Transcript $60M ACERT PPL Challenge - Transport Topics Online

John Campbell
Director
On-Highway Engine Products
March 16, 2004
American Trucking Association
Technology & Maintenance Council
2007 Emissions Requirements
• PM = 0.01 g/bhp-hr
U.S.
0.35
– Requires Particulate Filter
• NOx + HC = 1.2 g/bhp-hr
Particulates (g/bhp-hr)
0.3
– Assumes Use of Phase-In Provision
– Requires NOx Aftertreatment, Advanced
Combustion, or Both
‘91
0.25
0.2
• Crankcase Emissions Counted As Part
of Cycle Emissions
Engine
Modifications
0.15
‘02
0.1
‘98
ACERT
0.05
‘10
– Drives Closed Crankcase Filter and/or
Closed Crankcase
‘94
• On-Board Diagnostics (OBD)
Engine
Modifications
‘07
0
0
1
2
3
4
5
6
NOx (g/bhp-hr)
Cat Will Follow the 2007/2010
Phase-In Provision
7
– OBD Changed to EMD (Engine
Manufacturers Diagnostics)
– Monitoring Performance of Engine
Components
– Warning Light to Dashboard Fault
– Isolation to Component Level
• Emissions System Useful Life
– 435,000 Miles for HD
– 185,000 Miles for MR
ACERT™ Is The Foundation for 2007 / 2010
1998
Engine
10/02
Bridge
Add:
– Split Inj
– Oxicat
10/03
ACERT
Add:
– VVA
– Series
Turbo
2007
ACERT
Add:
– Adv Comb
– Flex Fuel
System
– Diesel Part Filter
– Thermal Mgmt
2010
ACERT
– Adv Comb
and NOx
Aftertreatement
• Our Technology Strategy & Approach
– Build Upon 2003 ACERT™
– Continue to Enhance Engine Performance While Incrementally Introducing
Aftertreatment
– Investigate Multiple Particulate Technologies
– Provide Best Value To Customer and Least Disruptive Technology to Truck OEMs
Particulate Matter (PM)
Reduction Technologies
Engine Out Particulate Matter
(PM) Reduction
 Lower Engine Out PM is an
Enabler for Passive or “Less
Active” Diesel Particulate
Filters (DPF)
 Less Soot Into The Filter
Translates Into Lower Fuel
Consumption Penalties for
Regeneration
 Developing Strategies to
Reduce Engine Out PM
Engine-Out Cycle PM (g/bhp-hr)
0.28
0.24
0.2
0.16
Current Fuel /
Combustion
System
0.12
0.08
Continue
Improvements
Cycle
0.04
Advanced Fuel /
Combustion
System
NOx (g/hp-hr)
0
0
0.5
1
1.5
2
Cycle NOx (g/hp-hr)
2.5
3
 Combustion Development
 Fuel Injection Improvements
 Better Fuel Air Mixing
Prime Path: Engine + EMD System
Ceramic Filter with Engine Thermal
Management for Regeneration
Quick Disconnects
Highest Filtration Efficiency
Lowest 1st Cost
Best Fuel Economy
Challenge: “Cold” Applications
Temperature, Pressure Sensors
ECM/EMD
(Electronic Control Module/Engine Manufacturers Diagnostics)
Ceramic
Filter
Temperature, Pressure Sensors
System Design for Engine Thermal
Management
100ºC
ACERT
Oxidation
Catalyst
2007
Aftertreatment
Not Too Hot,
Not Too Cold
Bring On
The Heat !
200ºC
300ºC
400ºC
500ºC
 System Requirements for Thermal Management &
Regeneration
 Short Setback
 Single Can
Preferred
600ºC
 Engine Measures to Avoid Low Exhaust Temp
 ECM Tracking of Emissions & Thermal History
 Control System Logic to Trigger Thermal Events
Secondary Path: Self-Regenerating PM Filter
Internally “Active” Regeneration;
Filter is Heated by Auxiliary Means
Quick Disconnects
Regenerate Under All Conditions
Challenge: Cost & Complexity
Heat
Generator
ECM/EMD
Temperature, Pressure Sensors
Controller
Thermal
Source/
Diffuser
Ceramic or
Metallic
Filter
Heat
Generator
Temperature, Pressure Sensors
Aftertreatment Installation
Round Filters are the Standard
 Oval Configurations to be Explored but Considered High Risk
Setback Distance Will Be Important
 Specifying Short Converter Setbacks will Enable Lower Cost Components &
Better Fuel Consumption Solutions
 Target 5 Feet from Turbo Outlet to DPF Inlet (Heat Retention)
 Back-of-Cab and Side-of-Cab Mounting Not Probable
Target Is Single Can
 Lower Cost, Better for Regeneration
Filter System Needs to Be Serviceable
 Ash Removed at Specified Interval
 Filter System Designed for Easy Service
 Location must be Accessible
Oxides of Nitrogen (NOx)
Reduction Technologies
NOx Reduction Options (2003)
T
C
2003
ACERT
Engine
Engine NOx Technology
Advanced
Diesel
Combustion
Particulate
Filter
NOx
AT
Aftertreatment NOx Technology Options
DeNOx
Catalyst
NOx
Adsorber
Urea
SCR
• Engine-Out NOx Measures Reduce Size / Cost of Aftertreatment
• Aftertreatment Options Need to be Evaluated for Maturity and Cost
• Combination of Engine Out and Aftertreatment may Provide Best NOx
Reduction Value Path
Engine Measures for NOx Reduction (2004)
• Caterpillar Continues to Expand the
Envelope On Engine Out Performance
• ACERT has Further Ability to:
– Reduce NOx & PM Emissions
– Improve Fuel Consumption and
Heat Rejection
• Modifications for Engine Out NOx:
–
–
–
–
Fuel Systems
Air Systems
Piston/Ring/Liner Designs
MorElectric Initiative Systems Possible
Advanced
Combustion
Closed Crankcase Ventilation System
(CCV)
Closed Crankcase Ventilation (CCV)
System Design Options
2007 Requirement

CCV
Filter
System
Crankcase Emission Control Exception for
Turbocharged Heavy-Duty Diesel Engines
Eliminated
Crankcase Emissions Treated Same as (i.e.,
Added to) Other Exhaust Emissions
C
Particulate
Filter
T
C

T
Option 1:
Filter and Route
to Air Intake
Pump /
One-Way
Valve
CCV
Filter
System
CCV
Filter
System
CCV Filter
Component
Option 2:
Filter and Route to
Exhaust Upstream of DPF

Option 3:
Filter and Vent to
Atmosphere
Manufacturers Expected to
Control Crankcase Emissions
by:
 Routing to Intake
 Routing to Exhaust Stream
Upstream of the
Aftertreatment
2007 System Architecture
2007 System Architecture
Heavy Duty
Pre
Cooler
T
T
C
Option 1
C
ATAAC
CCV
Filter
System
Particulate
Filter
W/ or W/O
Auxiliary
Device
Variable Valve Actuation
w/ Thermal Management
Function
Higher
Pressure
Injection
System
Series
Turbo Chargers
2007 System Architecture
Midrange
Option 1
T
C
ATAAC
CCV
Filter
System
Diesel
Particulate
Filter
W/ or W/O
Auxiliary
Device
Device for
Thermal Management
Function
Higher Pressure
Injection
System
Conventional
Turbo Charger
Timelines
2007 HD Program Timeline
2003
Q1
Q2
Q3
R 2005
2004
Q4
Q1
Q2
Q3
Q4
Q1
Q2
Q3
2006 S
Q4
Q1
Q2
OEM Engines
Field Test Engines
Customer Evaluation Engines
Additional Customer Evaluation Engines
C13
C15
Production
Q3
Q4
2007 MD Program Timeline
2003
Q1
Q2
Q3
2005
2004
Q4
Q1
Q2
Q3
Q4
Q1
Q2
Q3
2006
Q4
Q1
Q2
OEM Engines
Field Test Engines
Customer Evaluation Engine
Additional Customer Evaluation Engines
C7
C9
Production
Q3
Q4
Caterpillar Conclusions
Finalizing Technologies for 2007
Diesel Particulate Filter Required
Engines Available for Fleet Purchase Mid - 2005