SCR Engine Development at VOLVO

Transcription

1 SCR Engine Development at VOLVO Presentation Content Maurice Brown European City bus Product Manager Volvo Bus Corporation Volvo Environmental Care Euro # engine development EGR and Volvo EGR v SCR decision criteria SCRT experience SCR System Technology SCR engine Development Adblue & Logistics Conclusions 1

2 Our Core Values We use our expertise to create transport-related products and services of high quality, safety and environmental care for demanding customers. Quality Safety Environment 2

3 Legislation not only emission levels Euro 1 Euro 2 Euro 3 Euro 4 Euro Oct 2001 Oct 2006 Oct 2009 Certification of the engine Conformity of production Defeat device language Durability, On Board Diagnostics No. 1, Anti-tampering, In-use testing programme On Board Diagnostics No. 2. NTE, In-use compliance 3

4 Euro 4 legal requirement Certification before Oct 1-05 Euro 4 step I Mandatory Euro 4 step II Additional requirement Certify new engines for Euro 4 Driver warning if: AdBlue tank is empty Dismounted catalyst Lack of AdBlue dosing Driver warning if: > 5 g. NOx/ kwh 40% torque reduction if: > 7 g. NOx/ kwh Oct 1 Oct 1 Oct

5 Legislative Demands Exhaust Emission Standards PM (Particulate Matter) [g/kwh] Increased injection pressure & retarded engine Which lowers efficiency but suppresses NOx formation Phase out 10 litre engine Develop lower friction components 2 new engines 9 & 12 litre with unit injectors Euro 5 (2009) Euro 6 (2012?) Euro 4 (2006) SCR/EGR? Euro 3 (2001) Euro 2 (1996) NO x [g/kwh]

6 Volvo 7 & 10 litre VEC system (EGR) EGR was pioneered by Volvo with over 400 buses built Conclusion: Difficult to achieve acceptable PM emission to allow CRT regeneration at low load/temp cycles 6

7 Gas system + EGR MG9 CNG EGR Solution Cooled EGR P2/T2 sensor EGR valve Lambda 1 Stoechiometric engine 3-way catalyst to treat NOx, HC and CO Use of EGR (Exhaust gas recirculation) in order to reduce exhaust temperatures 3-way catalyst Advantages: Durable concept: Possibility to have EURO6 Emissions level Development based on a advanced engineering project Engine able to adapt with different Natural gas

8 Volvo EGR solution for USA 80,000 EGR s in service across the USA since introduction in 2002 V Pulse EGR similar the the MG9 CNG engine + 4-5% fuel consumption penalty Use of an additive is prohibited in the legal framework due to lack of trust on Operators compliance To fulfil US O7 Volvo will utilise cooled EGR with PM after treatment This solution has also been introduced in Japan due to late agreement for use of an Additive The next generation Japanese engines to be introduced in 2008 are likely be SCR according to statements by two domestic manufacturers. VGT (variable geometry turbocharger) will be used in the new generation engines 8

9 SCR technology SCR - Selective Catalytic Reduction Selective Removes NOx in the presence of oxygen Catalytic Decreases the activation energy for the chemical reaction which Enables reaction at C when amonia is released from the Adblue solution Reduction Reduces NOx by 75% - 95%

10 Incentive Euro 5 SCRT 340 bhp 12 litre Introduced in April 2003 with 27 test buses on the Swedish west coast Denox 1 system with air assisted injection and non cooled injector 100 buses equipped with this solution and are all operating well Adblue consumption is approx 2 2.5% due to the lower Nox reduction of the base Euro 3 engine Good solution for Euro 3 5 due to lower Nox reduction No reduction of fuel consumption + Adblue cost Note: 1% Adblue = -1 gm NOx approx 10

11 Volvo CRT /SCR system Meets the proposed Euro 5 emission standard 27 buses in field test since April 2003 Market introduction in late l Euro 3 engine 340 Hp for city/intercity application Modular after treatment system CRT Clean up catalyst AdBlue injection SCR 11 Open loop system

12 Exhaust Emission Strategy - HD Diesel - Europe 0.10 Particulates g/kwh EU5 Cooled EGR DPF EU4 EU3 Trade-off Present HD Diesel SCR η=65% SCR η=80% NO x g/kwh 12

13 Comparison SCR vs. Cooled EGR EGR Fuel Economy Green House Gases (~Fuel Economy) Heat rejection and Chassis Cooling Packaging (installation dependent) Weight Engine durability Fuel flexibility (Sulphur) Urea need (On-Board and Infrastructure) Oil Drain Interval Chassis System Cost Development cost SCR Source: Volvo Powertrain, September 2005

14 SCR - Selective Catalytic Reduction Power plants Established technology since Possibility to reach 95% NO x -conversion with NH 3. Marine applications Catalytic converters for marine applications to meet NO x -emission levels <2 g/kwh. Heavy duty vehicles Test around the world, mainly Europe. Meet legal requirement of NO x -emission <3,5 2 g/kwh. 14

15 Chemical reaction with SCR (simplified) From engine: NO + NO 2 In hot exhaust: 2NH 3 In SCR catalyst: 2N 2 + 3H 2 O 15

16 AdBlue 32.5 % urea solution in desalinated water ph value of A stable, colourless water-like fluid Urea is made of ammonia and CO 2 AdBlue composes slowly to ammonia and carbon dioxide in room temperature Freezing point = -11 C DIN standard to ensure consistent quality AdBlue is not a hazardous substance There are no known health hazards related to handling of AdBlue solution Urea is produced in large volumes, stable price levels AdBlue per litre 16

17 Global production of Heavy Duty Diesel Engines 2004* Volvo Powertrain DC Powersystems Weichai Power Caterpillar Cummins Scania MAN Yaroslavl * Engine 17 Production 2004, 9-18 litre (excluding licensees / JV s)

18 New Heavy Platform - common technology One Cylinder Head Overhead Camshaft Four Valves per Cylinder Central Vertical Injector Electronic Unit Injectors Electronic Management System Rear End Transmission Integrated Engine Brake Wet Liners 18

19 Euro 4 Engine Features Injection system Injector Type : E3 Same packaging as former E1 version. Injection pressure : 2000bar Opening and closing pressure : flexible Multiple injection capability Rate shaping and multiple injection capability g Benefits: Euro 4 ultra low particulate emissions levels can be reached without filter. Reduced noise and improved cold startability thanks to pilot injection capability. 19

20 Electronically controlled Turbocharger Water cooled - Insulated Machined from solid compressor wheel Closed loop electronic control of the waste gate, replacing the former mechanical boost pressure control. Benefits: Full flexibility to control waste gate opening and thus boost pressure Air valve unit Precise adjustment of the air quantity into the engine in all operating conditions, for improved transient response, better fuel economy and lower emissions. 20

21 Volvo EURO4 Engine Mapped for city bus & coach applications Specific needs of a city bus and coach applications have been integrated in the performance development TORQUE Using detailed analysis of bus and coach driving conditions the engine was optimised where it is used, leading to decreased fuel consumption SPEED London driving duty cycle analysis

22 SCR - Selective Catalytic Reduction AdBlue tank AdBlue level & temp sensor AdBlue pump and injection system control unit AdBlue AdBlue injector + temp sensor SCR catalyst & muffler Upstream catalytic converter NO x sensor Clean-up catalyst for removal of NH 3 to avoid smell 22

23 Components for SCR system AdBlue Pump and Dosing Unit and sensors Temperature sensor AdBlue pump and dosing unit NO x sensor 23

24 SCR Muffler and AdBlue injection Temp sensor AdBlue Injection nozzle NO x sensor Pre Catalyst - Standard on all 9 litre engines and 340bhp 12 litre engines AdBlue injection nozzle 24

25 AdBlue tank and filling neck The industry has agreed on a automotive AdBlue tank filling neck insert standard to facilitate sealed depot system AdBlue tanks l Level Sensor & temp sensor B C Filling neck insert drawing. B = /+0.1 mm C = > 26.8 mm 25

26 SCR technology

27 AdBlue Usage Range COACH 40 litre tank based on 4% usage and diesel consumption of 28.2 l/100km (30l x 94%) = x 25 / 28.2 x 100 = 3546km max range 60 litre tank based on 4% usage and diesel consumption of 28.2 l/100km 60 x 25 / 28.2 x 100 = 5319km max range GENERAL 40 litres of AdBlue is equivalent to 960 litres of diesel fuel consumption for Euro 4 and 950 litre for Euro 5 27

28 AdBlue filling Fuel stations Rapid expansion of public systems throughout Europe Major oil companies develops infrastructure (Total, Shell, OMV) Spill free filling 28

29 AdBlue filling Depot option Several suppliers of AdBlue within Europe Tailor made solutions for depot filling Volvo partner YARA can support customers with infrastructure and AbBlue supplies Spill-free coupling offers AdBlue filling integrated in atomised depot system for diesel fuel 29

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31 Euro 4 Emission Levels Emission levels Euro g/kwh Euro 4 norms D7E level D9B level DH12E level HC CO Nox Pt

32 Future Euro 5 development Lower Consumption & Emissions Rate shaping and multiple injection with E3 injector Higher injection pressure at lower revolutions Higher efficiency SCR from 80% to 90+% Improved gas exchange within the exhaust and inlet systems Lower Fuel consumption Higher combustion peak pressure + 200bar Stronger base engine block & cyl. Head Lower Emissions More optimised control with additional engine and SCR sensors 32

33 In Summary - No Compromise SCR delivers Low emissions Lower Fuel consumption min 3 7% Longer maintenance Intervals Euro 5 capability from production start in 2006 Euro 4 upgradeable to Euro 5 without hardware changes With Euro 6 generation even better fuel economy 33

34 and finally..thank you for your kind attention 34