Clean Air Bus Transport. Future proof and sustainable technology Robert Staimer, SRNB, Israel, January 2013

Transcription

1 Clean Air Bus Transport Future proof and sustainable technology Robert Staimer, SRNB, Israel, January 2013

2 Future proof and sustainable technology Environment: Diesel Diesel Hybrid Electric Hydrogen Compressed Natural Gas (CNG) Compressed BioGas (CBG) Infrastructure Gas Supply Gas Equipment Service & Health & Safety < 2 >

3 Future proof and sustainable technology Natural Gas is the world s fastest growing alternative fuel. Why? < 3 >

4 Future proof and sustainable technology CNG vs. Conventional Liquid Fuel Environmental Benefits Improved Safety Increased Efficiency Optimum Availability Economic Advantages < 4 >

5 Future proof and sustainable technology The number of Natural Gas Vehicles is growing exponentially and currently at the rate of over 250,000 vehicles per month. No of Natural Gas Buses increased by 31% in the last year. From 317,000 to 401,000 These include buses, HGVs, light vans, refuse trucks and passenger cars, FLTs, By 2020 the number of gas vehicles is expected to exceed 65,000,000 < 5 >

6 Agenda 1 MAN CNG bus history 2 Actual CNG bus & engines portfolio 3 MAN CNG buses sales worldwide 4 Actual CNG technology Euro 6 5 Advantages of CNG technology (compared to Diesel) 6 Cost Calculation 7 Summary < 6 >

7 History 1972 LNG Bus for Munich Olympic Games 2001 CNG Bus for Zwickau, Germany 1988 SL 202 CNG Bus 2003 CNG Bus for Frankfurt/Oder, Germany < 7 >

8 Products A74 EGO Ankara A23 Augsburg A23 Saarbrücken A21 Nürnberg A26 Stockholm A26 Liechtenstein < 8 >

9 Agenda 1 MAN CNG bus history 2 Actual CNG bus & engines portfolio 3 MAN CNG buses sales worldwide 4 Actual CNG technology - Euro 6 5 Advantages of CNG technology (compared to Diesel) 6 Cost Calculation 7 Summary < 9 >

10 CNG Product Portfolio 1) also available as Lion`s City L LE with 2 or 3 doors 2) height with standard CNG storage system 3) height with optional CNG storage system 4) also available as Lion`s City G LE with 2 or 3 doors 5) also available as Lion`s City GL LE with 2 or 3 doors < 10 >

11 CNG product portfolio cont`d 12 m low floor chassis - solobus 18 / 18,75 m low floor chassis articulated bus 12 m low entry chassis - solobus < 11 >

12 Component overview CNG storage- and fuel supply system Wide range of storage systems available Highest safety standards available (cylinders & supply system) ECE R-110 certified EEV-/ Euro VI engine turbocharged engine, 12.8 litres 310 bhp / Nm (LUH07) 272 bhp / Nm (LUH08) Low noise level Fuelling system fill nozzle with safety system filling duration similar to Diesel bus < 12 >

13 engine development milestones < 13 >

14 Agenda 1 MAN CNG bus history 2 Actual CNG bus & engines portfolio 3 MAN CNG buses sales worldwide 4 Actual CNG technology Euro 6 5 Advantages of CNG technology (compared to Diesel) 6 Cost Calculation 7 Summary < 14 >

15 sales figures worldwide CNG Sales Country Units Australia Finland 31 France 2 Germany Great Britain 37 Italy 65 Luxembourg Mexico 1 Netherland Norway 211 Austria Poland 29 Portugal 294 Russia Sweden 867 Switzerland Slovakia 1 Spain 555 Turkey 1289 Total < 15 >

16 CNG share Lion`s City Sales Sales Region Northern & Southern Europe (except Benelux, Germany, Iberia, Holland, France) , ,5 % share 1234,0 16,9 % share 1467,0 22,2 % share ,0 419,0 251, Diesel CNG & LPG < 16 >

17 Agenda 1 MAN CNG bus history 2 Actual CNG bus & engines portfolio 3 MAN CNG buses sales worldwide 4 Actual CNG technology Euro 6 5 Advantages of CNG technology (compared to Diesel) 6 Cost Calculation 7 Summary < 17 >

18 Dynamics in emission legislation Euro 1 Euro 6 0,5 Particles [g/kwh] 0,4 0,3 Euro I (1993) 0,2 Euro II (1996) 0,1 Euro III (2000) Euro V (2008) Euro IV (2005) Euro VI (2013) 0,0 0 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 9,0 10,0 EEV (2009) NOx [g/kwh] < 18 >

19 Environmental Aspects ETC / WHTC CO NMHC Nox CH 4 PM particle number NH3 (ppm) (g/kwh) (g/kwh) (g/kwh) (g/kwh) (g/kwh) (10 11 / kwh) Euro III limit 5,45 0,78 5-0, Euro IV limit 4 0,55 3,5-0, Euro V limit 4 0,55 2-0, EEV limit 3 0,4 2-0, Euro VI limit 4 0,16 0,46 0,5 0, MAN E EEV 0,72 0,04 0,02 0,02 0, MAN E Euro 6 0,3 0,02 0,31 0,14 0,001 2,59 8,86 < 19 >

20 WHTC emission limits - Euro 6 10,0 10,00 10,00 8,0 WHTC = World-wide Harmonised Transient Cycle weighting: 14% cold + 86 % hot Emissionen 6,0 4,0 4,00 6,00 * 2,0 0,0 0,50 0,46 0,16 CO NMHC Methan NOx Partikel NH3 Partikelzahl g/kwh g/kwh g/kwh g/kwh mg/kwh ppm 10E11 * Diesel engine limits, particle number limit for CNGs expected until < 20 >

21 WHTC test results 10,0 10,00 10,00 Emissionen 8,0 6,0 4,0 2,0 0,0 EURO VI (WHTC - Grenzwert) E 2876 LUH07 7,12 6,00 * 4,00 2,14 1,25 0,50 0,28 0,46 0,160,02 0,22 0,38 CO NMHC Methan NOx Partikel NH3 Partikelzahl g/kwh g/kwh g/kwh g/kwh mg/kwh ppm 10E11 WHTC = World-wide Harmonised Transient Cycle Wichtung: 14% kalt + 86 % warm Prüfgas: G25, Emissionwerte inklusive Verschlechterungsfaktoren * Diesel engine limit. Particle no. limit for CNG engines expected < 21 >

22 emissions CNG engine E2876 LUH - Euro 6 WHTC = World-wide Harmonised Transient Cycle weighting: 14% cold + 86 % hot Emissions of CNG engine E2876LUH 07 Euro 6 WHTC 12,0 10,0 8,0 6,0 Euro 6 limit Fuel: GR Measured 4,0 Fuel: G25 Measured 2,0 0,0 [g/kwh] [g/kwh] [g/kwh] [g/kwh] [g/kwh] [ppm] CO THC CH4 NOX PT/PM NH3 PTN * Diesel engine limits, particle number limit for CNGs expected until < 22 >

23 Challenges of EURO VI for HD Vehicles Trends Influencing EURO VI Heavy Duty Legislation global harmonization world-wide harmonized heavy duty certification (WHDC, gtr 4) world-wide harmonized OBD (WWH-OBD, gtr 5) harmonization of OBD communication (ISO 27145) 100% PM 8% 6,25% NO x persistent legislative focus on emission reduction necessity of exhaust after-treatment increasing system complexity (engine, exhaust after-treatment) EIII EIV EV EVI *ETC vehicle operation / on-road capabilities further focus on transient & real world engine operation (WHTC) inclusion of engine cold start into certification process focus on on-road capabilites/ in-service confomity (PEMS/IUPR) torque speed driver notification / inducement noticeability of emission faults (discriminatory display strategy) emphasis on importance of NOx reduction (driver inducement) roadworthiness in terms of emissions (roadside check ISO 27145) < 23 >

24 Euro 6 test cycle World-wide Harmonised Heavy-Duty Certification Procedure (WHDC) split into: 1. stationary test WHSC (World-wide Harmonised Stationary Cycle) 2. transient test WHTC (World-wide Harmonised Transient Cycle), 2 parts: 1. cold engine start 2. hot engine start after 10 min < 24 >

25 WHTC engine rpm and torque progression - E2876LUH N [1/min] Zeit [s] M [Nm] Zeit [s] < 25 >

26 EURO 6 challenges for HD vehicles Durability Legislation demands persistent low exhaust emissions (i.e. performance of the exhaust gas aftertreatment) over a mileage of km or 7 years for trucks > 7,5 t as well as km or 5 years for buses and coaches. In Service Conformity, ISC = proof of durability WWH-OBD / EURO VI-OBD exhaust system check (filters, catalysts) for existence and function control of all exhaust emission relevant actuators and sensors PEMS-measurements Emission measurements on vehicles on the road, carried out in defined time intervals and in accordance with test cycles, which fulfill certain criteria (city/ intercity /highway mix), Installation of a certified measuring system (PEMS, Portable Emission Measurement System), reporting through standardised software. Repair and Maintenance Instructions, RMI OEMs are obliged to make repair & maintenance instructions accessible for certified persons Conformity of production, COP Check of production quality by means of emission measurements of 1 % of series engines Guarantee of quality from outside supplier parts by means of supplier COP. < 26 >

27 technical solutions / WWH-OBD functionalities WWH-OBD functions control of exhaust emission system for correct performance control of exhaust emissions General demands control of all electric wires to ECU control of components and sensors reference electrical faults (cable break, battery or earth shortage) and plausibility check Conducting functional tests and check of components fault display by means of MIL (Malfunction Indicator Lamp) and storage in ECU fault memory Accessibility of fault memory by means of standardized, free vendible diagnostic devices Realized control function for EGC4: catalyst diagnosis check of oxygen storage ability inside catalyst < 27 >

28 EURO VI challenges fault classification Fault classification: A: expected excess of OBD-limit B1: emission relevant, OBD-limit may be exceeded, but unclear impact on emission B2: emission relevant, without exceeding OBD-limits C: emission relevant, without exceeding legal emission limits Emissionen (WHTC kalt/warm) C B2 B1 A OBD-treshold emission limits fault class, priority (MIL) emissiontreshold highest OBD - limits NOx [g/kwh] CO [g/kwh] THC [g/kwh] NH3 [ppm] particle mass [mg/kwh] no. of particles [#/kwh] 0,46 4 0, (6e+11) 1, < 28 >

29 Technology Otto-cycle Gas engine Spark plug and special combustion chamber with lower compression ratio Diesel engine Diesel injector and combustion chamber with high compression ratio < 29 >

30 Technology comparison Diesel vs. CNG (Otto) Features of MAN CNG engines External mixture forming: Natural gas injected into compressed intake air, forming mixture upstream of combustion chamber. Externally induced ignition: mixture being ignited in cylinder by means of spark plug Engine power regulation: engine power regulated through mixture quantity. The amount of gas/air mixture is being controlled by means of a throttle valve and charge air pressure Features of MAN-Diesel engines Internal mixture forming: during intake stroke only air will enter combustion chamber. Mixture forming by means of Diesel fuel injection Self ignition: Intake air heated up during compression, leading to self-ignition of injected Diesel fuel, without external igniter Engine power regulation: engine power regulated through mixture quality. Depending on engine speed the amount of intake air stays almost constant. Only quantity of injected fuel varies 1 Spark plug 2 Diesel Injector 3 Combustion chamber < 30 >

31 E 2876 LUH < 31 >

32 Technology E2876LUH Number of cylinders: 6 Displacement: 12,8 l Power output: Torque: Exhaust gas std: Euro kw / 2000 rpm 1250 Nm/ rpm E0836LOH Number of cylinders: 6 Displacement: 6,9 l Power output: 206 kw /2000 rpm Torque: 1000 Nm/ rpm Exhaust gas std: Euro 6 < 32 >

33 EGC4 - Technology < 33 >

34 EGC4 load sensoring sensor signals used to make air mass flow meter redundant < 34 >

35 Liner Technology Type III cylinders are manufactured from seamless, thin aluminum liners, wrapped with carbon fibre laminate advantage: weight saving up to 70 % Type IV cylinders are full plastic liners wrapped with fiberglass/carbon Type I Type II Type III - Dynecell Type IV < 35 >

36 Safety Aspects What makes the CNG bus so safe? European regulation ECE-R110, StVZO, German pressure cylinder regulation, safety and accident prevention regulations are fulfilled Individual inspection of every vehicle prior to start of operation (by officially certified inspector) Filing nozzle with integrated check valve and shut-off valve Fuel lines and unions made of stainless steel, gas tight Liners Aerospace proven materials Operating pressure 200 bar, test pressure 300 bar, rated pressure 500 bar Safety factor 2,5! Cylinder lifetime 20 years without need for intermediate inspection Solenoid valves shut off fuel supply when ignition is switched off Cylinder valves equipped with Flow limiter PRD (pressure relieve device): melting fuse will prevent cylinders from overpressure (in case of fire) < 36 >

37 Agenda 1 MAN CNG bus history 2 Actual CNG bus & engines portfolio 3 MAN CNG buses sales figures 4 Actual CNG technology Euro 6 5 Advantages of CNG technology (compared to Diesel) 6 Cost Calculation 7 Summary < 37 >

38 Euro 6 strategies / Diesel & CNG comparison Euro 6 Diesel requires EGR & SCR technologies to be combined: Euro 6 CNG only requires 3-way catalyst! < 38 >

39 Environmental Aspects - cont`d Limit values & emissions busdrive trains (ETC) Euro 3 Diesel PM (g/kwh) EEV stoichiometric CNG EEV diesel closed soot trap Hybrid diesel closed soot trap Euro Euro 5 diesel closed soot trap EEV Lean burn CNG Euro 4 Diesel PM-Kat Euro 6 Euro EEV Euro < 39 >

40 Environmental Aspects - cont`d < 40 >

41 Environmental Aspects - cont`d Overview: environmental performance of buses < 41 >

42 Environmental Aspects - cont`d!! < 42 >

43 Agenda 1 MAN CNG bus history 2 Actual CNG bus & engines portfolio 3 MAN CNG buses sales worldwide 4 Actual CNG technology Euro 6 5 Advantages of CNG technology (compared to Diesel) 6 Cost Calculation 7 Summary < 43 >

44 Financial Aspects-/ Cost comparison 1. vehicle costs (complete vehicle, Lion`s City) 180,0 160,0 140,0 120,0 100,0 80,0 60,0 40,0 20,0,0 vehicle investment for different drive technologies [%] A37 Diesel A37 Hybrid A21CNG < 44 >

45 Financial Aspects-/ Cost comparison 2. fuel costs Diesel: Fuel cost comparison [EUR] CNG: Calculation basis: 10 year period annual mileage: km Diesel cost: 1,40 EUR per litre CNG cost: 1,00 EUR per kg fuel consumption: 50/50 % mix from SORT 1 and SORT 2 values < 45 >

46 Financial Aspects-/ Cost comparison 3. repair & maintenance comparison , , , , ,0 maintenance costs [EUR] preventive maintenance costs [EUR] repair costs [EUR] Maintenance costs for Diesel and alternative drive technologies [%] ,0 Hybrid Gas Diesel Diesel 0 Hybrid /D08 CNG / E28 Diesel / D20 Diesel / D08 Calculation basis: 10 year period annual mileage: km labour rate & parts cost to German standards < 46 >

47 Agenda 1 MAN CNG bus history 2 Actual CNG bus & engines portfolio 3 MAN CNG buses sales worldwide 4 Actual CNG technology Euro 6 5 Advantages of CNG technology (compared to Diesel) 6 Cost Calculation 7 Summary < 47 >

48 Summary The cleanest, CO2 neutral, reliable, non-fossil and affordable solution for public transport: Buses readily available Proven reliable technology Highest well to wheel efficiency on CO2 reduction Lowest PM emission Lowest NOx emission Low noise production No link with food chain discussion < 48 >

49 Summary The cleanest, CO2 neutral, reliable, non-fossil and affordable solution for public transport: Euro 6 No AdBlue No battery packs, disposal of, replacement no spillage risks future proof biogas option manure, municipal waste, food waste not crop reliant biogas can be fed directly into the gas main < 49 >

50 Backup Backup < 50 >

51 Prospects The European Union has set the target of increasing the share of biofuels and so-called alternative fuels, including natural gas, in traffic to 10 and 20 %, respectively, by A European project called GasHighWay has been established, aiming to the realisation of a comprehensive network of filling stations for these fuels spanning Europe from the north, Finland and Sweden, to the south, Italy - in other words: the GasHighWay < 51 >

52 Summary < 52 >

53 Summary Biofuel comparison how far will biofuel made from crops grown on 1 hectare take you? < 53 >

54 Summary Biomethane plants in Germany Number of plants Capacity [m 3 /h] number estimated number capacity estimated capacity < 54 >

55 Focus: Carbon Footprint Combined Heat & Power (CHP) < 55 >

56 World reserves of fossile energy Erdöl Crude oil uncertainty range of resources Erdgas Natural Kohle Coal years Mittelwerte aus verschiedenen Quellen < 56 >

57 ? < 57 >

58 Future proof and sustainable technology Thank you for your attention!