Aneja (2006) - Heavy-Duty Engine Technology For High Thermal Efficiency at EPA 2010 Emissions Regulations

Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
Craig Savonen, Guangsheng Zhu, Houshun Zhang, Sandeep Singh, Rakesh Aneja August 23, 2006
Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Detroit Diesel Standard Template.ppt
Presentation Outline
Technical Status Towards Project Objectives Technology Development Methodology Technology Building Blocks Example Case Studies
9 Combustion 9 Fuel Injection System 9 Air and EGR System 9 Controls 9 System Integration
Conclusions
Conclusions
Project Objectives
Develop and validate on-highway truck engine technologies for 50% thermal efficiency and nearzero emissions (NZ-50) that are viable for subsequent product development and eventual commercialization Project Duration Project Sponsorship CY2000-CY2006 U.S. DOE, Office of Vehicle Technologies
Emphasis on Enabling Sub-system Technologies

9 Low Emissions Combustion Processes 9 Fuel Injection Events 9 Engine Charge
Flexible, Precise, Repeatable, Distributed, Modulated Pressure / Rate-shape Efficient Charging and EGR Cooling; Efficient, Variable Breathing Model-based, Adaptive, Closed-Loop Vehicle Boundary Conditions
NZ-50 Multi-cylinder Test-bed
9 Controls and Automated Calibration Techniques 9 Basic Aftertreatment and System Integration
Representative Over-the-Road Truck Route

Percent Time Spent as a Function of Engine Speed and Load Typical Over-the-Road Operation - Class 8 Truck with 80,000 lbs. GVW Detroit, MI to Carlisle, PA
100
10
90 80 70 Load [%] 60 50 40
6 10 14
14 10 6
30 20 10 0 400 600 800 1000

6
1200 1400 1600 Speed [rpm]
1800
2000
2200
In addition to the project objective of peak thermal efficiency at a single operating condition, emphasis placed on fuel economy (equivalent thermal efficiency) during over-the-road representative cycles
D e t r o itD ie s e lS t a n d a r dT e m p la t e .p p t4
Thermal Efficiency Status
Integrated Experimental and Analytical Results Peak Thermal Efficiency at a Single Operating Condition
Roadmap for >50% Equivalent Thermal Efficiency Being Developed Technologies to Achieve 50.2% Thermal Efficiency Demonstrated
Phas e
I I -B
FY05 Joule Milestone Demonstration
NZ-50 Phase I Demonstration
Phase II-B Interim Results
Phase II-A Interim Result
Phase I Phase II-A

Current Production Engines
Out-of-Box with 07 Emissions
Thermal Efficiency Roadmap - Key Building Blocks
Peak Thermal Efficiency at a Single Operating Condition
Increased Turbo System Efficiency Variable Breathing Aftertreatment Back-pressure Reduction Parasitic Loss Reduction Higher Compression Ratio (Higher Peak Firing Pressure) High Efficiency NOx Aftertreatment Exhaust Energy Recovery (Turbo-compounding)
Selective Implementation of Low Emissions Combustion Basic NOx Aftertreatment Integration
Combustion Optimization Distributed Injection Events EGR Cooling System Optimization Charging and Breathing Efficiency Improvement Basic Exhaust Recovery
Progress Towards Near-zero Emissions

Experimental Multi-Cylinder Engine Results
System-out Emissions Demonstrated to be Below 2010 Emissions Levels over Representative Over-the-road Conditions
Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved. Detroit Diesel Standard Template.ppt
Progress Towards Near-zero Emissions

Experimental Multi-Cylinder Engine Results
Integrated System/ Controls Optimization
Conventional Combustion Optimization
Selective Implementation of Low Emissions Combustion
EPA 2010 System-out Emissions Levels Demonstrated over Transient FTP

Conclusions
DDCs Integrated System Development Approach

Transient Multi-cylinder Development Validates Steady-state Development; Simulates Vehicle Vehicle Development Validates Transient Development; Identifies Baseline for Next-generation
2010+ Technology
Steady-state Multi-cylinder Development Validates Analysis; Simulates Transient
Conceptual Targets Identified via Analysis
10
NZ-50 Phase II-B Technology Integration

Builds on Phase I, Phase II-A
Phase I, II-A Demo Transferable Technology
2010+ System-level Boundary Conditions
Advanced Transient Combustion & Emissions
Model-based Control Strategies Phase II-B
Fuel System Flexibility
Next Generation EGR System & Exhaust Recovery Concepts

Integration of Aftertreatment Technologies

11
NZ-50 Phase II Multi-cylinder Test-beds
NZ-50 Phase II Test-beds based on Multi-cylinder Series 60-2007 (shown above) and Prototype Heavy-duty Engine Prototype Heavy-duty Engine Test-bed Equipped with Exhaust Energy Recovery Hardware and Increased Peak Firing Pressure Capability Test-beds Equipped with Multiple-leg Exhaust System with Bypass to Provide Flexibility for Testing Engine-out and Tailpipe-out Configurations Test-beds Equipped with Multiple Emissions Sampling Capability to Provide Spatial and Temporal Resolution of Exhaust Species for Low Emissions Combustion
12
Conclusions
13
Example Combustion System Result Low Emissions Combustion Development on NZ-50 Phase II-B Engine Demonstrated Up to 70% Load (~15bar BMEP)
Low Emissions Combustion
Technical Demonstration of EPA 2010 Emissions Engine-out However, Technology not Viable for Commercialization in the Near-to-Mid Term due to Significant Thermal Efficiency Deterioration
In-cylinder Spatial Distribution of Temperature and Equivalence Ratio for Traditional Diffusion Limited Combustion and Low Emissions Combustion DOE-DDC Light Truck Program CY2002
14
Example Fuel Injection / Controls System Result Technology Demonstration of Precise, Distributed Injection Events
Simulated NZ-50 engine cam/crank timing configuration 5 injection events with 360 to 360 CA injection timing span There is overlapping of injection among six cylinders
Cam Signal
720CA
Injector #1
Injector #3 240CA Crank Signal
TDC
15
Example Air and EGR System Result Variable Breathing Optimization of Exhaust Valve Event and Intake Valve Event Using Design of Experiments
10 9 BSFC Improvement (%) 8 7 6 5 4 3 2 1 0 A25
BSFC
BSFC
Various Modes B25 C25Engine B50 Operating A75 C75 A100 B100
Comprehensive Engine Cycle Simulation Model Developed and Calibrated Model Coupled with Design of Experiments and being Utilized to Analytically Optimize Engine Breathing Events to Reduce Pumping Losses, for Thermal Management and for In-cylinder Temperature Control for Low Emissions Combustion Initial Application of the Model over Steady-state Operating Conditions, Followed by Application over Transient Conditions
16
Example Controls and Calibration System Result Model-Assisted Total System Calibration and Optimization Demonstrated improvement in FTP emissions (NOx, CO) and fuel economy Method emerging as a promising tool for calibrating and optimizing increasingly complex total system comprising engine, aftertreatment (NOx and PM) and vehicle systems The next step involves 2nd iteration of model generation and experimental validation over steady state and transient
Baseline
Optimized window showing improvement in NOx, Smoke and BSFC Analytical example shown here demonstrates ~6% reduction in fuel consumption and over 20% reduction in NOx and smoke emissions
17
Example System Integration Result Demonstration of Transient EPA 2010 Emissions over FTP Cycle Experimental Multi-Cylinder Engine Results
Integrated System/ Controls Optimization
Conventional Combustion Optimization
Selective Implementation of Low Emissions Combustion
EPA 2010 System-out Emissions Levels Demonstrated over Transient FTP

18
Conclusions
19
2004 vs. 2007 DDC Fuel Economy Comparison
Testing showed EPA07 engine to be within 1% of the EPA04 engine. All runs were within 2% variance. This test was a preliminary look at EPA07 vs. EPA04 Fuel Economy.
20
Conclusions
Demonstrated Technologies, via Integrated Experiments and Analysis, to Achieve the Technical Objectives of the DOE-DDC Heavy Truck Project (NZ-50)
9 50.2% Peak Thermal Efficiency at a Single operating Condition 9 EPA 2010 Emissions Regulations over Steady-state and Transient Operation
Significant Risks and Challenges Remain for Application and Commercial Viability of Some of the Technology Enhancements However, Collaborative DOE-Industry Programs Lay a Strong Technology Foundation for Subsequent Industry-led Product Development to Address These Challenges Forward Engineering Methodologies Enabled by Analytical Tools were Beneficial to Develop and Validate the Technical Roadmap to Enhance Thermal Efficiency and Reduce Emissions
21
Acknowledgements
DOE-DDC Collaborative Heavy-Truck Project (NZ-50) Department of Energy, HQ

9 Gurpreet Singh 9 Roland Gravel
National Energy Technology Laboratory

9 Carl Maronde 9 Jeffrey Kooser
22

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Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations

Detroit Diesel Standard Template.ppt

Detroit Diesel Standard Template.ppt

Detroit Diesel Standard Template.ppt

Emphasis on Enabling Sub-system Technologies

NZ-50 Multi-cylinder Test-bed

Detroit Diesel Standard Template.ppt

Representative Over-the-Road Truck Route

30 20 10 0 400 600 800 1000

1200 1400 1600 Speed [rpm]

Thermal Efficiency Status

FY05 Joule Milestone Demonstration

NZ-50 Phase I Demonstration

Phase II-B Interim Results

Phase II-A Interim Result

Phase I Phase II-A

Out-of-Box with 07 Emissions

Detroit Diesel Standard Template.ppt

Thermal Efficiency Roadmap - Key Building Blocks

Peak Thermal Efficiency at a Single Operating Condition

Selective Implementation of Low Emissions Combustion Basic NOx Aftertreatment Integration

Detroit Diesel Standard Template.ppt

Progress Towards Near-zero Emissions

Progress Towards Near-zero Emissions

Integrated System/ Controls Optimization

Conventional Combustion Optimization

Selective Implementation of Low Emissions Combustion

EPA 2010 System-out Emissions Levels Demonstrated over Transient FTP

Detroit Diesel Standard Template.ppt

DDCs Integrated System Development Approach

Steady-state Multi-cylinder Development Validates Analysis; Simulates Transient

Conceptual Targets Identified via Analysis

Detroit Diesel Standard Template.ppt

NZ-50 Phase II-B Technology Integration

Phase I, II-A Demo Transferable Technology

2010+ System-level Boundary Conditions

Advanced Transient Combustion & Emissions

Model-based Control Strategies Phase II-B

Fuel System Flexibility

Next Generation EGR System & Exhaust Recovery Concepts

Integration of Aftertreatment Technologies

Detroit Diesel Standard Template.ppt

NZ-50 Phase II Multi-cylinder Test-beds

Detroit Diesel Standard Template.ppt

Detroit Diesel Standard Template.ppt

Low Emissions Combustion

Detroit Diesel Standard Template.ppt

Injector #3 240CA Crank Signal

Detroit Diesel Standard Template.ppt

10 9 BSFC Improvement (%) 8 7 6 5 4 3 2 1 0 A25

Detroit Diesel Standard Template.ppt

Integrated System/ Controls Optimization

Conventional Combustion Optimization

Selective Implementation of Low Emissions Combustion

EPA 2010 System-out Emissions Levels Demonstrated over Transient FTP

Detroit Diesel Standard Template.ppt

2004 vs. 2007 DDC Fuel Economy Comparison