MAN CNG Buses. MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
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1 MAN CNG Buses MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
2 MAN CNG Buses Content 1. MAN CNG bus history 2. Actual CNG bus & engines portfolio 3. MAN CNG buses sales worldwide 4. Actual CNG technology 5. Concept Comparison 6. New developments 7. Advantages of CNG technology (compared to Diesel) 8. Cost comparison 9. Summary MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
3 MAN CNG Buses Content 1. MAN CNG bus history 2. Actual CNG bus & engines portfolio 3. MAN CNG buses sales worldwide 4. Actual CNG technology 5. Concept Comparison 6. New developments 7. Advantages of CNG technology (compared to Diesel) 8. Cost comparison 9. Summary MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
4 MAN Gas Buses History History First MAN Gas Bus, Augsburg MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
5 MAN Gas Buses History 1972 LNG Bus for Munich Olympic Games 2001 CNG Bus for Zwickau, Germany 1988 SL 202 CNG Bus 2003 CNG Bus for Frankfurt/Oder, Germany MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
6 MAN CNG Buses Products MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
7 Milestones in the Development of MAN Natural Gas Engines E 2866 DUH01 E 2866 DF01 E 2866 DUH03 Euro 2-engines Euro 3-engine EEV-engine naturally aspirated engines stoichiometric E 2866 DOH01 E 2866 DUH02 E 2866 LUH02 E 2876 LUH02 turbocharged engines lean-burn lean-burn/mix E 2866 LUH01 E 2876 LUH MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
8 MAN CNG Buses Content 1. MAN CNG bus history 2. Actual CNG bus & engines portfolio 3. MAN CNG buses sales worldwide 4. Actual CNG technology 5. Concept Comparison 6. New developments 7. Advantages of CNG technology (compared to Diesel) 8. Cost comparison 9. Summary MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
9 MAN CNG-Buses and CNG-Buses with MAN-Natural Gas Engines MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
10 MAN CNG Buses Content 1. MAN CNG bus history 2. Actual CNG bus & engines portfolio 3. MAN CNG buses sales worldwide 4. Actual CNG technology 5. Concept Comparison 6. New developments 7. Advantages of CNG technology (compared to Diesel) 8. Cost comparison 9. Summary MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
11 MAN gas engines Technology - MAN gas engines are based on the mass produced MAN Diesel engine type D 28 - Most parts are identical to the Diesel engines especially the expensive ones as crankcase, crankshaft connection rods etc. - Gas engines are dedicated engines with a lot of special features MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
12 Engine cross section Gas engine Diesel engine Otto-cycle Gas engine Spark plug and special combustion chamber with lower compression ratio Diesel engine Diesel injector and combustion chamber with high compression ratio TVA-N, MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
13 Features of MAN gas engines I - Cylinder heads with armored valves and armored valve seats for low abrasion - Optimized cylinder head cooling, especially good cooling of the spark plug - Inlet valves with shaft sealing for minimized oil consumption - Outlet valve guides made from special material with self lubricating quality for low abrasion - Valve tappets with hard metal plates for low abrasion of the cams - Special pistons and piston rings for low oil consumption - Piston rings with special coating for low abrasion MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
14 Features of MAN gas engines I I - Bearing shells for con rods and crankshaft with non abrasive surface - Water cooled exhaust gas manifold for naturally aspirated engines - Turbo charger with water cooled bearing house - Turbo charger equipped with waste gate - Engine management system Bosch Motronic GAS 1 - Long life Platinum/Iridium spark plugs (60000 km) - Exhaust gas aftertreatment with a three-way catalyst (at lean operation oxidation only) - Summary: the number of differences indicate it makes no sense to convert Diesel to CNG engines! MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
15 CAN-structure of gas vehicles ABS/ ASR Accelerator pedal Gearbox control Driveline CAN Vehicle management computer (FFR) MASTER Engine CAN Motronic ME7-Gas1 engine management SLAVE MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
16 Components of the Engine Management System Motronic ME7-GAS Butterfly valve actuator 2 Injection valves Control unit 4 Phase sensor 5 Speed sensor 6 Boost air temperature sensor 7 Boost pressure sensor 11 8 Coolant temperature sensor 9 Natural-gas pressure sensor 10 Natural-gas temperature sensor Igniting stages 12 Spark coils 13 Hot film air mass sensor 14 Knock sensors 15 Proportional valve for wastegate Broad-band lambda sensors 17 Exhaust gas temperature sensor MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
17 Functions of the Motronic ME7-GAS1 Output control by means of electrically driven butterfly valve actuator and boost pressure control via waste gate control Fuel control using a completely electronic sequential gas injection system and an air mass measurement system Ignition control using a map transistor ignition system with open-circuit high voltage distribution Safety functions as self surveillance and diagnostic of sensors and actuators Engine starter control Lambda = 1 control for naturally aspirated engines by means of a broad band Lambda sensor Lambda = 1 or Lambda > 1 control for turbo charged engines by means of a broad band Lambda sensor Cylinder individual anti-knock control with the help of two knock sensors Idle speed filling control MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
18 Gas Mixer Unit of the Natural Gas Engines E 2866 DUH03 and E 2876 LUH02 gas pressure sensor throttle valve gas inlet gas injectors (12 x) gas temperature sensor MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
19 Evaluation of the Central Gas Mixer Unit 8 excellent homogenity of the natural gas/air-mixture, very important for lean-burn operation 8 very compact component 8 very good accessibility of the gas mixer unit for service 8 good dynamic behaviour during transient engine operation 8 many identical parts of the gas mixer unit for the naturally aspirated and the turbocharged engine version MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
20 MAN CNG Buses Content 1. MAN CNG bus history 2. Actual CNG bus & engines portfolio 3. MAN CNG buses sales worldwide 4. Actual CNG technology 5. Concept Comparison 6. New developments 7. Advantages of CNG technology (compared to Diesel) 8. Cost comparison 9. Summary MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
21 EEV- Gas Engines for Buses EEV = Enhanced Environmentally friendly Vehicle Fuel Engine type Engine concept Mixture Installation CNG LPG E 2866 DUH03 E 2876 LUH01/02 G 2876 DUH01 naturally aspirated three-way-catalyst turbocharged and aftercooled three-way-catalyst naturally aspirated three-way-catalyst lean-burn / mix stoichiometric stoichiometric Power [kw] Exhaust gas standard horizontal 180 EEV horizontal 228 EEV *) horizontal 200 EEV H2 H 2876 UH01 naturally aspirated reduction-catalyst stoichiometric horizontal 150 EEV**) *) gas grup limitation e **) not jet certified MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
22 Evaluation of Concepts for turbocharged Natural Gas Engines Lean-Burn Concept Stoichiometric Concept Lean-burn/Mix-Concept acceptable emissions excellent emissions very good emissions Emissions suitable for Euro 3 also Euro 4 with restriction to the driveability fulfil Euro 5 and EEVstandard suitable for Euro 6 fulfil Euro 5 and EEVstandard Fuel consumption good high (in relation to lean-burn) acceptable ( between lean-burn and stoichiometric) Thermal Stress low thermal stress exhaust gas temperatures comparable to these of a Diesel engine very high exhaust gas temperatures (> 900 C) acceptable thermal stress exhaust gas temperatures slightly higher to these of a Diesel engine high costs Costs acceptable costs expensive materials are needed heat protection in the engine compartment is necessary acceptable costs MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
23 Differences between Leanburn and Lean-burn/Mix - Concepts Lean-burn Concept Lean-burn / Mix Concept 8 Operation of the engine in the complete operation map with high excess air 8 Lambda value between 1,3 and 1,65 depending on engine load 8Stoichiometric operation of the engine in a part of the operation map 8 Switch over to operation with high excess air depending on the load and the speed of the engine 8 Lambda value between 1,0 and 1,65 depending on the engine load MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
24 The Way from an Euro 3- towards an EEV-Natural Gas Engine with Turbocharger Lean-Burn Concept NOx [g/kwh] 4,20 4,0 Lean-Burn/Mix Concept Euro 3-Natural Gas Engine E 2866 LUH02 2,0 EEV-Natural Gas Engine E 2876 LUH02 CH4 [g/kwh] 1,00 0,65 0,30 1,80 0,02 Particles [g/kwh] EEV-Limits 0,10 0,50 0,005 0,40 3,0 NMHC [g/kwh] CO [g/kwh] MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
25 The Way from an Euro 3- towards an EEV-Natural Gas Engine with Turbocharger 0,50 MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
26 Natural Gas Engine E 2876 LUH02, turbocharged and intercooled, EEV Number of cylinders: 6 Displacement: 12,8 l Power output: 228 kw/2000 rpm Torque: 1250 Nm/ rpm Exhaust gas standard: EEV Concept features: central gas mixer unit gas injection system Motronic ME7-GAS1 lambda 1 -control three- way catalyst MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
27 Function Chart of Natural Gas Engine E 2876 LUH02 pressure regulator gas cylinders throttle valve sensors intercooler air by-pass air mass sensor gas mixer unit spark coils turbocharger wastegate silencer with three-way-catalyst Lambda sensors engine control unit vehicle management controller MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
28 Performance diagram of Natural Gas Engine E 2876 LUH02 Leistung [kw] Drehmoment [Nm] Verbrauch [g/kwh] DAEQ Drehzahl [1/min] Motor-Typ.: E 2876 LUH01 Leistung : 228 kw bei /min Drehmoment : 1250 Nm bei /min Kraftstoffverbrauch : 208 g/kwh DAEQ Nenndrehzahl : /min Abnahme nach 80/1269 EWG Leistungsdiagramm E2876LUH01 MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
29 MAN CNG Buses Content 1. MAN CNG bus history 2. Actual CNG bus & engines portfolio 3. MAN CNG buses sales worldwide 4. Actual CNG technology 5. Concept Comparison 6. New developments 7. Advantages of CNG technology (compared to Diesel) 8. Cost comparison 9. Summary MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
30 New developments Small CNG engine E08 MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
31 Performance diagram of the Turbocharged Gas Engine E 0836 LOH01 Highlights: Euro 6 & OBD 2 compliant 206 kw (280 bhp) 1000 NM ( /min) New optimized ECU MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
32 MAN CNG Buses Content 1. MAN CNG bus history 2. Actual CNG bus & engines portfolio 3. MAN CNG buses sales worldwide 4. Actual CNG technology 5. Concept Comparison 6. New developments 7. Advantages of CNG technology (compared to Diesel) 8. Cost comparison 9. Summary MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
33 Exhaust-Gas Emissions of EEV-Natural Gas Engines in the ETC Homologation values, rounded Gaseous emissions [g/kwh] 6,00 5,00 4,00 3,00 2,00 1,00 0,00 5,45 4,00 4,00 3,00 0,25 0,15 Euro 3 Euro 4 Euro 5 EEV E 2866 DUH03, Lambda =1, EEV E 2876 LUH02, lean-burn/mix, EEV 0,78 0,55 0,55 0,40 1,60 1,10 1,10 0,65 0,00 0,05 0,050,10 5,00 3,50 EEV ETC 2,00 2,00 0,40 = Enhanced Environmentally friendly Vehicles = European Transient Cycle Range of variation depends on the composition of the test gases 1,90 0,16 1,60 0,3 0,03 0,30 0,20 0,02 0,05 < 0,005 0,05 0,30 0,20 0,10 0,00 Particles [g/kwh] CO NMHC Methane NOx Particles MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
34 Exhaust-Gas Emissions Euro 3 to Euro 6 ETC Overview: legal requirements for heavy duty vehicles Euro 3 to Euro 6 ETC: European Transient Cycle MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
35 Specific Fuel Consumption and CO 2 - Emission in the European Transient Cycle (ETC) 140 [%] 120 Spec. fuel consumption CO2-emission D 2876 LF with SCR E 2866 LUH02 E 2866 DUH03 E 2876 LUH02 EEV EURO 3 EEV EEV Specific fuel consumption = Diesel equivalent MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
36 Particle Size Distribution in the Exhaust Gas of Diesel and Natural Gas Engines Test cycle: ESC 1,00E+15 1,00E+14 dn/dlogdp [1/kWh] 1,00E+13 1,00E+12 1,00E+11 1,00E+10 Diesel-engine, Euro 2, raw exhaust gas Diesel-engine, Euro 2, after CRT CNG-engine, EEV indoor air 1,00E+09 1,00E electrical mobility diameter [nm] MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
37 Advantages of CNG technology Focus: Biogas Overview: environmental performance of buses MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
38 Advantages of CNG technology Focus: Biogas MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
39 MAN CNG Buses Content 1. MAN CNG bus history 2. Actual CNG bus & engines portfolio 3. MAN CNG buses sales worldwide 4. Actual CNG technology 5. Concept Comparison 6. New developments 7. Advantages of CNG technology (compared to Diesel) 8. Cost comparison 9. Summary MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
40 Cost comparison Source: MAN NL MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
41 MAN CNG Buses Content 1. MAN CNG bus history 2. Actual CNG bus & engines portfolio 3. MAN CNG buses sales worldwide 4. Actual CNG technology 5. Concept Comparison 6. New developments 7. Advantages of CNG technology (compared to Diesel) 8. Cost comparison 9. Summary MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
42 Advantages of CNG technology CNG/LPG Exhaust gas emissions are significantly better than Diesel emissions CNG/LPG engines are quieter than Diesel engines (up to -2 db(a) less) Worldwide known resources for natural gas expected to last up to 300 years Biogas provides the optimal fuel reference greenhouse effect and local air quality CNG as fuel provides a higher safety standard than Diesel! MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
43 Advantages of CNG technology MAN Nutzfahrzeuge AG SRN MAN CNG Buses May
44 Thank you for your attention. MAN Nutzfahrzeuge AG Author Title of presentation DD Month YYYY 44
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