MD/HD CO2 Reduction by Hybridization & WHR

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
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)
EPA CO2e (CO2 N2O, CH4 caps BC)
Tighter EPA Regs
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
Fuel consumption evolution in EuropeACEAs
Goal() 20 Fuel consumption reduction by 2020
Assume vehicle
10 mpg per CCJ 3/31/10 quoting DTNA _at_ 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/1
2845.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
Hybridization impact on conventional powertrain
-Combustion engine selection (downsized)
operation (less transient)
Ref DTF 3-08 Volvo
12
Combustion Engine Downsizing -Example (MB
Citaro G)

• Conventional
• 12l, OM 457 LA
• Hybrid
• 4.8l, OM 924 LA
• Compensation for torque power
• 4 wheel hub electric motors, ea. _at_
• 60 kW continuous
• 80 kW peak

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
Series Electric Class 8 Truck City Bus w/ Range
Extender-Freightliner Columbia
(Parker-Artisane-Capstone), ZEM (Italy)
Parker, HTUF 2010 http//zemplc.com/technology.ph
p
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/hyb
rid_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
Context Engine based fuel economy levers
Reduced pumping losses -intake -exhaust (e.g. A/T)
Heat Energy Recovery
Energy Flow Chart _at_ B50 point of a 290kW engine,
Behr, Wien 2009
29
Heat Energy Recovery Approaches
30
BMWs 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, gt10ltrs and with 2010 emissions
compliance
32
Cummins Example-showing R245fa working fluid
Cummins, SIAT Jan. 2011
33
Iveco Glider-Concept Vehicle

• Condensor
• ExpanderTurbine
• Boiler

Lastauto Omnibus 12/2010
34
Expander machines under consideration
35
RD ongoing for expander machines

• Turbine
• High rpm speeds
• Piston
• e.g. Voiths Steam Expander
• 2 cylinder, 0.75l displacement
• Rotary/Sliding Vane
• Axial piston rotary
• Considerations
• Expansion ratio
• Ability to handle wet vapor (Xlt1), 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 -gt 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!