2010 MidRange Engines

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Louise Armstrong
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1 2010 MidRange Engines

2 Global On-Highway Standards NOx g/hp-hr EURO IV EURO V US98 US US07 EURO VI 0.0 US Particulate g/hp-hr 2

3 ISB & ISC/ISL

4 Integrating Critical Subsystems Air Handling & EGR Combustion Aftertreatment Electronic Controls Fuel Systems 4

5 Introducing the ISB6.7 & ISC8.3/ISL9 The Right Technology for 2010! 5

6 2010 ISB6.7 Improved Combustion System Increased Power Density Best-in-class Fuel Economy Advanced VG Turbocharger Improved Cooled EGR Subsystem/Cooling Circuit Fully Integrated Electronic Controls New Cummins Aftertreatment System Improved Reliability 6

7 ISB6.7 Cooling System Changes Improved EGR Coolant Flow Cooling Circuit Rebalanced with increased flow to critical areas New Coolant Circuit for SCR Components Cooled EGR Improved EGR Cooler Improved Cold-Side EGR Valve Improved EGR Measurement New Intake Connection for Better EGR Mixing Electronics CM2250MD with A/T, EGR/AH Controls New Wiring Harness 7

8 ISB6.7 Open Crankcase Ventilation Coalescing Filter Fed to Atmosphere Combustion System Improved Combustion System and Optimized Calibration for Lower Engine Out Particulates 8 VGT Turbocharger Improved Coolant Plumbing Improved Efficiency Lead Free Bearings

9 2010 ISC8.3/ISL9 Improved Combustion System Increased Power Density Heavy Duty Design - Replaceable Liners Advanced VG Turbocharger Improved Cooled EGR Subsystem/Cooling Circuit Fully Integrated Electronic Controls New Cummins Aftertreatment System Improved Reliability Comparable Fuel Economy 9

10 ISC8.3 & ISL9 Cooling System Changes Circuit Rebalance for SCR System heating & cooling New Coolant Circuit for SCR Components Cooled EGR Improved Cold-Side EGR Valve Improved EGR Measurement New Intake Connection for Better EGR Mixing Electronics CM2250MD with A/T, EGR and AH Controls New Wiring Harness New Temperature and Pressure Sensor 10

11 ISC8.3 & ISL9 VGT Turbocharger Improved Efficiency Combustion System Improved Combustion System and Optimized Calibration for Lower Engine Out Particulates 11

12 2010 MR Engine Platforms & Ratings ISB6.7 ISC8.3/ISL HP HP

13 Cummins Aftertreatment System

14 Cummins Aftertreatment System Diesel Oxidation Catalyst Wall-Flow Filter Cummins Particulate Filter 14

15 Cummins Aftertreatment System Selective Catalytic Reduction (SCR) Catalyst Decomposition Reactor Cummins Particulate Filter Diesel Exhaust Fluid (DEF) Dosing Valve 15

16 Cummins Aftertreatment System DEF Dosing Valve Cummins Particulate Filter Decomposition Reactor Selective Catalytic Reduction (SCR) Catalyst ENGINE-OUT PM 0.01 PM Filter PM Filter TAIL-PIPE OUT NOx SCR 0.2 EGR SCR ENGINE-OUT TAIL-PIPE OUT 16

17 Diesel Exhaust Fluid (DEF) Update

18 What is Diesel Exhaust Fluid (DEF)? Diesel Exhaust Fluid (DEF) is the reactant for the SCR system - Urea is solid at room temperature - DEF is prepared by dissolving solid Urea to create 32.5% solution in purified water 18

19 Diesel Exhaust Fluid (DEF) Primary reactants for DEF production: - Ammonia (NH3) - Carbon Dioxide (CO2) Raw materials used to produce NH3 & CO2 include: - Natural Gas - Coal - Other Petroleum Products 19

20 20 How Much Diesel Exhaust Fluid (DEF) Will I Use? Approximately 2% DEF consumption Every 50 gallons of fuel = 1 gallon of DEF

21 Diesel Exhaust Fluid (DEF) Availability and Accessibility Disposable 275 Gal Tote Plastic 55 Gal Drum Plastic 330 Gal Tote Bulk 21

22 European Pump Pricing Country Pump price without tax / Litre $/Gal (exch 1.59) Austria Belgium Denmark Finland France Germany Italy Luxembourg Netherlands Spain Sweden UK Average = $3.09 a Gallon 22 03/2007

23 Cost Structure for U.S. DEF Retail Cost Structure ~ DEF Solution U.S. DEF Cost Structure 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 12% 34% 17% 11% 26% 2008 Retail Dispensing Transportation Packaging Blending Raw ~ urea 23

24 Projected 2010 U.S. DEF Pricing DEF Pump prices: - $2.50-$3.50 gallon (Fleet pricing will likely be less) gallon containers (IBC s): - $2.00-$2.50 Bulk delivery (Tanker): - Less than $2.00/gallon (Pricing will likely vary by region) No estimate for jug pricing at this time 24

DEF Infrastructure Major investments in DEF production to serve the on-highway market are currently being made and will be in place in 2010.

25 DEF Infrastructure Major investments in DEF production to serve the on-highway market are currently being made and will be in place in Pilot has announced it will carry DEF at the pump. - Flying J, TravelCenters of America & Love s will carry DEF, but still determining at what level. 25

26 All Outlets Cummins Outlets - Red OEM Outlets Green Parts Distribution Centers (PDC) Blue Independent Distribution - Yellow 26

27 How Can I Determine how Much DEF I will Use? Example Medium Duty Annual miles for average truck = 20,000 miles MPG for average truck = 10 mpg 20,000 miles / 10 mpg = 2,000 gallons diesel fuel per year DEF 2% of fuel consumption = 40 gallons of DEF / year 40 gallons / 10 gallon tank (average size) = 4 DEF fill-ups / year 27 Example Only

28 Common DEF Misconceptions

29 Myth #1 - DEF degradation will be a major problem. As with many automotive fluids, DEF will degrade over an extended period of time. The shelf life of DEF is dependent on storage temperature and exposure to sunlight. When stored as recommended (between 11 F and 86 F), DEF shelf life will be greater than one year. For typical school bus use, that includes a period of inactivity in the summer, DEF degradation will not be an issue. 29

30 Myth #2 DEF is toxic. DEF is a non-toxic, non-polluting and nonflammable substance. Poses no serious risk to humans, animals, equipment or the environment when handled properly. The product is slightly alkaline with a ph of approximately 9.0. SCR systems are designed fully compatible to DEF s properties. 30

31 DEF Properties DEF is safe to handle and store Non-toxic Non-polluting Non-flammable Acidic ph When stored at extreme temperatures, neither DEF nor Urea become toxic DEF is slightly alkaline with a ph of approximately 9 31

32 Myth #3 Frozen DEF will render a Vehicle Unusable. The freezing point of DEF is 11 degrees F. SCR system is designed to provide heating for the DEF tank and supply lines. If DEF freezes, start up and normal operation of the vehicle is not inhibited. DEF is not damaged or destroyed if it is frozen and is fully usable when thawed. 32

33 Myth #4 DEF is Difficult to Use. Cummins will provide installation recommendations on tank size based upon EPA guidelines DEF consumption is expected to be approx. 2% of fuel consumption dependent on vehicle operation duty cycle, geography, rating, etc. 33

34 Myth #5 DEF will be difficult to find. DEF will be readily available for customers to purchase Cummins is working with industry partners to ensure DEF is readily available. Cummins is working to ensure availability of DEF through our distributor and dealer network. 34

35 Diesel Exhaust Fluid (DEF) Diesel Exhaust Fluid is 32.5% strength urea water solution with high purity requirements. The specification of Diesel Exhaust Fluid is currently defined according to the DIN and the ISO specifications. Water purity: ISO grade 3, produced for example by single distillation, de-ionization, ultra-filtration or reverse osmosis. 35

36 Why 32.5% for DEF? The 32.5% wt urea water solution provides the lowest freezing point while also maintaining the solution in constant phase. Urea and water freeze together at 11 F so the frozen solution has the same 32.5% wt. When thawed, it will remain at the same concentration of urea solution feeding the SCR system. What happens at different concentrations of Urea: Greater concentrations Urea freezes before water Reduced concentrations Water freezes before Urea 36

37 Cummins Aftertreatment System Architecture DEF Dosing Valve sprays a fine mist of DEF into hot exhaust stream Cummins Particulate Filter Selective Catalytic Reduction (SCR) Catalyst Decomposition occurs in 3 steps within the Decomposition Reactor Step 1: Evaporation Step 2: Thermolysis Step 3: Hydrolysis 37

38 DEF Storage Shelf life of DEF is a function of ambient storage temperature. ISO Spec details the Storage, Handling and Shelf Life minimum expectations for DEF throughout the distribution chain. Expectations for shelf life as defined by ISO Spec are the minimum expectations for shelf life when stored at constant temperatures. 38

39 DEF Freeze Point Freezing of DEF begins at approximately 11 F. Once the DEF has melted, it can be used without problem. The first melted drop has the same consistency as defined in the Diesel Exhaust Fluid specification. The SCR system is designed to provide heating for the DEF tank and supply lines which will reduce the melting time for frozen DEF. If DEF freezes, start up and normal operation of the vehicle is not inhibited so the operator is not impacted. 39

40 DEF Storage & Handling Recommendations Storage temperature below 86 F is recommended to maintain shelf life Storage temperature above 11 F is recommended to avoid freezing The maximum temperature of stored diesel exhaust fluid on the vehicle should not exceed 122º F 40

41 DEF Storage & Handling Conclusions DEF will degrade in time depending on temperature and exposure to sun light. Stated shelf life is based on continuous exposure to heat and sunlight. - Continuous exposure is unlikely. Concerns over shelf-life have been over-stated. 41

42 DEF Quality System - API Certification Proposed DEF quality seal. - Currently, the seal has not yet been approved. Most likely it will feature the full name American Petroleum Institute (API) in a square quality seal. 42

43 In-Cylinder solution

44 Cummins Integrated Solution Advantages Increased Power Density Stronger Performance Increased Reliability Comparable Fuel Efficiency Minimal Installation Impact 44

45 Disadvantages of In Cylinder Technology Fuel Economy Significantly Compromised Throttle Response/Driver Satisfaction Significantly Compromised Horsepower and Power Density Significantly Compromised Significant Increase in Heat Rejection Complex System Integration Higher EGR Flow Air Handling System Vehicle Cooling System 45

46 Disadvantages of In Cylinder Technology Fuel Economy Significantly Compromised 5-9% loss Combustion Efficiency degradation: Higher engine pumping losses Increased intake & exhaust manifold pressures Increased Particulate Filter regenerations 46

47 Disadvantages of In Cylinder Technology Horsepower and Power Density Significantly Compromised Deterioration of hp for same displacement Higher EGR flow & EGR controls compromises engine performance 47

48 Disadvantages of In Cylinder Technology Significant Increase in Heat Rejection 20% increase Higher EGR flow: Multiple EGR coolers on & off engine Larger vehicle cooling package Major redesign of radiator / Charge Air Cooler / Fan systems 48

49 Disadvantages of In Cylinder Technology Engine Life-to-Overhaul significantly reduced Higher EGR flow produces excessive acidic condensation: Corrosion of internal engine systems High rate of lube oil contamination Negative impact on Durability 49

50 Cummins is Ready for 2010! 50

51 Our Commitment 51 The Right Technology Product for Every Need Depend On Cummins

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