DEUTZ Variable Emission Reduction Technology. Tier 4 our driving force, your advantage.
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1 DEUTZ Variable Emission Reduction Technology Tier 4 our driving force, your advantage.
2 Since the industrialisation of the internal combustion engine at the end of the 19th century, the increasing need for more compact engines with a higher power density and lower fuel consumption has led to the continuous further development of the Diesel engine. One other important driving force since 1996 has been the need to fulfil increasingly demanding exhaust emission legislation passed at short time intervals. The subject of emission reduction is an extremely complex one. Therefore, in addition to radical optimisation in the design of the basic engine and the implementation of emission reduction measures within the engine, exhaust gas aftertreatment (EAT) methods are now also being implemented in order to comply with the extremely low limits of current emission legislation. We are currently focussing on the fulfilment of EU Stage IV or US EPA Tier 4, so far the strictest emission standard for so-called non-road applications. These will be phased in gradually between 2014 and 2015, differentiated according to power category. Here we remain true to our philosophy: technical changes will only be introduced where they serve to implement legal requirements or result in an improvement in customer benefits. Above all, the economy and reliability of DEUTZ engines always remain the priority.
3 The development of the emission legislation Ever since the emission legislation was introduced for mobile machinery, emissions of nitric oxide (NO X ) and diesel soot (PM) have both been considerably reduced. The chart to the 100% 90% 9.2 g/kwh 0.7 g/kwh right illustrates this. With DVERT, we have developed a modular system kit that meets all these requirements. A thorough knowledge and 80% considerable investment in R&D were both necessary to put this technological concept into practice. 70% With the introduction of the current emission standards Stage IIIB in Europe and Tier 4 Interim in the USA, limits for nitrogen oxides (NO X ), hydrocarbons (HC) and particles (PM) have been considerably reduced once again. Thanks to DVERT, our engines are also capable of fulfilling all further legal requirements without any difficulty and even providing a better performance at the same time in most cases. 60% 50% 40% = NO X (+HC) [g/kwh] = Particulates [g/kwh] 30% 20% 10% 0.4 g/kwh g/kwh 0% EU Stage I US EPA Tier kw EU Stage II US EPA Tier kw EU Stage IIIA US EPA Tier kw EU Stage IIIB US EPA Tier 4i kw EU Stage IV US EPA Tier kw
4 EU STAGE III A US EPA TIER 3 EU STAGE III B US EPA TIER 4 INTERIM EU STAGE IV US EPA Tier 4 VISION FUEL INJECTION COMBUSTION MANAGEMENT Mechanical pump-line-nozzle Direct and indirect injection systems Mechanical distributor injection pump DEUTZ Common Rail (DCR ) Magnetic valve system (MVS ) Natural aspirated engines Wastegate exhaust turbochargers Charge air cooling 2-valve and 4-valve systems EXHAUST AFTERTREATMENT LOWER PARTICULATES With improved engine combustion & fuel injection systems and using the following aftertreatment methods: EXHAUST AFTERTREATMENT REDUCING NO X Using a combination of the following aftertreatment technologies introduced in Tier 4 interim: Reduction of soluble particulate matter by means of diesel oxidation catalyst (DOC) Reduction of soluble particulate matter by means of diesel oxidation catalyst (DOC) ZERO EMISSION DIESEL ENGINES ENGINE CONTROL TECHNOLOGY Mechanical fuel injection and control Mechanical fuel injection with electronic speed control and engine data recording (EMR 2) Fully electronic engine control (EMR 3) NO X REDUCTION TECHNOLOGY Simple, uncontrolled internal exhaust gas recirculation (EGR) Controlled exhaust gas recirculation with valve stroke management (VLM ) Controlled and cooled exhaust gas recirculation Reduction of diesel soot by means of diesel particulate filters (DPF) NO X reduction by means of the selective catalytic reduction (SCR) Reduction of diesel soot by means of diesel particulate filters (DPF). NO X reduction by selective catalytic reduction (SCR) DVERT is our answer to the problem of harmonising future emission regulations with our customers requirements. DVERT stands for a modularly structured system which is incorporated into different configurations of our engines. The basic principle is: As much technology as necessary and not as much as possible. Almost all the elements of the DVERT system kit can be combined with each other to ensure the desired result with regard to engine performance, observance of emission limits and competitiveness. With our flexible modular system we can ensure that overengineering is avoided and only as much technology as is necessary and useful is used. The following EAT variants will show you how we have solved this issue for the entire power range because we are in the business of creating facts.
5 Tier 4 interim/tier 4: TCD 2.9 L4 Tier 4 interim: TCD 3.6 L4 1 With engines of < 4 L, 15% more power than comparable Tier 3 engines Up to 10% lower average fuel consumption through downsizing Maintenance free and compact EAT system which can be optionally mounted onto the engine Tier 4 in combination with SCR system (> 56 kw)
6 Tier 4 interim: TCD 4.1 L4 TCD 6.1 L6 TCD 7.8 L6 2 With engines of 4-8 L, up to 25% more power than comparable Tier 3 engines Fuel consumption up to 5% lower Compact EAT system & variants designed for easy installation Suitable for low-emission zones Burner regeneration w/o operation interference under every operating condition (>130 kw)
7 Tier 4 interim: TCD 4.1 L4* TCD 6.1 L6* TCD 7.8 L6* TCD 12.0 V6 TCD 16.0 V8 * Agricultural engines only 3 Highly efficient EAT system with UREA injection Engine performance improved by up to 8%* Average fuel consumption up to 5% lower
8 Tier 4: TCD 3.6 L4 4 Up to additional 10% increase in power and more torque Lower noise and fuel consumption Proven and robust SCR technology Durable design for all applications and markets
9 Tier 4: TCD 4.1 L4 TCD 6.1 L6 TCD 7.8 L6 TTCD 6.1 L6* TTCD 7.8 L6* * Agricultural engines only 5 Highly efficient EAT system with particle filtration and UREA injection Reduced exhaust noise 25 db (A), eliminates the need for an additional silencer Lower fuel consumption Proven and robust SCR technology
10 Overview of DEUTZ product line-up Tier 4 interim Technology: Electronically controlled high pressure common rail (HPCR) injection Model ceegr Diesel Oxidation Wall-Flow Selective DEUTZ Heat Catalyst (DOC) System (DPF) Catalytic Burner Management Reduction (SCR) System* kw Overview of DEUTZ product line-up Tier 4 Technology: Electronically controlled high pressure common rail (HPCR) injection Model ceegr Diesel Oxidation Wall-Flow Selective Heat Catalyst (DOC) System (DPF) Catalytic Management Reduction (SCR) System* kw D 2.9 L4 TD 2.9 L4 TCD 2.9 L4 TD 3.6 L4 n n n n D 2.9 L4 n n TD 2.9 L4 n n TCD 2.9 L4 n n s s TD 3.6 L4 n n s s kw TCD 3.6 L4 n n s s TCD 4.1 L4 n n n l s n TCD 6.1 L6 n n n l s n ** n TCD 7.8 L6 n n n l n kw TCD 3.6 L4 n n s n n TCD 4.1 L4 n n n n n TCD 6.1 L6*** n n n n n TCD 7.8 L6*** n n n n n TCD 12.0 V6 TCD 16.0 V8 n n TCD 12.0 V6 n n n TCD 16.0 V8 n n n n = Standard; s = Option; l = Agricultural engines, with SCR only * Regeneration support by engine internal measures; ** TCD 6.1 L6 > 130 kw Burner standard n = Standard; s = Option *** Agri high performance version with dual stage TC TTCD 6.1/7.8 As an engine system supplier, we take pride in being specialists in solving complex drive requirements. Our job is to meet and exceed current and future exhaust regulations safely and effectively. By developing customised solutions for our customers, DEUTZ has set a high standard with DVERT, and by using modular solutions, all engines meet the latest emission regulations efficiently and economically.
11 When making the decision to fit a T4 engine, the following Operating costs Exhaust gas aftertreatment systems (EAT systems) SCR (Selective Catalytic Reduction) questions are frequently asked, to which we would like to DEUTZ engines traditionally stand out on account of their The current EU Stage IIIB / US EPA Tier 4 interim standards Alternatively, the NO X emissions can be reduced by means briefly respond: low fuel consumption. With our new Tier 4 engines, we set require the use of measures within the engine in combination of SCR technology to such a low level that the strict particle Engine installation Strict emission standards make it necessary to use additional components for exhaust gas aftertreatment (EAT). Unfortunately, the installation space available in the equipment cannot be increased at will, which can result in huge challenges and changes for the equipment manufacturer. new standards in fuel efficiency. We optimise power and torque through the use of the most modern engine and combustion management systems, while at the same time reducing consumption. The saving in fuel compared with comparable Tier 3 engines is up to 10%, depending on the equipment application and the usage profile. with an EAT system; either to reduce the NO X values or to reduce the particle values, whereby the other limit can then be achieved in each case engine internally. A further reduction of emission limits by the EU Stage IV / US EPA Tier 4 standards for the range kw ultimately requires the use of a second EAT system installed in series. limits are also to be achieved through optimisation within the engine. For SCR, an additional operating fluid (called urea or AdBlue ) is needed, which is sprayed into the exhaust gas upstream of the SCR catalyst in order to achieve a reduction in harmful emissions within the catalyst. The more complex Here, DEUTZ is able to show individual solutions for making the best possible use of the installation space. Already at the planning stage of new equipment, we offer the possibility of configuring the engine and the EAT system, together with our customers, from an extensive range of installation options from our modular Technology Construction Kit DVERT. Power density DEUTZ engines with modern EAT technology generally have a considerably higher power density than engines without advanced emission control. Therefore, the downsizing concept known by the automobile industry is now also being applied in numerous DEUTZ applications. For our customers, this means replacing an existing Tier 3 engine with a considerably more compact Tier 4 engine having a smaller cubic capacity, but a higher power density. The resulting Service In general, engines with EAT require no more effort for servicing than comparable predecessor models. All relevant components of the DVERT System Kit have the same service life as the engine itself. The only technology-related exception to this is the closed Diesel particle filter (DPF). Owing to the accumulation of ash in the filters, and depending on engine workload, these must be cleaned at the earliest after 3000 hours in the power class below 130 kw and at the earliest after 4500 hours above 130 kw. A warning signal indicates to the operator in good time that a filter clean is due. To provide our customers with a trouble-free and rapid DPF service, the well-established DEUTZ Xchange program has been extended to include the Diesel Particle Filter product range. The following EAT system categories have to be differentiated: a. Open EAT systems What we understand by these systems are all EAT systems without particle accumulation, which do not require regeneration, i.e, either DOC or SCR, or a combination of these. DOC Here an optimised combustion with very low NO X and PM is targeted using a maintenance-free DVERT Oxidation Catalyst (DOC). With slight limitations with regard to the power density, this results in a maintenance-free system which requires no regeneration and offers the advantage of a compact and efficient solution for all operating conditions. installation (dosing unit, pump unit, urea tank, etc.) contrasts with the advantages of a very high power density together with a very low fuel consumption, and low heat transfer into the cooling system. In the case of Stage IV / Tier 4, all DEUTZ engines > 56 kw are equipped with SCR systems, either in combination with a DOC, or with a DPF, or with a second SCR catalyst, depending on the power range and the engine series. b. Closed EAT systems When a closed DVERT Particle Filter (DPF) is used, carbon particles are filtered out almost entirely (> 99%) and oxidised, or burnt off, continually or in phases. This process is called regeneration which, when certain framework conditions are met, occurs either automatically, or it can be actively initiated. We therefore differentiate between passive and active systems. additional installation space often compensates for the additional room needed for cooling and emission control.
12 Systems with passive or active regeneration are used by DEUTZ, depending on the power class and application. Passive regeneration Passive systems are characterised by regeneration of the filter without an active initiation of the oxidation process. The system applied by DEUTZ of a DVERT Particle Filter optimised for continuous regeneration (CRT ) consists of a DPF with an upstream DOC. The NO contained in the exhaust gas is oxidised to NO 2 in the DOC, which then reacts with the carbon particles in the DPF at temperatures above 250 C. If the minimum temperature required for continuous regeneration of the particle filter is not achieved, then active intervention is possible even with this system. A clever heat management system then increases the exhaust gas temperature through targeted measures within the engine. This simple and robust solution is implemented in Stage IIIB / Tier 4 interim for engines of < 130 kw. Only in rare, exceptional cases and under certain conditions a stand-still regeneration can be required for low-load profiles that have an extremely low exhaust gas temperature. The advantages of this solution are: The regeneration takes place automatically during operation without impact on the performance of the equipment. Overloading of the particle filter and an increase of exhaust gas backpressure are reliably avoided, particularly during operation under low load conditions. This solution facilitates regeneration of the particle filter at any time, even under very low-load operation conditions. Summary With the DVERT Kit, DEUTZ offers the possibility of configuring EAT systems with only minor design modifications for cost-efficient installation, and to configure them for a wide range of requirements and usage profiles in construction equipment. In the case of Stage IV / Tier 4, the addition of an SCR system leads to a significant optimisation of the boundary conditions for regeneration, such that the passive system can be used for all engines with DPF. Active regeneration With the Stage IIIB / Tier 4 interim emission standards, the use of a passive regeneration system alone is not possible with powers > 130 kw because of the low NO X limit. In the case of engines in this power range which use a DPF, DEUTZ offers solutions with active regeneration. Regeneration of the filter in this case takes place by means of a burner in combination with a catalytic reaction in the DOC. The burner generates a primary flame, by means of which additional fuel injected into the exhaust gas is vaporised. This mixture leads to a thermal reaction in the downstream DOC, through which the exhaust gas temperature is raised to the level needed for regeneration of the DPF (>600 C >1112 F).
13 worldwide: DEUTZ AG Ottostr Cologne, Germany Phone: +49 (0) Telefax: +49 (0) info@deutz.com DEUTZ Corporation 3883 Steve Reynolds Blvd. Norcross, GA 30093, USA Phone: Telefax: engines@deutzusa.com DEUTZ AG (Beijing) Engine Co., Ltd CITIC Building 19, Jian Wai Dajie, Beijing, P.R. China Phone: Telefax: dbj@deutz.com.cn DEUTZ Asia-Pacific (Pte) Ltd. 10 Gul Crescent Singapore Phone: Telefax: / dap@deutz.com Order-No / 02 / 2013 / VC-CM DEUTZ Australia PTY. LTD Unit 4, Brough Street SPRINGVALE VIC 3171 Phone: Telefax: deutz.oz@deutz.com
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