Transcript MD/HD CO 2 Reduction by Hybridization & WHR
MD/HD CO
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Reduction by Hybridization & WHR Technology Impact on Emission Control
Dr. Uwe Zink, Corning Incorporated Director, Emerging Industry Technology
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April 4, 2011
Agenda
CO 2 Context
Hybridization
Motivation
Powertrain implication Aftertreatment design considerations Technology sorting
Heat Energy Recovery Approaches in Industry
Rankine cycle considerations
Summary
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CO
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Context & considerations
On-Road focus
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HD CO 2 /Fuel Consumption Reduction: Different approaches JP: Fuel consumption, EU: CO 2 focus(?), EPA: GHG focus
JP: Fuel cons. -12% vs 2002 Tighter JP Regs (assumption) EPA CO 2 e (CO 2 ; N 2 O, CH 4 caps; BC) Tighter EPA Regs 2011 2012 2013 2014 2015 2016 2017 New EU Regs CO 2 (assumption) 2018 2019 2020 2021 2022 2023 2024 DoE SuperTruck Vehicle fuel eco demo
DoE: +50% freight efficiency Prototype demo
DAG’s “Shaping Future Transportation” (*) “Road to Emission Free Mobility (LD & HD)”(*)
ACEA: 20% reduction goal (*) CO 2 /Fuel Eco - Government / OE Initiatives (*): www.Daimler.com
, MTZ 1 ’09, http://www.cat.com/sd2009 , http://www.deere.com/en_US/globalcitizenship/stewardship/metrics.html 4
Fuel consumption evolution in Europe ACEA’s Goal (*) : 20% Fuel consumption reduction by 2020 –Assume vehicle
-20% 10 mpg per CCJ 3/31/10 quoting DTNA @ MATS 5 (*) MTZ 1 ’09, Daimler SAE Gothenborg 9-’10
CO 2 & 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
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Class 6-8 Hybrid Truck Production: Hybrid Trucks to Set to Account for 8 Percent of Total Truck Production by 2015 (Frost & Sullivan, HTUF 10/’09)
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MD/HD-Vocational Applications are Targets for Hybridization High Potential for Braking Energy Recovery Kinetic Energy Loss Comparison of Various Types of Medium and Heavy Vehicles
100% 80% 60% 39 11 40% 50 20% 0% Delivery 5/07 Michigan Clean Fleet Conference 31 4 23 18 47 65 59 35 Bus Refuse Vehicle Type 18 Class 8 Rolling Aero Braking 8
Targeting combustion engine operation at optimum BSFC points
Ref: Hydraulic Hybrid Vehicle System Panel 9
Ricardo, SIAT Jan 2011 10
Hybridization impact on conventional powertrain Combustion engine selection (“downsized”) & operation (less transient”)
Ref: DTF 3-08 Volvo
Diesel Engine Operation Steady State Transient “Hybridization”
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Combustion Engine “Downsizing” -Example (MB Citaro G) OM 457 LA
Conventional:
12l, OM 457 LA 1900 1500 800 400 OM 457 LA OM 924 LA 1000 1400 1800 2200 rpm OM 924 LA
Hybrid:
4.8l, OM 924 LA
Compensation for torque & power
4 wheel hub electric motors, ea. @
60 kW continuous
80 kW peak
12 Mercedes Benz Website http://www.mercedes-benz.de
Cost, Certification & OBD issues need to be resolved
Navistar, HTUF 10/2009 13
HILS – Making its way into MD/HD Homologation Procedures
J-MLIT at ACEA Mtg Dec.3, 2009: A Global Approach to Sustainable Freight Transport 14
Outlook: Waste Heat Recovery in combination with Hybrids “Integrated Powertrain and Vehicle Technologies for Fuel Efficiency Improvement and CO2 Reduction”, DDC, DEER 2009
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Aftertreatment Design Considerations
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Multiple drivers for aftertreatment requirements
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A/T Impact of Hybridization on Freightliner M2
DPF Regeneration Interval increases 18 Freightliner, HTUF 10/2009
A/T Impact of Hybridization on Freightliner M2
DPF Regeneration Interval increases 19 Freightliner, HTUF 10/2009
Series Electric Class 8 Truck & City Bus w/ Range Extender -Freightliner Columbia (Parker-Artisane-Capstone), ZEM (Italy)
Parker, HTUF 2010; http://zemplc.com/technology.php
Emissions are very low… aftertreatment likely not needed.
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LD Example (Prius III, 1.8l ICE) -Intermittent ICE Operation, Lower exhaust gas temps & aggressive catalyst heating
Umicore, 4/2010 Aggressive Catalyst Heating in Prius 21
Market dynamics
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Class 6-8 Hybrid Truck Production: Hybrid Trucks to Set to Account for 8 Percent of Total Truck Production by 2015 (Frost & Sullivan, HTUF 10/’09)
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Current offerings (NAFTA)
http://www.afdc.energy.gov/afdc/vehicles/heavy/hybrid_systems 24
Hybridization Market Triggers
Fuel prices
CO2 regs
Tax incentives
Cost reduction -some anticipate $4++(US) -getting into place -key to mitigate -significant effort needed
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Three areas that could affect A/T for the ICE
Time frame Enabler
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ICE -
Downsizing Short / Medium
A/T - Impact
Serial Hybrid, High battery capacity Parallel Hybrid: medium potential Downsizing, NR: possible avoidance (kW-segment specific) 2. Modified ICE ops cycle 3.
Homologation / Certification Medium / Long Long Above and OE focused effort Functional shift Light-off, heat retention importance Regulatory approaches, new cert cycles / limits Potential functional reduction
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Heat Energy Recovery Approaches
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Context: Engine based fuel economy levers
Reduced pumping losses -intake -exhaust (e.g. A/T)
Heat Energy Recovery
38.7%
Engine Hard/Software, NOx calibration, A/T Efficiency
28 Energy Flow Chart @ B50 point of a 290kW engine,
Behr, Wien 2009
Stanton, Deer 2009
Heat Energy Recovery Approaches
Turbo Charging Series production LD & HD Turbo Compounding Series production HD
e.g. 1953 on DC-7, Wright 3350
Process Heat (e.g. Rankine Cycle) Emerging HD Thermoelectric Emerging LD
and later up to today on HD as well (CAT, Cummins, DAF, Hino, Scania, Volvo, DDC/DAG ) MAN’s
Thermo Efficiency System, Marine & Stationary
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BMW’s TEG in EGR Loop 4 cyl Diesel engine
Ref: BMW, 5th Emission Control, Dresden, 6/10
EGR Cooling TEG
Suggested to move to exhaust system location for higher recovery (500W rather than 100W on EGR) 30
Mechanical/Electrical Turbocompounding -extracting heat upstream of aftertreatment
DDC Mechanical Turbocompounder
Bowman Industries, SAE ComVec 2009
31 BSFC simulation data for from a “typical” heavy duty
Cummins Example -showing R245fa working fluid
Cummins, SIAT Jan. 2011 32
Iveco Glider -Concept Vehicle
•Condensor • Expander:Turbine • Boiler 33 Lastauto Omnibus 12/2010
Expander machines under consideration
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R&D ongoing for expander machines
Turbine
High rpm speeds
Piston
e.g. Voith’s “Steam Expander”
2 cylinder, ~0.75l displacement
Rotary/Sliding Vane
Axial piston rotary
Considerations:
Expansion ratio
Ability to handle wet vapor (X<1), i.e. two-phase flow with droplets
Working fluid compatibility GWP
other
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Working Fluids under Consideration
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Rankine Working Fluid candidates R245fa, Ethanol, Water, Water/Ethanol, other Choice based upon:
•Critical point •Decomposition temperature •Slope of saturated vapor line •Environmental/Safety aspects •other 37
Working fluids considerations
Chemical and physical characteristics
E.g. decomposition temperature
Achievable system pressure
cost for pumps, condensor, heat exchanger along with pressure level
Environmental considerations
GWP
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Technologies emerging that will have an impact on aftertreatment design -> A/T industry needs to prepare for
Hybridization
ICE downsizing Shift in operating points Certification/Homologation procedures
Exhaust Heat Energy Recovery
New processes
Additional components
Weight
Space
Backpressure
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Thank you for your kind attention!
Questions are welcome!
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