man cng bus presentation-05-2009
TRANSCRIPT
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 1
MAN CNG Buses
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 2
MAN CNG BusesContent
1. MAN CNG bus history2. Actual CNG bus & engines portfolio3. MAN CNG buses – sales worldwide4. Actual CNG technology5. Concept Comparison6. New developments7. Advantages of CNG technology (compared to Diesel)8. Cost comparison9. Summary
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 3
MAN CNG BusesContent
1. MAN CNG bus history2. Actual CNG bus & engines portfolio3. MAN CNG buses – sales worldwide4. Actual CNG technology5. Concept Comparison6. New developments7. Advantages of CNG technology (compared to Diesel)8. Cost comparison9. Summary
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 4
MAN Gas BusesHistoryMAN Gas BusesHistory
1943 - First MAN Gas Bus, Augsburg
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 5
MAN Gas BusesHistory
1988 – SL 202 CNG Bus
1972 – LNG Bus for Munich Olympic Games 2001 – CNG Bus for Zwickau, Germany
2003 – CNG Bus for Frankfurt/Oder, Germany
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 6
MAN CNG BusesProducts
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 7
Milestones in the Development of MAN Natural Gas Engines
naturallyaspiratedengines
stoichiometric
1990 1995 2000 2005
turbochargedengines
lean-burnlean-burn/mix
E 2866 DUH01 E 2866 DF01 E 2866 DUH03
E 2866 DOH01
E 2866 LUH01
Euro 2-engines
Euro 3-engine
E 2876 LUH01
E 2866 DUH02 E 2876 LUH02E 2866 LUH02
EEV-engine
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 8
MAN CNG BusesContent
1. MAN CNG bus history2. Actual CNG bus & engines portfolio3. MAN CNG buses – sales worldwide4. Actual CNG technology5. Concept Comparison6. New developments7. Advantages of CNG technology (compared to Diesel)8. Cost comparison9. Summary
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 9
MAN CNG-Buses and CNG-Buseswith MAN-Natural Gas Engines
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 10
MAN CNG BusesContent
1. MAN CNG bus history2. Actual CNG bus & engines portfolio3. MAN CNG buses – sales worldwide4. Actual CNG technology5. Concept Comparison6. New developments7. Advantages of CNG technology (compared to Diesel)8. Cost comparison9. Summary
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 11
MAN gas enginesTechnology
- MAN gas engines are based on the mass produced MAN Diesel engine type D 28
- Most parts are identical to the Diesel enginesespecially the expensive ones as crankcase, crankshaft connection rods etc.
- Gas engines are dedicated engines with a lot of special features
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 12TVA-N, 01.02.00
Otto-cycle Gas engine Diesel engine
Engine cross sectionGas engine – Diesel engine
Spark plug and special combustion chamber with lower
compression ratio
Diesel injector and combustion chamber with high compression
ratio
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 13
Features of MAN gas engines I
- Cylinder heads with armored valves and armored valve seats for low abrasion
- Optimized cylinder head cooling, especially good cooling of the spark plug
- Inlet valves with shaft sealing for minimized oil consumption- Outlet valve guides made from special material with self
lubricating quality for low abrasion- Valve tappets with hard metal plates for low abrasion of the cams- Special pistons and piston rings for low oil consumption- Piston rings with special coating for low abrasion
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 14
Features of MAN gas engines I I
- Bearing shells for con rods and crankshaft with non abrasive surface
- Water cooled exhaust gas manifold for naturally aspirated engines- Turbo charger with water cooled bearing house - Turbo charger equipped with waste gate - Engine management system Bosch Motronic GAS 1 - Long life Platinum/Iridium spark plugs (60000 km) - Exhaust gas aftertreatment with a three-way catalyst (at lean
operation oxidation only)
- Summary: the number of differences indicate it makes no sense toconvert Diesel to CNG engines !
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 15
ABS/ASR
Gearboxcontrol
Vehiclemanagement
computer (FFR)
MotronicME7-Gas1
enginemanagement
Accelerator pedal
Driveline
CAN CAN
Engine
CAN-structure of gas vehicles
MASTERSLAVE
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 16
Components of the Engine Management System Motronic ME7-GAS1
1
2
3
4
5
6
7
8910 15
11
12
13
14
17
161 Butterfly valve actuator2 Injection valves3 Control unit4 Phase sensor5 Speed sensor6 Boost air temperature sensor7 Boost pressure sensor8 Coolant temperature sensor9 Natural-gas pressure sensor10 Natural-gas temperature sensor11 Igniting stages12 Spark coils13 Hot film air mass sensor14 Knock sensors15 Proportional valve for wastegate16 Broad-band lambda sensors17 Exhaust gas temperature sensor
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 17
Functions of the Motronic ME7-GAS1
• Output control by means of electrically driven butterfly valve actuator and boost pressure control via waste gate control
• Fuel control using a completely electronic sequential gas injection system and an air mass
measurement system
• Ignition control using a map transistor ignition system with open-circuit high voltage distribution
• Safety functions as self surveillance and diagnostic of sensors and actuators • Engine starter control
• Lambda = 1 control for naturally aspirated engines by means of a broad band Lambda sensor
• Lambda = 1 or Lambda > 1 control for turbo charged engines by means of a broad band Lambda
sensor
• Cylinder individual anti-knock control with the help of two knock sensors • Idle speed filling control
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 18
Gas Mixer Unit of the Natural Gas EnginesE 2866 DUH03 and E 2876 LUH02
throttle valve
gas pressure sensor
gas temperature sensor
gas inlet
gas injectors (12 x)
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 19
Evaluation of the Central Gas Mixer Unit
8 excellent homogenity of the natural gas/air-mixture,very important for lean-burn operation
8 very compact component
8 very good accessibility of the gas mixer unit for service
8 good dynamic behaviour during transient engine operation
8 many identical parts of the gas mixer unit for the naturallyaspirated and the turbocharged engine version
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 20
MAN CNG BusesContent
1. MAN CNG bus history2. Actual CNG bus & engines portfolio3. MAN CNG buses – sales worldwide4. Actual CNG technology5. Concept Comparison6. New developments7. Advantages of CNG technology (compared to Diesel)8. Cost comparison9. Summary
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 21
EEV = Enhanced Environmentally friendly Vehicle
Fuel Engine type Engine concept Mixture Installation Power[kW]
Exhaust gas standard
E 2866 DUH03 naturally aspiratedthree-way-catalyst
stoichio-metric horizontal 180 EEV
CN
G
E 2876 LUH01/02turbocharged and
aftercooledthree-way-catalyst
lean-burn / mix horizontal 228 EEV *)
LPG
G 2876 DUH01 naturally aspiratedthree-way-catalyst
stoichio-metric horizontal 200 EEV
H2 H 2876 UH01 naturally aspirated
reduction-catalyststoichio-metric horizontal 150 EEV**)
*) gas grup limitatione
**) not jet certified
EEV- Gas Engines for Buses
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 22
Evaluation of Concepts for turbocharged Natural Gas Engines
acceptable ( between lean-burn and
stoichiometric)
high (in relation to lean-burn)goodFuel
consumption
acceptable costs
high costsexpensive materials are neededheat protection in the engine compartment isnecessary
acceptable costs Costs
acceptable thermal stressexhaust gas temperaturesslightly higher to these of a Diesel engine
very high exhaust gas temperatures (> 900 °C)
low thermal stressexhaust gas temperaturescomparable to these of a Diesel engine
Thermal Stress
very good emissionsfulfil Euro 5 and EEV-standard
excellent emissionsfulfil Euro 5 and EEV-standardsuitable for Euro 6
acceptable emissionssuitable for Euro 3 also Euro 4 with restrictionto the driveability
Emissions
Lean-burn/Mix-ConceptStoichiometric ConceptLean-Burn Concept
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 23
Differences between Lean-burn and Lean-burn/Mix -Concepts
Lean-burn Concept
8 Operation of the engine in thecomplete operation map with highexcess air
8 Lambda value between 1,3 and 1,65 depending on engine load
8Stoichiometric operation of theengine in a part of the operationmap
8 Switch over to operation with highexcess air depending on the loadand the speed of the engine
8 Lambda value between 1,0 and 1,65 depending on the engine load
Lean-burn / Mix Concept
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 24
CH4 [g/kWh]
NOx [g/kWh]
NMHC [g/kWh] CO [g/kWh]
Particles [g/kWh]0,65
0,40 3,0
2,0
0,02
4,0
1,00
0,10
0,30
1,80
0,005
0,50
4,20
Euro 3-Natural Gas Engine
E 2866 LUH02
EEV-Natural Gas Engine
E 2876 LUH02
The Way from an Euro 3- towards an EEV-Natural Gas Engine with Turbocharger
EEV-Limits
Lean-Burn Concept Lean-Burn/Mix Concept
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 25
0,50
The Way from an Euro 3- towards an EEV-Natural Gas Engine with Turbocharger
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 26
Natural Gas Engine E 2876 LUH02, turbochargedand intercooled, EEV
Number of cylinders: 6Displacement: 12,8 lPower output: 228 kW/2000 rpmTorque: 1250 Nm/1000 - 1700 rpmExhaust gas standard: EEV
Concept features: central gas mixer unitgas injection system Motronic ME7-GAS1lambda ≥ 1 -controlthree- way catalyst
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 27
Function Chart of Natural Gas Engine E 2876 LUH02
vehiclemanagementcontroller
gas cylinders
pressure regulator
sensors
gas mixer unit
silencer withthree-way-catalyst
spark coils
throttlevalve
engine control unit
Lambdasensors
air masssensor
air by-pass
turbocharger waste-gate
intercooler
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 28
Performance diagram of Natural Gas Engine E 2876 LUH02
Motor-Typ.: E 2876 LUH01Leistung : 228 kW bei 2000 1/minDrehmoment : 1250 Nm bei 1000 - 1700 1/minKraftstoffverbrauch : 208 g/kWh DAEQNenndrehzahl : 2000 1/minAbnahme nach 80/1269 EWG
Leistungsdiagramm E2876LUH01
Verb
rauc
h [g
/kW
h] D
AEQ
200
210
220
230
240
250
260
270
280
Drehzahl [1/min]600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100
Dre
hmom
ent [
Nm
]
700
800
900
1000
1100
1200
1300
1400
Leis
tung
[kW
]
70
80
90
100
110
120130
140
150
160
170
180190
200
210
220
230240
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 29
MAN CNG BusesContent
1. MAN CNG bus history2. Actual CNG bus & engines portfolio3. MAN CNG buses – sales worldwide4. Actual CNG technology5. Concept Comparison6. New developments7. Advantages of CNG technology (compared to Diesel)8. Cost comparison9. Summary
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 30
New developments„Small“ CNG engine E08
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 31
Performance diagram of theTurbocharged Gas Engine E 0836 LOH01
Highlights:
Euro 6 & OBD 2 compliant
206 kW (280 bhp)
1000 NM (900-1900 1/min)
New optimized ECU
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 32
MAN CNG BusesContent
1. MAN CNG bus history2. Actual CNG bus & engines portfolio3. MAN CNG buses – sales worldwide4. Actual CNG technology5. Concept Comparison6. New developments7. Advantages of CNG technology (compared to Diesel)8. Cost comparison9. Summary
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 33
5,45
0,78
1,60
5,00
1,60
4,00
0,55
1,10
3,50
0,3
4,00
0,55
1,10
2,00
0,30
3,00
0,40
0,65
2,00
0,200,150,00 0,05
0,40
0,050,25
0,05 0,10
1,90
0,05
0,00
1,00
2,00
3,00
4,00
5,00
6,00
CO NMHC Methane NOx Particles
Gas
eous
em
issi
ons
[g/k
Wh]
Euro 3Euro 4Euro 5EEVE 2866 DUH03, Lambda =1, EEVE 2876 LUH02, lean-burn/mix, EEV
Range of variation dependson the composition of thetest gases
EEV = EnhancedEnvironmentally friendlyVehicles
ETC = EuropeanTransientCycle
0,10
0,20
0,30
0,00
0,16
0,03
< 0,005
Par
ticle
s [g
/kW
h]
Exhaust-Gas Emissions of EEV-Natural Gas Engines in the ETC
Homologation values, rounded
0,02
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 34
Exhaust-Gas Emissions Euro 3 to Euro 6ETC
Overview: legal requirements for heavy duty vehicles – Euro 3 to Euro 6
ETC: European Transient Cycle
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 35
Specific Fuel Consumption and CO2-Emission in the European TransientCycle (ETC)
100
121
132125
10093
10196
0
20
40
60
80
100
120
140
D 2876 LF with SCR E 2866 LUH02 E 2866 DUH03 E 2876 LUH02
Spec. fuel consumptionCO2-emission
EEV EEV EEVEURO 3
[%]
Specific fuel consumption = Diesel equivalent
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 36
Particle Size Distribution in the Exhaust Gas of Diesel and Natural Gas EnginesTest cycle: ESC
1,00E+08
1,00E+09
1,00E+10
1,00E+11
1,00E+12
1,00E+13
1,00E+14
1,00E+15
1 10 100 1000
electrical mobility diameter [nm]
dN/d
logD
p[1
/kW
h]
Diesel-engine, Euro 2, raw exhaust gasDiesel-engine, Euro 2, after CRTCNG-engine, EEVindoor air
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 37
Advantages of CNG technologyFocus: Biogas
Overview: environmental performance of buses
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 38
Advantages of CNG technologyFocus: Biogas
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 39
MAN CNG BusesContent
1. MAN CNG bus history2. Actual CNG bus & engines portfolio3. MAN CNG buses – sales worldwide4. Actual CNG technology5. Concept Comparison6. New developments7. Advantages of CNG technology (compared to Diesel)8. Cost comparison9. Summary
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 40
Cost comparison
Source: MAN NL
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 41
MAN CNG BusesContent
1. MAN CNG bus history2. Actual CNG bus & engines portfolio3. MAN CNG buses – sales worldwide4. Actual CNG technology5. Concept Comparison6. New developments7. Advantages of CNG technology (compared to Diesel)8. Cost comparison9. Summary
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 42
Advantages of CNG technology
CNG/LPG Exhaust gas emissions are significantly better than Diesel
emissions
CNG/LPG engines are quieter than Diesel engines (up to -2 dB(A) less)
Worldwide known resources for natural gas expected to last up to 300
years
Biogas provides the optimal fuel reference greenhouse effect and local air
quality
CNG as fuel provides a higher safety standard than Diesel !
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 43
Advantages of CNG technology
MAN Nutzfahrzeuge AG Author Title of presentation DD Month YYYY 44
Thank you for your attention.