Advanced Emission Control Technologies for Gasoline Engines
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1 Advanced Emission Control Technologies for Gasoline Engines Manufacturers of Emission Controls Association (MECA) November PZEV Systems Continue to Evolve with Advanced Emission Control Systems MY 2007 Volvo S40/V Liter PZEV System Quick light-off UHEGO linear sensor Perforated metal substrate with Integrated lambda sensor ivvt Gas mixing (but less heat) cam sensor (fast synch) 3rd brick Ce 400/4 HEGO binary lambda sensor 2nd brick Ce 600/3 L-Ocatalyst Me600PE/0.04 1
2 MECA PZEV Test Program: Advanced Emission Technology Demonstration Goal - PZEV/SULEV tailpipe emissions on two large light-duty trucks: 2004 Ford F150, 5.4L Triton V GMC Yukon Denali, 6.0L Vortec V8 Integration of advanced TWC systems with modified engine calibrations FTP Evaluations on de-greened and engine aged advanced emission systems GMC Denali Advanced Catalyst System Design Total TWC Catalyst Volume: 4.46 L (0.74 SVR) 0.67 L 1.56 L 6.0L V8 Engine 900 cpsi ceramic; 150 g/ft3, Pt/Pd/Rh=1/16/2 600 cpsi ceramic; 60 g/ft3 Pd/Rh=4/ L 1.56 L CC UF 2
3 Denali Advanced TWC System Substrate Face 4 from Flange Ford F-150 Advanced Catalyst System Design Total TWC Catalyst Volume: 4.34 L (0.80 SVR) 5.4L V8 Engine 0.72 L 900 cpsi ceramic; 200 g/ft3, Pd/Rh=47/ L 600 cpsi ceramic; 100 g/ft3, Pd/Rh=9/ L 1.45 L CC UF 3
4 F-150 Advanced TWC System Baseline FTP Emissions (4K mi, stock) and Program Emission Targets LEV-I ULEV (100k) LEV-I ULEV (50k) NOx (g/mile) LEV II ULEV (120k) SULEV (120k) PZEV (150k) K stock Denali NMOG (g/mile) CO (g/mile) 4K stock F150 Denali & F-150 F with 4K advanced catalyst system: mg/mi NMOG; mg/mi NOx 4
5 Denali Calibration Modified for Improved Cold-Start and Hot-Start Performance Cold idle speed increased from 900 to 1100 rpm Spark timing retarded during cold-start to accelerate catalyst light-off Less fuel enrichment during cold-start Closed-loop air-fuel control enabled right after cold crank Slight rich bias applied to first FTP hill after hot-start to reduce NOx spike Tight Air-Fuel Control Important for Achieving and Maintaining Low Exhaust Emissions Engine-out Air/Fuel Ratio Denali engine-out AFR varies from approx to 13.8 during first 100 sec. compared to 15.8 to 12 for the F150. F150 Baseline Calibration vs. Denali Final Calibration After temperature stabilization, Denali AFR is very stable, but F150 still varies significantly FB DG EO DF DG EO Time, seconds 5
6 Advanced Emission Systems Aged for 220 hours Using an Accelerated Engine Aging Protocol Denali System Aging History Cat Bed Temperature Temperature, deg. C AFR=Stoichiometric (40 sec.) AFR=Rich (6 sec.) AFR=Rich w/ Air Inj. (10 sec.) AFR=Stoich w/ Air Inj. (4 sec.) Time, Sec Left Bed Histogram Right Bed Histogram Time, sec Catalyst Bed Temperature, deg. C Denali Catalyst System FTP Conversion Efficiencies Remain High After 220 h of Aging Average THC Catalyst Efficiency Average CO Catalyst Efficiency Before Aging After Aging Efficiency,,% 94 Efficiency, % Before Aging After Aging Bag1 Bag 2 Bag 3 88 Bag1 Bag 2 Bag 3 Average NOx Catalyst Efficiency 100 Before Aging After Aging Efficiency, % Bag1 Bag 2 Bag 3 6
7 GMC Denali & Ford F-150 F Fully Aged Advanced Emission Systems FTP Performance Near Tier 2, Bin 3 Limits FTP Emissions, mg/mi K SULEV; Tier 2, Bin 2 Denali - adv. TWCs, fully aged F adv. TWCs, fully aged 120K Tier 2, Bin 3 0 NMOG/NMHC NOx Denali Results Include Modified Calibration Strategy; F-150 Results Using Stock Engine Calibration GMC Denali Fully Aged Advanced Emission System SFTP Performance - Below Current ARB/EPA 4K Limits NMHC + NOx, g/mi US SC03 (A/C) ARB 4K PC/LDT1 ARB 4K LDT2 Denali - adv. TWCs, fully aged 7
8 Light-Duty Vehicle Emission Technology Developments Beneficial to Full Range of Spark-Ignited Engine Applications High Performance Aftermarket Converters CARB OBD-Compliant Aftermarket Converters Medium & Heavy-Duty Engines Motorcycles/Mopeds Closed-Loop TWC Systems for California/U.S. Motorcycles Recreational Vehicles & Engines ATVs, Off-road Motorcycles, Marine engines > 25 hp Off-Road Applications Advanced Closed-Loop TWCs to Achieve 2010 CARB Standards on Fork Lifts, GSE, Generator Sets Closed Loop TWC Retrofit Systems Handheld Equipment & Non-Handheld Equipment Blowers, String Cutters, Chain Saws, Lawn Mowers, Riding Mowers Alternative Fuels E-85, CNG, Propane 8
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