2006 DEER Conference Emission Controls for Heavy-Duty Trucks

Overview

� Emission Standards – US and Worldwide � Technology Options for Meeting Emissions � System Integration � Particulate Filter Technology � SCR Technology � Summary

2006 DEER Conference

NOx

g/HP

-hr

US07 Emission Regulation NOx Emissions Time Line and StandardsNOx Emissions Time Line and Standards2.5

2.0

1.5

1.2 1.0

0.5

0.2 0.0

2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

Current 2.5g/HP-hr

0.2g/HP-hr

Phase-In Period

2006 DEER Conference

2006 DEER Conference

Particulate Emissions Time Line and StandardsParticulate Emissions Time Line and Standards

2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 0.00

0.02

0.04

0.06

0.08

0.10

0.01 g/HP-hr

Current 0.10 g/HP-hr

Parti

cula

te g

/HP-

hr

0.01

US07 Emission Regulation

2006 DEER Conference

US2010 Requires Further NOx Reductions – Engine + Aftertreatment

Engine In-Cylinder

Improvements

US07 Technology Selection was driven by Emissions Strategy

US10

0 1 2 3 4 5 NOx/(NOx+HC) [g/HP-hr]

6 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10

Parti

cula

te [g

/HP-

hr]

US07 (Phase-In)

20022002 19981998

Active Particulate

Filter

2006 DEER Conference

Nonroad Emissions Standards - US

MOBILE OFF-HIGHWAY EMISSIONS REGULATIONS SCHEDULES

NOx / HC / CO / PM (g/kW-hr) [Conversion: (g/kW-hr) x 0.7457 = g/bhp-hr] (NOx+HC) / CO / PM (g/kW-hr) [Conversion: (g/kW-hr) x 0.7457 = g/bhp-hr]

U.S. EPA kW (HP)

0 - 18 (0 - 24) ( 7.5 ) / 8.0 / 0.80

19 - 36 (25 - 48) ( 7.5 ) / 5.5 / 0.60 ( 7.5 ) / 5.5 / 0.30

37 - 55 (49 - 74)

56 - 74 (75 - 99)

75 - 129 (100 - 173) ( 4.0 ) / 5.0 / 0.30

130 - 560 (174 - 751) ( 4.0 ) / 3.5 / 0.20

>560* (>751)* ( 6.4 ) / 3.5 / 0.20

a. Applies to portable power generation >1200hp. b. Applies to portable power generation >751hp.

Tier 4B Tier 1 Tier 2 Tier 3 Tier 4A

2004 2005 2006 2007 2008 2009 2010 2017

( 7.5 ) / 6.6 / 0.40

( 4.7 ) / 5.0 / 0.03

2012 2013 2014 2015 2011 2016

2.0 / 0.19 / 3.5 / 0.02 0.40 / 0.19 / 3.5 / 0.02

( 7.5 ) / 5.0 / 0.40

3.5 / 0.40 / 3.5 / 0.10 0.67 / 0.40 / 3.5 / 0.10 a

3.5 / 0.19 / 3.5 / 0.04 0.67/ 0.19 / 3.5 / 0.03 b

( 4.7 ) / 5.0 / 0.30 ( 4.7 ) / 5.0 / 0.40

3.4 / 0.19 / 5.0 / 0.02 0.40 / 0.19 / 5.0 / 0.02

Parti

cula

te [g

/kW

Parti

cula

te [g

/kW

-- hr]hr]

Heavy-Duty Emission Standards – Worldwide

0.14

0.12

0.10

0.08

0.06

0.04

0.02

US10 0.00

US02/04

Transient

Japan - NLT Tier IV B Tier IV A EURO-V EURO-IV

Japan - PNLT US07

0 1 2 3 4 5

NOx [g/kWNOx [g/kW--hr]hr] 2006 DEER Conference

Technology Options for Heavy-Duty Truck Emissions

� In-Cylinder Emissions Control Technology �more difficult with increasingly stringent standards � Particulate Filter Technology � Demonstrated in retrofit systems (> 10,000 units) and light-duty � Active regeneration required to cover all duty cycles � Low sulfur fuel and Low ash oil enable this technology � SCR Technology � Introduced in Europe to meet Euro 4 standards � Urea infrastructure required to enable this technology � Lean NOx Trap (LNT) Technology � Technology is still under development - significant challenges � Combined System Technologies

2006 DEER Conference

2006 DEER Conference

System Integration – On-Road Laboratory

MERLINMERLIN -- Mobile EmissionsMobile Emissions Research LaboratorResearch Laboratory

MERLIN • Custom-Designed Straight Truck • Extended Sleeper Cab for Computer W/Stations • 6L 2002 Cooled EGR Engine • NOx and SOx Adsorbers • Particulate Filter • Exhaust Fuel Injection Capability • Comprehensive Data Acquisition • Full System Simulation On-Board • Controls Rapid-Prototyping • Commissioned February 2002

2006 DEER Conference

Heavy-Duty System Integration

Vehicle + Engine + Aftertreatment System Integration is Key

2006 DEER Conference

Particulate Filter Exhaust Assembly – Vehicle Mounted

Inlet Section

Oxidation Catalyst

Particulate Filter

Outlet Section

V-Band Clamp

Gasket

ΔP Sensor Assembly

2006 DEER Conference

>> Porous ceramic walls capture both soot and ash from exhaustPorous ceramic walls capture both soot and ash from exhaust>> High filtration efficiency enables engines to meet USHigh filtration efficiency enables engines to meet US’’07 std07 std>> Soot removed by periodic regenerationSoot removed by periodic regeneration>> Ash accumulates and requires removal and maintenanceAsh accumulates and requires removal and maintenance

>> On a catalyzed filter, soot is consumed by:On a catalyzed filter, soot is consumed by:>> NONO22 andand ““passive regenerationpassive regeneration”” between 220between 220 -- 450450ººCC>> Catalytic reactions between 350Catalytic reactions between 350 -- 550550ººCC>> OO22 burning at 500burning at 500ººC and aboveC and above

Particulate Filter Overview

Soot & Ash

2006 DEER Conference

Kenworth T2000, 2001Kenworth T2000, 2001ISXISX--450 1850 lb450 1850 lb--ft @1200 RPM,ft @1200 RPM,Eaton CST Autoshift 12 SpeedEaton CST Autoshift 12 Speed

SCR Catalyst

50 Gallon Urea Tank

Urea Dosing Unit

> U.S. Vehicle System Demonstration> U.S. Vehicle System Demonstrationfor Technology Integrationfor Technology Integration> In production in Europe> In production in Europe

Selective Catalytic Reduction – SCR Europe On-Highway (Euro 4)

2006 DEER Conference

Selective Catalytic Reduction - SCR SCR - NOx Aftertreatment

Exhaust StreamExhaust StreamExhaust Stream

Aqueous (32%) UREA Storage

Vessel

Compressed Air Supply

UREA Metering System

Sensor Inputs

Engine Control Module

Diesel Engine

Catalyst

2006 DEER Conference

Selective Catalytic Reduction - SCR

SCR - NOx Aftertreatment

Exhaust Stream

Hydrolysis H2N-CO-NH2 + H2O > 2 NH3 + CO2

4NO + 4NH3 + O2 > 4N2 + 6H2O 8 NH3 + 6 NO2 > 7 N2 + 12 H2O

Oxidation Catalyst 4NH3+3O2 > 2N2 +6H2O

NOx Catalyst

Diesel Engine

Aqueous Urea Supply

Summary System Integration to meet Customer Expectations and Emission Standards

� Integration with the Vehicle Design � Integration between Engine and Aftertreatment – not a bolt-on device

Technology Development prior to Product Development � Cross-functional team focused on Product Preceding Technology project

Disciplined Approach to Product Development � New Product Introduction teams in place with defined VPI project milestones / gates � Design for Six Sigma (DFSS) tools applied during design / development

Analysis Led Design � Extensive use of modeling and analysis tools during the design phase � Dynamic system modeling of vehicle / engine / aftertreatment / controls

Application of Platform Architecture across engine platforms � Increased experience during development phase � Allows for validation over broad range of applications and duty cycles

2006 DEER Conference