MEASUREMENT CHALLENGES FOR MODERN HEAVY DUTY ENGINES

Transcription

1 MEASUREMENT CHALLENGES FOR MODERN HEAVY DUTY ENGINES Brian Mace Market Manager HORIBA Automotive Test Systems 2016 HORIBA, Ltd. All rights reserved

2 Agenda 1 HORIBA Corporate Outline 2 Heavy Duty On-Highway Vehicle Standards 3 Incremental Changes in Measurement Techniques 4 Engine Technology for NOx Below 0.1 g/kwh 5 The Value of In-Service Conformity Programs 6 HORIBA On-Board System OBS-ONE FADEEAC 30-November

3 HORIBA Corporate Outline global business segments Automotive Test Systems Sales Breakdown by Segment Sales: B.JPY (1.46 BUSD) 15% Process & Environmental Medical Semiconductor 23% Semicon 38.8 (333) 16% Scientific 25.7 (220) Medical 26.5 (228) Automotive 62.2 (534) P&E 16.7 (143) 10% 37% ( ) =Segment Sales in MUSD Scientific % = Segment Sales Ratio (Sales of FY2016) FADEEAC 30-November

4 HORIBA Major Global Sites Nuneaton, UK (Automotive) Oberursel, Darmstadt, Germany (Automotive, Process & Environment, Semiconductor, Scientific) Olomouc, Czech (Automotive) Production R&D Kyoto, Japan (Automotive, Process & Environment, Medical, Semiconductor, Scientific) Ann Arbor MI, USA (Automotive) Northampton, UK (Automotive, Process & Environment, Semiconductor, Scientific) Shanghai, China (Automotive, Process & Environment, Medical, Semiconductor, Scientific) Montpellier, France (Medical) Saclay, France (Semiconductor, Scientific) India, New Delhi (Automotive, Process & Environment, Medical, Scientific) Irvine CA, USA (Automotive, Process & Environment, Medical, Semiconductor, Scientific) Aso, Japan (Automotive, Process & Environment, Medical, Semiconductor, Scientific) Sunnyvale CA, USA (Semiconductor) Edison NJ, USA (Scientific) Longjumeau, France (Semiconductor, Scientific) Sao Paulo, Brazil Shiga,Japan/HORIBA BIWAKO E-HARBOR (Process & Environment, (Automotive, Process & Environment, Medical, Medical, Scientific) FADEEAC Semiconductor, 30-November-2017 Scientific) 4

5 Heavy Duty Vehicle Standards Argentina: model year 2006 and later emissions standards Source: DieselNet ( FADEEAC 30-November

6 Heavy Duty Vehicle Standards EU & US emission standards for heavy duty on-highway engines EU -71% -55% -43% -77% -67% -41% US CARB optional (20.8) (20.8) (0.19) (0.19) (0.27) (0.03) -90% (0.01) (0.01) Units: g/bhp-hr (g/kwh) Indicates aftertreatment technology forcing (LNT, SCR, DPF, etc.) FADEEAC 30-November Source: DieselNet (

7 Incremental Changes in Measurement Techniques Euro V to Euro VI or US 2010: traditional approaches for approximately one order of magnitude reduction in HC, NOx and PM Direct (Raw) Sampling NOx emissions from SCR equipped engines tend to accumulate in short duration peaks (breakthrough) once the catalyst is hot, making time alignment with exhaust flow very critical for accurate mass calculation For this reason, direct measurement technique is not well suited for modern NOx reduction technologies Constant Volume Sampling (CVS) Continue to use continuous dilute sampling method System Improvements: Lower range, faster response analyzers Tighter control on analyzer interferences Reduction in leakage Reduction in residuals via material selection and temperature control Improved flow control and monitoring Improved water management and accounting Computational Improvements: Real time water accounting Real time dilution ratio accounting Corrections for analyzer drift FADEEAC 30-November

8 Incremental Changes in Measurement Techniques CARB position on additional NOx reductions tons per day US EPA affirms CARB position in a December 2016 response to petition: On December 20, 2016, EPA responded to petitions submitted by 20 state and local government agencies from across the country and other organizations. EPA s response acknowledges that there is a need for further NOx reductions from heavy duty onroad trucks, buses, and other vehicles to reduce adverse health impacts from ground-level ozone and microscopic airborne particles... CARB is likely to mandate sub 0.05 g/bhp-hr NOx standard along with new Phase 2 greenhouse gas regulation to be published in 2018 Sources: SCAQMD ( US EPA ( FADEEAC 30-November

9 Incremental Changes in Measurement Techniques potential measurement techniques for NOx standards below 0.1 g/kwh Summary of a Southwest Research Institute report to the Truck and Engine Manufacturers Association on very low NOx measurement issues (March, 2016) Primary Challenge: Cold start NOx concentrations are projected to be similar to current production engines, so analyzer turndown, accuracy and drift are critical Reference Method: Continuous Dilute Constant Volume Sampling (CVS) Determination: feasible Current analyzer technology can meet the required turndown, drift and stability performance Determining engine intake airflow by chemical balance calculation may induce a positive bias in background mass determination; measuring airflow is recommended Variations in background NOx concentration can be problematic; proportional background sampling is presented as a possible countermeasure Possible Alternative: CVS with Bag Sampling Proven method for light duty vehicles (US SULEV) HC measurement via continuous sampling Primary benefit: eliminates high turndown necessary for continuous measurement, potentially lower variability Primary deficit: additional equipment and increased test time due to additional bag sampling Possible Alternative: Partial Flow Sampling Proven method for light duty vehicles (US SULEV) HC measurement via continuous sampling Primary benefit: smaller installation, lower cost Primary deficit: requires high accuracy engine exhaust flow measurement FADEEAC 30-November Source: SwRI project number final report, March 2016

10 Incremental Changes in Measurement Techniques proportional ambient sampling (PAS) for continuous dilute method Current CVS technology fills ambient bags at a constant flow rate determined by bag volume and test length PAS ambient bag fill is proportional to actual dilution air flow rate; flow is controlled by mass flow controllers FADEEAC 30-November

11 Incremental Changes in Measurement Techniques partial flow sampling method Hypothetical diagram, not based on any current product HC measurement is still continuous dilute method Bag fill rate is proportional to engine exhaust flow rate; high accuracy engine exhaust flow measurement required Gaseous sample is diluted at a fixed ratio Dry synthetic gas can be used for dilution Additional second stage of dilution for PM sampling is possible Inclusion of PN measurement system is possible FADEEAC 30-November

12 Engine Technology for NOx Below 0.1 g/kwh CARB technology evaluation project diesel engine Diesel Demonstration Engine Base technology: 2014 Volvo 13 liter turbo-compound Multiple aftertreatment technologies and configurations were evaluated Final configuration: Passive NOx adsorber (PNA) Mini burner for supplemental heat (MB) DEF injection system SCR-on-filter (SCRF) catalyzed DPF Flow-through SCR Ammonia slip catalyst (ASC) Demonstrated NOx performance with catalysts aged to projected useful life: g/kwh composite US FTP g/kwh composite WHTC Performance with green catalysts ~0.013 g/kwh Some tradeoff with GHG performance due to requirement for supplemental heat FADEEAC 30-November Source: CARB (

13 Engine Technology for NOx Below 0.1 g/kwh CARB technology evaluation project natural gas engine Natural Gas Demonstration Engine Base technology: 2012 Cummins ISX12-G Final configuration: Addition of three-way catalyst Advanced air-fuel-ratio control Cold-start warmup strategy for optimal catalyst performance Demonstrated NOx performance with catalysts aged to projected useful life: g/kwh composite US FTP g/kwh composite WHTC Diesel vs. Gas Engines Practical Considerations Benefits diesel Fuel supply infrastructure already exists Service infrastructure already exists incremental technology change Challenges diesel Unproven catalyst technology, feasibility demonstration Lifecycle total cost of ownership likely higher Benefits gas engine Proven catalyst technology with less complexity Lifecycle total cost of ownership may be lower Challenges gas engine Fuel supply infrastructure lacks capacity Service infrastructure is limited, but would scale with engines sales FADEEAC 30-November Source: CARB (

14 Engine Technology for NOx Below 0.1 g/kwh engines already certified to the CARB optional low NOx standard All engines meeting current EPA GHG standards AND the CARB optional low NOx standard Most engines are natural gas fueled, two propane and one gasoline Most engines considered medium duty for US utilization, not viable for long-haul trucking However, Cummins has announced 12 liter natural gas ISX engine: Likely suitable for long-haul trucking Undercuts the current NOx standard by 90% Very clean gas engines are available now for markets that can provide the necessary fueling infrastructure! FADEEAC 30-November

15 The Value of In-Service Conformity Programs Situation in the US LDD HDD HDV: Existing in-service conformity program for on-highway heavy duty diesel engines (HDIUT) HDV: Manufacturer supplied data surfaces problems with the program, but EPA and CARB are aware and considering countermeasures LDV: Admission of cheating by VW was an embarrassment to regulators due to the duration prior to discovery LDV: Changes to the certification process were implemented as countermeasure, but no RDE or inservice conformity program is planned Off-Road: In-service conformity program for NRMM is desired by EPA and CARB, but timing is not defined FADEEAC 30-November

16 The Value of In-Service Conformity Programs Situation in Europe LDD Emissions limits vs. on-road measurements (g/km) HDD Euro V Euro VI NOx/CO 2 ratio HDV: Existing in-service conformity program for onhighway heavy duty diesel engines LDV: Rapid introduction of RDE legislation for light duty passenger vehicles due to large disparity between type approval and realworld emissions performance Off-Road: Implementation of inservice conformity program for NRMM is underway Bottom Line: air quality improvements based on reduction in type approval standards cannot be assumed, real-world validation is important FADEEAC 30-November Graphics source: The ICCT (

17 HORIBA On-Board System OBS-ONE product features OBS-ONE-GS OBS-ONE-PN OBS-ONE-PM Measurement principle Heated NDIR Heated (dual) CLD Heated (dual) FID CPC (Condensation Particle Counter) Gravimetric filter method in combination with real time signal of DCS (Diffusion Charging Sensor) Components Features Legislation CO, CO 2, NO, NOx (NO 2 ), THC, CH 4, (NMHC) In house technology Hot, wet measurement of all gas components no cooler, no correction calculation from dry to wet, fast response time of analyzers EU LDV: NOx, CO 1 EU HDV: NOx, CO, THC, NMHC, CH 4 ² US HDV: NOx, CO, THC, NMHC, CH 4 1 without emission limit 2 CNG Particle number Technical leadership due to most advances CPC on the market (optimized system design for mobile applications) Excellent correlation to PMP compliant counters EU LDV: x EU HDV: --- US HDV: --- Particulate mass Real time measurement with high sensitivity Reliable proportional sampling under transient flow conditions EU LDV: --- EU HDV: --- US HDV: x FADEEAC 30-November

18 HORIBA On-Board System OBS-ONE applications Certification LDV and HDV RDE LDV legislation (EU) US HDV legislation CFR 1065 Subpart J EU HDV legislation No 582 / 2011 (EU) In-Service Conformity (ISC) Survey of exhaust gas values during use Research and Development Engine / vehicle calibration Road to rig Environmental research NRMM Non road mobile machinery FADEEAC 30-November

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