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INGAS Sub Project A3 „Boosted Lean Burn Gas Engine“ Status May 2010 [18-Month Meeting, Paris]

INGAS Sub Project A3 „Boosted Lean Burn Gas Engine“ Status May 2010 [18-Month Meeting, Paris]. FEV Motorentechnik, Bertold Hüchtebrock. INGAS 18 month meeting (Paris 21/05/2010). Content. Milestones / Deliverables Technical Content Work performed / results achieved @ partners. Content.

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INGAS Sub Project A3 „Boosted Lean Burn Gas Engine“ Status May 2010 [18-Month Meeting, Paris]

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  1. INGAS Sub Project A3 „Boosted Lean Burn Gas Engine“ Status May 2010 [18-Month Meeting, Paris] FEV Motorentechnik, Bertold Hüchtebrock

  2. INGAS 18 month meeting (Paris 21/05/2010) Content • Milestones / Deliverables • Technical Content • Work performed / results achieved @ partners

  3. Content Major Milestones / Deliverables in SP A3

  4. Milestones Milestone List SP A3

  5. Deliverables Deliverable List SP A3

  6. Content Technical Content

  7. Structure / Allocation of Tasks in SP A3 Subproject A3 Boosted Lean Burn Gas Engine Exhaust Gas Aftertreatment Engine & Vehicle • Methane (CH4)-Oxidation • Nitric Oxide (NOx)-Reduction • System Integration / Packageof Sub Systems • Combustion System • Boosting System • Engine Control Strategy • Vehicle Preparation & Testing GMPT-G CHALMERS RWTH GMPT-S FEV HT

  8. Aftertreatment system requirements SP A3 - Aftertreatment Values based on NICE 8

  9. Aftertreatment system (ATS) overview – present status 2 oxidation converters, 3L total volume 1 SCR converter, 4L volume Haldor Topsoe wash coats in OCs and in SCR NH3 used as reducting agent (not urea) Dual NOx sensors and NH3 sensor used for NH3 control SP A3 - Aftertreatment Oxidation catalyst Volume ca. 1L Oxidation catalyst Volume ca. 2L SCR catalyst Volume ca. 4L NH3 sensor 9

  10. Achievements so far Finalized EATS design regarding: converter volume positioning in vehicle (max. temp) converter canning design (max. flow uniformity, min pressure drop) Finalization of 2 alternative WCs for oxicats Procurement of aftertreatment system for testing Procurement of control system for NH3 injection Initiation of fundamental studies on optimal WC for lean CNG engines SP A3 - Aftertreatment 10

  11. SP A3 - Aftertreatment • SPA3 generation 2 OXICAT formulation fixed Comparison of 5 different Catalyst Compositions without and with sulphur 11

  12. Ongoing activities 1(2) Testing in vehicle (Test object: Lean engine) Evaluation of 2 alternative wash coats for oxicats Tuning of NH3 dosing system Impact of calibrations on conversion eff. and CO2 emission Hardware procurement 2 EATS to be delivered to FEV SP A3 - Aftertreatment

  13. Ongoing activities 2(2) Flow reactor testing Pt/Pd/CeO2 monolith samples with various degree of contact between the noble metals are prepared The importance of the degree of contact for the methane oxidation activity and sulfur stability will be evaluated SP A3 - Aftertreatment 13 Co-impregnated Pt/Pd/CeO2 Pre-mixed powder Pt/Pd/CeO2 CeO2 Pd/CeO2 Pt/CeO2 Pt Pd

  14. Work Packages A3.1 (Concept Phase and Design Specification) and A3.2 (Components, Engine Design andProcuremet): Study (based on Diesel engine) – supportto FEV Support thedefinitionofbaseengineandvehiclehardwaretomeetprojecttargets Selectionof a 1,9l DI Diesel engine out of GM Powertrain portfolioasbaseengine. Procurementanddeliveryofthree 1,9l DI Diesel baseenginesformodificationanddynotestingto FEV RecommendationforZafiravehiclesince CNG variant exists Draftpackagingofengineand T/C system (A3.1.4) Status and Work at GMPT-G 14

  15. Status and Work at GMPT-G • Work PackagesA3.2 (Components, Engine Design andProcuremet): • Simulations on potential turbochargersand T/C systemselection (A3.1.2) • Calibrationandtestingofleanburncombustion - „gas generator“ tosupportaftertreatmentdevelopmentat GMPT-S (explore potential leanoperationandgenerateinputforaftertreatmentsystemselection). (A3.2.3) • Design ofthepowertrainand gas systemsystempackaging. Package design of CNG engineandtransmissionintovehicleinfrastructure (A3.2.4) 15

  16. Status and Work at GMPT-G - Package investigation for vehicle application in progress Package Status for FEV - comparison of two potential 2-stage turbo charger alternatives Engine package for variant A – no possibility to fit variant A into vehicle package Engine package for variant B – selected turbo charger variant 2-stage TC for 1.9l diesel: variant A 2-stage TC for 1.9l diesel engine: variant B

  17. Status and Work at GMPT-G - Package investigation for vehicle application Engine Package with induction system and cooling module Package in engine compartment Package in vehicle Design work to package 1.9.l diesel engine, 2-stage TC, cooling module and air intake into engine compartment

  18. Status and Work at GMPT-G - Package investigation for vehicle application – first dummy package Possible package of 1.9l base engine with 2-stage turbo charger in Opel Zafira engine compartment Installation of 2-stage TC on1.9l diesel engine with air routing in Opel Zafira engine compartment. Close coupled catalyst to be packaged and provided by Saab Powertrain 1.9l diesel engine and selected 2-stage TC variant B in Opel Zafira engine compartment

  19. Status and Work at GMPT-G - Package investigation for vehicle application – first dummy package Possible package of 1.9l base engine with 2-stage turbo charger in Opel Zafira engine compartment Proposal for air routing from air filter to compressor inlet and shift of cooling module to the front Proposal for air routing into cooling module (charge air cooler)

  20. Status and Work at GMPT-G - Package investigation at GMPT-G to support vehicle built at FEV Package in vehicle Package of CNG specific parts like oil separator and pressure regulator in engine compartment of the Opel Zafira together with the 1.9l diesel engine

  21. Status and Work at GMPT-G - Package investigation at GMPT-G to support vehicle built at FEV Package in vehicle Opel Zafira vehicle front end / engine compartment Z19DTH diesel engine 2-stage turbo 6speed manual transmission Package of CNG tank and fuel system Overall design of the powertrain and gas system packaging for the 1.9l diesel engine

  22. VehicleEngine Packaging Final Package Proposal Engine Package with induction system and cooling module Installation of 2-stage TC on1.9l diesel engine with air routing in Opel Zafira engine compartment. Close coupled catalyst to be packaged and provided by Saab Powertrain

  23. MCE-TestingOperation Points Steady-State-Replacement-Test (NEDC) Reference: ZAFIRA (1.9 CDTI) 6 Speed Gearbox BMEP vs. Eng.-Speed S Idle: 326 s S Push: 138 s S Part Load: 716 s Additional Points MAP-Completion Highest Relevance Urban: 3x Extra-Urban: 1x

  24. Engine Testing / Procedure Hypercube  3-dimensional experiment space (DoE-Methodic) Operation point: n=1573 rpm BMEP=6.2 bar • Operation-Parameters: • Ignition Timing (ZZP) • End of NG-Injection (EOI) • Rel. A/F-Ratio (LAM) • DoE-Setup: • Due to driveability-reasons only a section of the „parameter-cube“ can be investigated ! • Setup is operation point selective ZZP EOI LAM

  25. MCE-TestingNEDC-Simulation / Procedure • Setup of DoE-Modell for each defined operation point • Stationary MCE-Testing ( DoE-Parameterisation) • DoE-Analysis  Modell-Calculation / Generation of functionalities • Engine MAP-Generation assuming different szenarios • TExhaust > Limit value (presetting) • BSFC, NOx, HC min. • Ignition Timing (presetting) • … • Projection on NEDC (Presetting: Vehicle & gear box) (Weighted) Combination possible

  26. MCE-TestingDoE-Input (Stationary Operation) AL_KW_ZZP_100128_01 INGAS\C_Data\C_Calibration\01_Test_Data\015_INGAS_N22_ausgewertet\GRAFIK n=2000 rpm / BMEP=6 bar / EGR=0 / l=var. / EOI=var. Impact EOI

  27. MCE-TestingDoE-Input (Stationary Operation) AL_KW_ZZP_100128_01 INGAS\C_Data\C_Calibration\01_Test_Data\015_INGAS_N22_ausgewertet\GRAFIK n=2000 rpm / BMEP=6 bar / EGR=0 / l=var. / EOI=var.

  28. MCE-TestingNEDC-Simulation NEDC_001_2_001_4_100518 INGAS\C_Data\C_Calibration\01_Test_Data\015_INGAS_N22_ausgewertet\GRAFIK Lean Operation Szenario: TExhaust, downstr. Turbine > Lower limit (if applicable) & BSFC min. Average Values(Cycle): 326°C 348°C

  29. MCE-TestingNEDC-Simulation NEDC_001_2_001_4_100518 INGAS\C_Data\C_Calibration\01_Test_Data\015_INGAS_N22_ausgewertet\GRAFIK Lean Operation Szenario: TExhaust, downstr. Turbine > Lower limit (if applicable) & BSFC min. hHC,req. [%] 93,8 91,9 hNOx,req. [%] 98,2 98,0 FC [kg/100 km]: 6,49 6,56 (+1,1 %) NOx [g/km]: 1,65 1,48 (-10 %) HC [g/km]: 1,61 1,23 (-24 %)

  30. MCE-TestingNEDC-Simulation NEDC_001_8_001_9_001_10_100518 INGAS\C_Data\C_Calibration\01_Test_Data\015_INGAS_N22_ausgewertet\GRAFIK Lean Operation Szenario: BSFC min. vs. NOx min. vs. HC min. hHC,req. [%] 94,6 91,5 88,4 hNOx,req. [%] 98,3 92,7 97,1 FC [kg/100 km]: 6,44 6,75 (+4,8 %) 6,85 (+6,3 %) NOx [g/km]: 1,71 0,41 (-76 %) 1,03 (-40%) HC [g/km]: 1,84 1,18 (-36%) 0,86 (-53 %)

  31. MCE-TestingNEDC-Simulation Lean Operation Szenario: TExhaust, downstr. Turbine > Lower limit (if applicable) & BSFC min. Difference-MAP: Ignition Timing  Retardation up to 15 deg CA for T>350°C  T>450°C 15°CA Ign.-Tim.-Retardation 0°CA

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