Vehicle: 5 -10% 15-20%

Engine: 6% 15-20%(*) expect cap on N2O, CH4, BC

33

CO2 & 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

34

SummaryEPA’10 represents tightest emission regulation for commercial vehicle engines todayEPA’10 represents tightest emission regulation for commercial vehicle engines today

Typically met by advanced engine technology and DPF plus SCR systemsTypically 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 enginesWhile meeting the regulations, OEs offered value to end user via reduced fuel consumption compared to 2007 engines

Typically higher NOx calibration with SCR DeNOxTypically higher NOx calibration with SCR DeNOx

Other engine based approaches observed as wellOther engine based approaches observed as well

Urea infrastructure in US is rapidly building Urea infrastructure in US is rapidly building

Expect similar system designs for EUVIExpect similar system designs for EUVI

Expect wall flow filter to meet PN regs across the boardExpect wall flow filter to meet PN regs across the board

OutlookOutlook

OBD next in US 2013OBD next in US 2013

COCO22 regulations coming in 2014 (US), assume EU will follow with CO regulations coming in 2014 (US), assume EU will follow with CO22

Expect next round of engine/aftertreatment system evolutionExpect next round of engine/aftertreatment system evolution

Thank you for your Thank you for your kind attention!kind attention!

Questions are welcome!Questions are welcome!