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2007 Program Update for ATA/TMC

2007 Program Update for ATA/TMC. John Campbell. 10 June 2003. Topics. 2007 Emissions Approach 2007 Program Objectives & Timeline Aftertreatment Technology Options and Installation Projected Capital Costs Summary. 2010 ACERT. 1998 Engine. 10/02 Bridge. 10/03 ACERT. 2007 ACERT.

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2007 Program Update for ATA/TMC

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  1. 2007 Program Update for ATA/TMC John Campbell 10 June 2003

  2. Topics • 2007 Emissions Approach • 2007 Program Objectives& Timeline • Aftertreatment TechnologyOptions and Installation • Projected Capital Costs • Summary

  3. 2010 ACERT 1998Engine 10/02 Bridge 10/03 ACERT 2007 ACERT • Adv Comb • NOx Aftertreatment • Add: • Split Inj • Oxicat • Add: • VVA • SeriesTurbo • Add: • Adv Combustion • NOx AT • Diesel Part. Filter ACERT™ Is The Foundation for 2007/2010 • Cat's Technology Strategy & Approach • Build Upon 03 ACERT™ • Continue to Enhance Engine Performance While Incrementally Introducing Advanced Aftertreatment • Investigate Multiple NOx Aftertreatment Technologies • Provide Best Value To Customer and Optimum Technology to Truck OEMs

  4. 2007 Program Objectives • 2003 Focus • Develop and Demonstrate Systems to Achieve 2007 Emissions • Maximize Reliability & Fuel Economy • Minimize Product Cost & Development Cost (for OEM & Cat) • Develop Solutions for Heavy Duty and Midrange • Performance and Durability in Engine Test Cell • Vehicle Integration Studies with Truck OEMs Deliver Customer Value

  5. Demos of 07 Emissions Technology (Multiple Paths) Sellable Customer Truck Target Demo OEM NPI Truck Production OEM Specs 2007 Timeline & Critical Dates 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2007 Research 2007 Field Demos 2007NTI Technology Selection 2007 Platform NPI 2007 Production TruckOEM NTI = New Technology Introduction Program NPI = New Product Introduction Program

  6. PM Reduction Technologiesand Activities

  7. Wall Flow Filter Technology Filter Substrate Cell Plugs Soot Collectson Inlet Walls CleanExhaust Out (CO2, H2O) Exhaust Inlet (Soot, CO,HC, NOx) • Diesel Particulate Filter (DPF) • Collects Soot • Oxidizes / Burns Soot • Wall Flow Ceramic Filter • Over 50,000 in Service

  8. Temperature Is Key to Filter Regeneration Need To Be In This Region • Optimum is 350°C (660°F) • Below 300°C (570°F) too Slow • Low Temperature • Above 400°C (750°F) even Slower • NO2 Generation Limits Reaction 0.10 0.08 0.06 >0 No Regen 0.04 0.02 Soot Collected - Soot Burned (g/hp-hr) 0.00 -0.02 -0.04 <0 Yes Regen -0.06 -0.08 -0.10 100 200 300 400 500 Temp (°C) Best Value Solution will be if Engine Can be Tailored for Thermal Management

  9. Cold Route Only 10% of Time Above 250°C Frequency % Time Above Temp Hot Route Over 60% of Time Above 250°C Frequency % Time Above Temp Temp (°C) Temperatures Vary With Application and Duty Cycle Temp (°C) • Exhaust Temperatures vary with: • Power • Installation • Application • Ambient Conditions

  10. NOx Reduction Technologiesand Options

  11. DeNOx Catalyst NOx Adsorber Urea SCR T T T T C C C C NOx Reduction Options 2003ACERT™Engine Particulate Filter NOxAT Engine NOx Technology Aftertreatment NOx Technology Options AdvancedDiesel Combustion • Engine-Out NOx Measures Can Reduce Size / Cost of Aftertreatment • Aftertreatment Options Need to Be Evaluated for Maturity and Cost • Combination of Engine-Out and Aftertreatment May Provide Best Value Path

  12. Engine Measures for NOx Reduction • Caterpillar Continues To Expand The Envelope On Engine-Out Performance • ACERT™ Has Further Potential to: • Reduce NOx & PM Emissions • Improve Fuel Consumption andHeat Rejection Advanced Combustion

  13. Advanced DeNOx Catalyst • Aftertreatment Technology to Reduce NOx Emissions • Capable of Substantial NOx Reduction • Current Development Work: • Integration of DeNOx With Engine Measures for NOx Reduction • System & Component Design • System Performance & Packaging • Catalyst Development • Catalyst Performance Evaluation • DeNOx Benefits • Simple CatalyticConverter • No 2nd FluidRequired • Drawbacks • Lower NOx Reduction Capability • Durability Unproven • Fuel Penalty

  14. ECM Urea Heater Urea Pump Urea Tank Urea Injector SCR Converter Selective Catalyst Reduction (SCR) • Low NOx Emissions Technology • Based On Industrial Technology • Currently In-Production on Cat 3516Stationary Engine • Potential Capability to MeetOn-Highway NOx Emission Levels • Reaction of NOx With Urea • Current Development Work: • System & Component Design • System Performance & Packaging • Catalyst Durability Evaluation • Truck Demonstration • SCR Advantages • EstablishedTechnology • FuelConsumptionBenefit • Drawbacks • Urea Infrastructure • Compliance Cat C-12 With SCR System

  15. Caterpillar SCR Experience Electric Power 3516 Ethanol DeNOx Aftertreatment 3500 SCR System Modular SCR 1970’s 1980’s 1990’s 2000 2001 2002 2003 Mobile SCR Test Evaluation On-Highway Ammonia SCR Truck Urea SCR Truck Demo C-12 SCR Test Engine Demo’d NOx Red • Component Development • Catalyst • Injection System • Control System

  16. NOx Adsorber • Low NOx Emissions Technology • Stores NOx Between Regeneration Cycles • Regeneration • NOx Reacts with Hydrocarbon (HC) Under Lean Exhaust Conditions • HC Provided by Rich Engine Cycle orIn-Exhaust Injection of Fuel • Current Development Work: • System & Component Design • Engine Management to Provide Rich / Hot Conditions for Regeneration • System Performance & Packaging • Engine Testing • NOx Trap Benefits • No 2nd FluidRequired • Drawbacks • Sulfur Intolerance • High Precious Metal Content • Regeneration Cat 3126 with NOx Adsorber System

  17. Aftertreatment Installation • Setback Distance Will Be Important • Round Cans Are Rule • Larger Diameter Single Can Preferable to Dual Exhaust • Filter System Will Need to Be Serviceable

  18. What was included in the EPA Cost Estimate? Fixed Costs + Variable Costs Change + Operating Cost Change = Cost Increase R&D hardware cost increase $0.05 fuel premium Tooling assembly cost increase CCV maintenance Certification associated mark-ups PM filter maintenance No fuel mileage change Lower engine maintenance due to 15 PPM fuel

  19. EPA Cost Estimate Fixed Costs • R&D • Total engine industry R&D is $385 M. • Total industry PM treatment R&D is $87 M. • Total industry NOx treatment R&D is $133 M. • R&D is amortized over 5 years. • 7% per annum is used for NPV calculations • Tooling • Light heavy duty - $6 M • Medium heavy duty - $9 M • Heavy heavy duty - $10 M • Certification • $30,000 per family with all families requiring certification • Total industry cost is $5 M.

  20. EPA Cost Estimate Variable Costs • Incremental hardware costs (2007) • NOx absorber $1080 MR $1650 HD • Catalyzed particulate filter $852 MR $1190 HD • Assumes the muffler is eliminated • Clean up catalyst (oxidation catalyst) $261 MR $338 • Closed crankcase system $42 MR $49 HD • Incremental assembly costs (included in above dollars) • Associated markups (included in above dollars) • 1% warranty assumption • 4% manufacturer carrying cost on extra inventory • 3% dealer carrying cost on extra inventory

  21. Summary • Technical Decisions Must Be Made In 2003 • Proven Technology Winner Is Not Confirmed • Customer Demonstrations Required in 2005 • Truck Installation Impact Being Investigated • Cost of Compliance Not Yet Confirmed

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