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John Campbell Director On-Highway Engine Products March 16, 2004

John Campbell Director On-Highway Engine Products March 16, 2004. American Trucking Association Technology & Maintenance Council. U.S. 2007 Emissions Requirements. PM = 0.01 g/bhp-hr Requires Particulate Filter NOx + HC = 1.2 g/bhp-hr Assumes Use of Phase-In Provision

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John Campbell Director On-Highway Engine Products March 16, 2004

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  1. John CampbellDirector On-Highway Engine ProductsMarch 16, 2004 American Trucking Association Technology & Maintenance Council

  2. U.S. 2007 Emissions Requirements • PM = 0.01 g/bhp-hr • Requires Particulate Filter • NOx + HC = 1.2 g/bhp-hr • Assumes Use of Phase-In Provision • Requires NOx Aftertreatment, Advanced Combustion, or Both • Crankcase Emissions Counted As Part of Cycle Emissions • Drives Closed Crankcase Filter and/or Closed Crankcase • On-Board Diagnostics (OBD) • 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 0.35 0.3 ‘91 0.25 0.2 Particulates (g/bhp-hr) Engine Modifications 0.15 ‘02 ‘98 ‘94 0.1 ACERT Engine Modifications 0.05 ‘10 ‘07 0 0 1 2 3 4 5 6 7 NOx (g/bhp-hr) Cat Will Follow the 2007/2010Phase-In Provision

  3. 1998Engine 10/02 Bridge 10/03 ACERT 2007 ACERT 2010 ACERT • Add: • Split Inj • Oxicat • Add: • VVA • SeriesTurbo • Add: • Adv Comb • Flex FuelSystem • Diesel Part Filter • Thermal Mgmt • Adv Comband NOx • Aftertreatement ACERT™ Is The Foundation for 2007 / 2010 • 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

  4. Particulate Matter (PM) Reduction Technologies

  5. 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 Combustion Development Fuel Injection Improvements Better Fuel Air Mixing Engine-Out Cycle PM (g/bhp-hr) Current Fuel / Combustion System Advanced Fuel / Combustion System Continue Improvements Cycle NOx (g/hp-hr) Cycle NOx (g/hp-hr) Engine Out Particulate Matter (PM) Reduction

  6. Prime Path: Engine + EMD System ECM/EMD • Ceramic Filter with Engine Thermal Management for Regeneration • Highest Filtration Efficiency • Lowest 1st Cost • Best Fuel Economy • Challenge: “Cold” Applications Quick Disconnects Temperature, Pressure Sensors (Electronic Control Module/Engine Manufacturers Diagnostics) Ceramic Filter Temperature, Pressure Sensors

  7. System Design for Engine Thermal Management • System Requirements for Thermal Management & Regeneration • Short Setback • Single Can Preferred ACERTOxidationCatalyst 2007 After-treatment Not Too Hot, Not Too Cold Bring On The Heat ! 100ºC 200ºC 300ºC 400ºC 500ºC 600ºC • Engine Measures to Avoid Low Exhaust Temp • ECM Tracking of Emissions & Thermal History • Control System Logic to Trigger Thermal Events

  8. Secondary Path: Self-Regenerating PM Filter Controller ECM/EMD • Internally “Active” Regeneration; Filter is Heated by Auxiliary Means • Regenerate Under All Conditions • Challenge: Cost & Complexity Quick Disconnects Heat Generator Temperature, Pressure Sensors Thermal Source/ Diffuser Ceramic or Metallic Filter Heat Generator Temperature, Pressure Sensors

  9. 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

  10. Oxides of Nitrogen (NOx) Reduction Technologies

  11. DeNOx Catalyst NOx Adsorber Urea SCR T T C C NOx Reduction Options (2003) 2003ACERTEngine Particulate Filter NOxAT Engine NOx Technology Aftertreatment NOx Technology Options AdvancedDiesel Combustion • 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

  12. 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 andHeat Rejection • Modifications for Engine Out NOx: • Fuel Systems • Air Systems • Piston/Ring/Liner Designs • MorElectric Initiative Systems Possible Advanced Combustion

  13. Closed Crankcase Ventilation System(CCV)

  14. T T C C Closed Crankcase Ventilation (CCV) System Design Options Option 1: Filter and Routeto Air Intake 2007 Requirement • Crankcase Emission Control Exception for Turbocharged Heavy-Duty Diesel Engines Eliminated • Crankcase Emissions Treated Same as (i.e., Added to) Other Exhaust Emissions CCV Filter System Particulate Filter CCV Filter Component Pump /One-WayValve Option 2: Filter and Route toExhaust Upstream of DPF CCV Filter System • Manufacturers Expected to Control Crankcase Emissions by: • Routing to Intake • Routing to Exhaust Stream Upstream of the Aftertreatment CCV Filter System Option 3: Filter and Vent to Atmosphere

  15. 2007 System Architecture

  16. T T T T C C C C 2007 System ArchitectureHeavy Duty Pre Cooler CCV Filter System Option 1 ATAAC Particulate Filter W/ or W/OAuxiliary Device HigherPressure Injection System Variable Valve Actuation w/ Thermal Management Function Series Turbo Chargers

  17. T T C C 2007 System ArchitectureMidrange CCV Filter System Option 1 ATAAC Diesel Particulate Filter W/ or W/OAuxiliary Device Device for Thermal Management Function Higher Pressure Injection System Conventional Turbo Charger

  18. Timelines

  19. Q1 Q1 Q1 Q1 Q2 Q2 Q2 Q2 Q3 Q3 Q3 Q3 Q4 Q4 Q4 Q4 C13 C15 2007 HD Program Timeline R S 2005 2003 2004 2006 OEM Engines Field Test Engines Customer Evaluation Engines Additional Customer Evaluation Engines Production

  20. 2005 2003 2004 2006 Q1 Q1 Q1 Q1 Q2 Q2 Q2 Q2 Q3 Q3 Q3 Q3 Q4 Q4 Q4 Q4 C7 Production 2007 MD Program Timeline OEM Engines Field Test Engines Customer Evaluation Engine Additional Customer Evaluation Engines C9

  21. Caterpillar Conclusions • Finalizing Technologies for 2007 • Diesel Particulate Filter Required • Engines Available for Fleet Purchase Mid - 2005

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