Integrated Engine and Aftertreatment System Technology for EPA 2010 Heavy-duty Emissions Regulations

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1 Integrated Engine and Aftertreatment System Technology for EPA 2010 Heavy-duty Emissions Regulations Presented by: Rakesh Aneja Engine Systems and Technology Detroit Diesel Corporation Series 60 MBE 900 MBE 4000 A DaimlerChrysler Company

2 Emissions Compliance in Simpler Times 2005 Detroit Diesel Corporation. All Rights Reserved. 2

3 The 2010 Challenge ~83% Reduction in NOx Compared to EPA 2007 On-board Diagnostics (OBD) Adjustment Factors for Emissions during Regeneration Not-to-Exceed (NTE) Enforced through In-use Emissions Test Run by Manufacturer 435,000 Miles Useful Emissions Life Initial and Lifecycle Costs will be a Challenge for the Industry 2005 Detroit Diesel Corporation. All Rights Reserved. 3

4 Presentation Outline Technology Development Methodology Combustion Sub-system Forward Engineering NOx Reduction Approaches Advanced Combustion NOx Aftertreatment Urea-based SCR Urea Infrastructure 2005 Detroit Diesel Corporation. All Rights Reserved. 4

5 Technology Development Philosophy Increasing Technical Complexity Inherently Demands a System (Engine, Aftertreatment, Vehicle) Approach to Technology Development System Level Technology Development Benefits Substantially from Integrated Analytical and Experimental Development Increased Emphasis on Advanced Analytical Tool Development for Advanced Combustion Regimes and Aftertreatment Government / Industry / Academia Collaborative Partnerships Accelerate the Technology Development Process 2005 Detroit Diesel Corporation. All Rights Reserved. 5

6 Integrated System Development Approach Develop Conceptual Targets AT 2010 Technology Steady State Engine AT Modal Development Analytical Tools AT Transient Engine AT Integration Vehicle Integration Simulation Screens Major Sub-systems Concepts Combustion, Air, EGR, Fuel, Aftertreatment Cooling, Thermo-mechanical mechanical Down-select and Procure Prototype Hardware Steady-state Test Cell Validates Simulation Conceptual Design Screens Options Simulates Transient Performance Transient Test Cell Validates Steady-state Test Cell Simulation Screens Options Simulates Vehicle Performance Vehicle Integration Validates Transient Test Cell Simulation Identifies Benchmark Results 2005 Detroit Diesel Corporation. All Rights Reserved. 6

7 Integrated System Virtual Lab Aftertreatment (DOC, DPF, SCR, LNT) Air Handling System Combustion Model-based Controls Valve Train Cycle Simulation Bearing and Cranktrain FISO GEN 1 Main Bearings Orbits Main # 1 Main # Main # 3 Main # Vehicle Simulation Cooling & Lubrication (1-d Flow Network, CFD) FEA 2005 Detroit Diesel Corporation. All Rights Reserved. 7

8 Combustion Sub-system Forward Engineering Model Establishment Combustion Modeling Integrated with Hydraulic Simulation and Cycle Simulation via Boundary Conditions 2005 Detroit Diesel Corporation. All Rights Reserved. 8

9 Combustion Sub-system Forward Engineering Model Validation Multi-dimensional Combustion Modeling Multi-cylinder Experimental Data PWM=60, EGR= Soot, g/kg-fuel Baseline Baseline (3b/9-160) Bowl 4, Optimized Design Smoke (FSN) Baseline Baseline Bowl 4, Optimized Design NOx, g/kg-fuel NOx (g/hp-hr) Combustion Modeling Utilized to Forward Engineer Combustion Systems Multiple Configurations Analyzed and Selective Promising Configurations Down-selected for Experimental Validation 2005 Detroit Diesel Corporation. All Rights Reserved. 9

10 Typical Lifecycle Cost Distribution Line Haul Trucks Europe Administrative Vehicle & trailer Insurance Taxes Taxes / Licenses / Permits 11% Driver Meals 6% U.S. Monthly Tractor Payments 11% Insurance 7% Road pricing Salary Fuel Driver Wages 30% Fuel Fuel 26% Tires Service Fuel Fuel Expense Typically Constitutes 25% - 30% of the Lifecycle Cost Component Repair 5% Source: White Paper on Life Cycle Cost Kenworth Truck Company Steer Tires (100,000 miles) 1% Drive Tires (250,000 miles) 1% Preventive Maintenance 2% 2005 Detroit Diesel Corporation. All Rights Reserved. 10

11 Combustion / Aftertreatment System Integration Establishing An Optimum Combination for 2010 Effective Fuel (Including Urea) Consumption Tailpipe Out NOx Target = 0.15 g/hp-hr 85% 93% 95% 96% 97% NOx Reduction Efficiency Advanced Combustion Varying Traditional Combustion System Strategies Optimum Effective Fuel Consumption Engine Out NOx ~ 3 g/hp-hr NOx Reduction Efficiency ~95% NOx (g/hp-hr) European Stationary Cycle Urea Cost = Diesel Fuel Cost Strategy to Determine Proportion of NOx Reduction Obtained via In-cylinder Means versus Aftertreatment Means Depends on Lifecycle Cost Considerations 2005 Detroit Diesel Corporation. All Rights Reserved. 11

12 In-cylinder NOx and PM Reduction via Advanced Combustion Normalized Value, % NOx Baseline Est. PM Baseline Advanced CLEAN Combustion ~80% Reduction in NOx with near-zero PM Emissions Compared to Baseline Baseline Representative of 2007 Engine Out Emissions DOE-DDC Heavy Truck Engine Project Normalized Value, % 2005 Detroit Diesel Corporation. All Rights Reserved Challenges Include o Increased HC and CO Typical of Advanced Combustion Processes o Thermal Efficiency o Operating Range o Inter-mode Transition 0 HC Baseline Baseline CO Advanced CLEAN Combustion

13 Advanced Combustion Development Strategy to Mitigate HC and CO Increase 200 Normalized Value, % NOx Est. PM HC CO Baseline Baseline Advanced CLEAN Combustion Data Shown above Represents Engine Out Emissions With PM Aftertreatment, Tailpipe Out PM, HC and CO Emissions are Near-zero DOE-DDC Heavy Truck Engine Project 2005 Detroit Diesel Corporation. All Rights Reserved. 13

14 Advanced Combustion Application over Range of Engine Speeds and Loads Normalized Est. PM, % 140 Baseline Advanced Combustion NOx, % Data Shown above Represents Engine Out Emissions 2005 Detroit Diesel Corporation. All Rights Reserved. 14

15 SCR NOx Reduction Potential Transient Test Cycles for Europe, US, Japan NOx Conversion* [%] Europe US Japan 2005 Detroit Diesel Corporation. All Rights Reserved. 15

16 SCR NOx Reduction Potential US Transient Test (FTP) Cycle NOx Conversion [%] FTP (Hot) FTP (Cold) Additional NOx Reduction Possible via Precise Exhaust Temperature Management 0 Strategy A Strategy B Strategy C 2005 Detroit Diesel Corporation. All Rights Reserved. 16

17 Urea Infrastructure Opportunities Opportunity to Extend Vehicle Driving Range beyond 25k Miles between Urea Refills With the Engine Out NOx being Significantly Reduced in 2010, Opportunity to Significantly Extend Driving Range ~25 k Miles with a 30 Gallon Tank (~1% Urea to Fuel Consumption) Potential Infrastructure Opportunities Affiliated Truck Stop Locations Large Truck Stop Chains Independent Provide Safety Net (Emergency Supply) Industry Stakeholders Urea Producers Commercial Distributors Truck Stop Operators Fleet Operators Component Manufacturers Engine Manufacturers Vehicle Manufacturers Opportunity to Collaborate Effort with Light Duty (LD) Alliance Currently Engaged in Urea Infrastructure Discussions 2005 Detroit Diesel Corporation. All Rights Reserved. 17

18 Progressive Urea Infrastructure Implementation 140 Truck Stop Locations (Less Than 3% of All Truck Stops) Can Ensure Urea Availability Within a 100 mile Radius for Greater Than 95% of the Heavy Duty Vehicle Miles Traveled 100% Proximity of Truck Stops to HD Diesel Vehicle Miles Traveled Percent of National HD Diesel Vehicle Miles Traveled 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Within 100 Miles Within 50 Miles Within 25 Miles Cumulative Number of Truck Stops 2005 Detroit Diesel Corporation. All Rights Reserved. 18

19 Summary Increasing Technical Complexity Inherently Demands a System (Engine, Aftertreatment, Vehicle) Approach to Technology Development System Level Technology Development Benefits Substantially from Integrated Analytical and Experimental Development NOx Reduction Technologies for 2010 Likely Include a Combination of In-cylinder Combustion-based Approaches Integrated with NOx Aftertreatment Strategy to Determine Proportion of NOx Reduction Obtained via In-cylinder Means versus Aftertreatment Means Depends on Lifecycle Cost Considerations Urea-based SCR Devices are a Viable NOx Aftertreatment Choice for Several Worldwide Applications Including US2010, Euro IV, Euro V and JP05 Model Based Control Systems with Feedback Sensors Will Enhance NOx Conversion Efficiencies, Determine Plausibility, and Help Detect NH3 Slip, Failure Modes, and Tampering 2005 Detroit Diesel Corporation. All Rights Reserved. 19

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