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MD/HD CO 2 Reduction by Hybridization & WHR

MD/HD CO 2 Reduction by Hybridization & WHR. Technology Impact on Emission Control Dr. Uwe Zink, Corning Incorporated Director, Emerging Industry Technology April 4, 2011. Agenda. CO 2 Context Hybridization Motivation Powertrain implication Aftertreatment design considerations

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MD/HD CO 2 Reduction by Hybridization & WHR

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  1. MD/HD CO2 Reduction byHybridization & WHR Technology Impact on Emission Control Dr. Uwe Zink, Corning Incorporated Director, Emerging Industry Technology April 4, 2011

  2. Agenda • CO2 Context • Hybridization • Motivation • Powertrain implication • Aftertreatment design considerations • Technology sorting • Heat Energy Recovery Approaches in Industry • Rankine cycle considerations • Summary

  3. CO2 Context & considerations On-Road focus

  4. 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

  5. -20% Fuel consumption evolution in EuropeACEA’s Goal(*): 20% Fuel consumption reduction by 2020 –Assume vehicle 10 mpg per CCJ 3/31/10 quoting DTNA @ MATS (*) MTZ 1-’09, Daimler SAE Gothenborg 9-’10

  6. 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

  7. 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)

  8. MD/HD-Vocational Applications are Targets for Hybridization High Potential for Braking Energy Recovery Vehicle Type 5/07 Michigan Clean Fleet Conference

  9. Targeting combustion engine operation at optimum BSFC points Ref: Hydraulic Hybrid Vehicle System Panel

  10. Ricardo, SIAT Jan 2011

  11. Diesel Engine Operation Steady State Transient “Hybridization” Hybridization impact on conventional powertrain -Combustion engine selection (“downsized”) & operation (less transient”) Ref: DTF 3-08 Volvo

  12. Conventional: 12l, OM 457 LA Hybrid: 4.8l, OM 924 LA Compensation for torque & power 4 wheel hub electric motors, ea. @ 60 kW continuous 80 kW peak OM 457 LA 1900 OM 924 LA 1500 800 OM 457 LA 400 1000 1400 1800 2200 rpm OM 924 LA Combustion Engine “Downsizing” -Example (MB Citaro G) Mercedes Benz Website http://www.mercedes-benz.de

  13. Cost, Certification & OBD issues need to be resolved Navistar, HTUF 10/2009

  14. HILS – Making its way into MD/HD Homologation Procedures J-MLIT at ACEA Mtg Dec.3, 2009: A Global Approach to Sustainable Freight Transport

  15. Outlook: Waste Heat Recovery in combination with Hybrids “Integrated Powertrain and Vehicle Technologies for Fuel Efficiency Improvement and CO2 Reduction”, DDC, DEER 2009

  16. Aftertreatment Design Considerations

  17. Multiple drivers for aftertreatment requirements

  18. A/T Impact of Hybridization on Freightliner M2 DPF Regeneration Interval increases Freightliner, HTUF 10/2009

  19. A/T Impact of Hybridization on Freightliner M2 DPF Regeneration Interval increases Freightliner, HTUF 10/2009

  20. Emissions are very low… aftertreatment likely not needed. 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

  21. LD Example (Prius III, 1.8l ICE) -Intermittent ICE Operation, Lower exhaust gas temps & aggressive catalyst heating Aggressive Catalyst Heating in Prius Umicore, 4/2010

  22. Market dynamics

  23. 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)

  24. Current offerings (NAFTA) http://www.afdc.energy.gov/afdc/vehicles/heavy/hybrid_systems

  25. Hybridization Market Triggers • Fuel prices -some anticipate $4++(US) • CO2 regs -getting into place • Tax incentives -key to mitigate • Cost reduction -significant effort needed

  26. Three areas that could affect A/T for the ICE

  27. Heat Energy Recovery Approaches

  28. 38.7% Engine Hard/Software, NOx calibration, A/T Efficiency Stanton, Deer 2009 Context: Engine based fuel economy levers Reduced pumping losses -intake -exhaust (e.g. A/T) Heat Energy Recovery Energy Flow Chart @ B50 point of a 290kW engine, Behr, Wien 2009

  29. Heat Energy Recovery Approaches

  30. EGR Cooling TEG BMW’s TEG in EGR Loop4 cyl Diesel engine Suggested to move to exhaust system location for higher recovery (500W rather than 100W on EGR) Ref: BMW, 5th Emission Control, Dresden, 6/10

  31. Mechanical/Electrical Turbocompounding-extracting heat upstream of aftertreatment DDC Mechanical Turbocompounder Bowman Industries, SAE ComVec 2009 BSFC simulation data for from a “typical” heavy duty engine, >10ltrs and with 2010+ emissions compliance

  32. Cummins Example-showing R245fa working fluid Cummins, SIAT Jan. 2011

  33. Iveco Glider-Concept Vehicle • Condensor • Expander:Turbine • Boiler Lastauto Omnibus 12/2010

  34. Expander machines under consideration

  35. 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

  36. Working Fluids under Consideration

  37. Rankine Working Fluid candidatesR245fa, Ethanol, Water, Water/Ethanol, other • Choice based upon: • Critical point • Decomposition temperature • Slope of saturated vapor line • Environmental/Safety aspects • other

  38. 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

  39. 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

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

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