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EPA ‘10 & EU VI Experience & Approach

EPA ‘10 & EU VI Experience & Approach . Dr. Uwe Zink Director, Emerging Industry Technologies Corning Incorporated April 4, 2011. Agenda . Regulatory framework Engine technology & calibration approaches System designs Certification examples Enabling framework Experience to-date

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EPA ‘10 & EU VI Experience & Approach

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  1. EPA ‘10 & EU VIExperience & Approach Dr. Uwe Zink Director, Emerging Industry Technologies Corning Incorporated April 4, 2011

  2. Agenda • Regulatory framework • Engine technology & calibration approaches • System designs • Certification examples • Enabling framework • Experience to-date • Outlook –future regulations

  3. Regulatory LandscapeEPA’10 required an 83% NOx reduction compared to 2007 OBD phases in Daimler Truck, MTZ Heavy Duty Conference 2009

  4. Observed Engine Technology Approaches • High pressure flexible injection systems • Unit injector • Common rail • Cooled EGR • Fixed/WG or VG Turbo • Single stage • Dual stage • Turbocompounding

  5. EPA’10 – EUVI General Calibration & Emission Control Approaches • EPA’10 Approach: • EPA’07 baseline with DPF • Add DeNOx (SCR) system • EUVI Approach • EUV baseline with SCR • Increased EGR • Add DPF system • US-FTP, NTE, PN • Implicit and very stringent compliance requirements (*): Observe wall flow filter in all EPA’10 systems

  6. EPA’10 / EUVI SystemsDesigns and Design Considerations

  7. Example of actual design as on vehicle Example of an EPA’10 Emission control system: -MD & HD application - DOC + DPF + SCR Cummins, SAE GOT 9/2010

  8. SCR add-on to a 2007 system http://www.tectrucks.com/assets/carbslideshow_volvo_scr.pdf

  9. DTNA “One Box” Design & Vehicle Integration-compact design http://www.detroitdiesel.com/emissions/epa2010/economy.aspx, DAG MTZ Heavy Duty Conf 11/2009

  10. System Design and components selection for reduced system back pressure Daimler Truck, MTZ Heavy Duty Conference 2009

  11. Fuel consumption and AdBlue Trade-off-Optimum provides benefit compared to EPA’07 systems Daimler Truck, MTZ Heavy Duty Conference 2009

  12. -Optimum provides benefit compared to EPA’07 systems-Example shown at ~ 2.5 g/HPh NOx Cummins, SAE GOT 9/2010

  13. Thermal Management approach to ensure SCR efficiency over cert & operating cycle Cummins, MinNOx 6/2010, SAE GOT 9/2010

  14. Examples of published EUVI Design Iveco, ATA Conference 2006 ww.scania.com/Images/P11301EN%20Euro%206%20engines%20ready%20for%20the%20market_240653.pdf, 2011, 13l 440 and 480 HP rating.

  15. EPA’10 Certification Examples

  16. Some examples of EPA 2010 NOx Certifications, various OEs-against Standard of 0.2 g/HPh and individual FELs 0.5 0.4 0.3 Std: 0.2 0.1 Cert against US FTP Family Emission Limit Cert against RMC/SET http://www.arb.ca.gov/msprog/onroad/cert/mdehdehdv/2011/2011.php

  17. Enabling FrameworkUrea/NH3 Delivery

  18. Intermediate Bulk Container (IBCs) or 2-2.5 gallon Jugs IBC, 55-gallon drum, 2 gallon jug Home Terminal Truck Stop Dealer / Distributor Fuel island filling DEF Logistics Building in the US http://www.factsaboutscr.com –SCR101: Getting Ready for EPA2010

  19. DEF Infrastructure -evolving across North America -currently ~ 3,000 stations Diesel Exhaust Fluid will soon be sold at over 2,500 locations all over North America. http://www.detroitdiesel.com/emissions/epa2010/availability.aspx

  20. AdBlue/DEF Logistics grown substantially in Europe Stations in Europe (3/29/11):3587 w/Pumps, 7333 w/Canisters http://www.findadblue.com/

  21. Emerging NH3 Systems

  22. Inj>220C Inj>180C The new mixer with revised calibration shows higher efficiency than without at all points. Point E is 181C; F is 225C. New mixer allows urea injection at T>180C-Key for thermal management and/or space mitigation Mixer has low pressure drop and high surface area. 4.8% max pressure drop in ESC (0.25 kPa) SwRI, SAE 2010-01-1185

  23. Update on ammonia adsorption SCRFirst commercial contract -production trial in 2011. Amminex, CTI SCR Conf, 7-10

  24. DPF Aspects

  25. DPF Maintenance Aspects-addressed already for the EPA’07 systems • Assume low sulfur diesel (<50 ppm) is available • Filter cleaning/service –several concepts • On-vehicle -air assisted • Off-vehicle -air/liquid • In workshop • Centrally • Lube oil: Low SAPS (<1%) oil CJ-4 recommended by OEs • Still CI-4 (<1.4% SAPS) in use • Filter cleaning intervals depend on duty cycle • Experience: • Several applications exceed min. design of 150,000 miles SAPS: Sulphated Ash Phosphorus Sulphur

  26. Maintenance & Inspection Guidelines

  27. EPA’10 ExperiencesGenerally 5-7% fuel consumption benefits

  28. Observe long DPF regeneration intervals with high NOx/Low PM -some advertise “no active regeneration” http://www.tectrucks.com/assets/carbslideshow_volvo_scr.pdf

  29. Customer feedback on 2010 Systems –positive throughout the industry (Example shown from Volvo) http://www.volvotrucks.com/SiteCollectionDocuments/VTNA_Tree/ILF/Products/2010/09-VTM095_testimonials_041509.pdf

  30. Outlook 2014+CO2 Regulations emerging

  31. 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 DoE SuperTruck Vehicle fuel eco demo ACEA: 20% reduction goal (*) DoE: +50% freight efficiency Prototype demo DAG’s “Shaping Future Transportation” (*) “Road to Emission Free Mobility (LD & HD)”(*) CO2/Fuel Eco - Government / OE Initiatives HD CO2/Fuel Consumption Reduction: Different approaches JP: Fuel consumption, EU: CO2 focus(?), EPA: GHG focus JP: Fuel cons. -12% vs 2002 Tighter JP Regs (assumption) Tighter EPA Regs EPA CO2e (CO2; N2O, CH4 caps; BC) New EU Regs CO2 (assumption) (*): www.Daimler.com, MTZ 1-’09, http://www.cat.com/sd2009, http://www.deere.com/en_US/globalcitizenship/stewardship/metrics.html

  32. CO2/Fuel Eco - Regulatory Landscape / Assumptions On-Road 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 JP: Fuel cons. -12% vs 2002 JP Regs + (assumption) EPA Baseline: 2009 EPA CO2e (*) EPA Regs + (assumption) Total: 11-16% 30-40% Vehicle: 5 -10% 15-20% Engine: 6% 15-20% (*) expect cap on N2O, CH4, BC EU Regs CO2 (assumption) HD CO2/Fuel Consumption Reduction: Different approaches JP: Fuel consumption, EU: CO2 focus(?), EPA: CO2 w/cap on GHG

  33. CO2 & fuel consumptions measures-Aerodynamics, vehicle weight, engine, tires, drivetrain Ref.: Technologies and Approaches to Reducing the Fuel Consumption of Medium- and Heavy-Duty Vehicles, April 2010; http://www.nap.edu/catalog/12845.html

  34. Summary • EPA’10 represents tightest emission regulation for commercial vehicle engines today • Typically met by advanced engine technology and DPF plus SCR systems • While meeting the regulations, OEs offered value to end user via reduced fuel consumption compared to 2007 engines • Typically higher NOx calibration with SCR DeNOx • Other engine based approaches observed as well • Urea infrastructure in US is rapidly building • Expect similar system designs for EUVI • Expect wall flow filter to meet PN regs across the board • Outlook • OBD next in US 2013 • CO2 regulations coming in 2014 (US), assume EU will follow with CO2 • Expect next round of engine/aftertreatment system evolution

  35. Thank you for your kind attention! Questions are welcome!

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