epa ‘10 & eu vi experience & approach dr. uwe zink director, emerging industry...
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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
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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
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Regulatory LandscapeEPA’10 required an 83% NOx reduction compared to 2007
OBD phases in
Daimler Truck, MTZ Heavy Duty Conference 2009
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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
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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
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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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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
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System Design and components selection for reduced system back pressure
Daimler Truck, MTZ Heavy Duty Conference 2009
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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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-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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Thermal Management approach to ensure SCR efficiency over cert & operating cycle
Cummins, MinNOx 6/2010, SAE GOT 9/2010
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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
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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
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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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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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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
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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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Update on ammonia adsorption SCRFirst commercial contract -production trial in 2011.
Amminex, CTI SCR Conf, 7-10
DPF AspectsDPF Aspects
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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
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Maintenance & Inspection Guidelines
EPA’10 ExperiencesEPA’10 Experiences
Generally 5-7% fuel consumption benefitsGenerally 5-7% fuel consumption benefits
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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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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
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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
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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
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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
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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!