MD/HD CO2 Reduction by
Hybridization & WHR
Technology Impact on Emission Control
Dr. Uwe Zink,
Corning Incorporated
Director, Emerging Industry Technology
April 4, 2011
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Agenda
CO2 Context
Hybridization
 Motivation
 Powertrain implication
 Aftertreatment design considerations
 Technology sorting
Heat Energy Recovery Approaches in Industry
 Rankine cycle considerations
Summary
2
CO2 Context &
considerations
On-Road focus
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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)
2011
2012
2013
2014
DoE SuperTruck
Vehicle fuel eco demo
2015
2016
2017
2018
2019
DoE: +50% freight efficiency
Prototype demo
2020
2021
2022
2023
2024
ACEA: 20% reduction goal (*)
DAG’s “Shaping Future Transportation” (*)
“Road to Emission Free Mobility (LD & HD)”(*)
CO2/Fuel Eco - Government / OE Initiatives
(*): www.Daimler.com, MTZ 1-’09, http://www.cat.com/sd2009, http://www.deere.com/en_US/globalcitizenship/stewardship/metrics.html
4
Fuel consumption evolution in Europe
ACEA’s Goal(*): 20% Fuel consumption reduction by 2020 –Assume vehicle
-20%
10 mpg per CCJ
3/31/10 quoting
DTNA @ MATS
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(*) MTZ 1-’09, Daimler SAE Gothenborg 9-’10
CO2 & fuel consumptions measures
-Aerodynamics, vehicle weight, engine, tires, drivetrain
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Ref.: Technologies and Approaches to Reducing the Fuel Consumption of Medium- and Heavy-Duty Vehicles, April 2010; http://www.nap.edu/catalog/12845.html
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)
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MD/HD-Vocational Applications are Targets for Hybridization High
Potential for Braking Energy Recovery
Kinetic Energy Loss Comparison of Various
Types of Medium and Heavy Vehicles
100%
39
80%
31
47
4
60%
23
18
Rolling
11
40%
65
50
59
20%
35
Aero
Braking
18
0%
Delivery
5/07 Michigan Clean Fleet Conference
Bus
Refuse
Vehicle Type
Class 8
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Targeting combustion engine operation at optimum BSFC points
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Ref: Hydraulic Hybrid Vehicle System Panel
10
Ricardo, SIAT Jan 2011
Hybridization impact on conventional powertrain
-Combustion engine selection (“downsized”) & operation (less
transient”)
Ref: DTF 3-08 Volvo
Diesel Engine Operation
Steady State
Transient
“Hybridization”
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Combustion Engine “Downsizing” -Example (MB Citaro G)
Conventional:
 12l, OM 457 LA
OM 457 LA
Hybrid:
 4.8l, OM 924 LA
OM 924 LA
1900
 Compensation for torque &
power
 4 wheel hub electric
motors, ea. @
1500
OM 457 LA
 60 kW continuous
800
OM 924 LA
400
1000
1400
1800
2200 rpm
 80 kW peak
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Mercedes Benz Website http://www.mercedes-benz.de
Cost, Certification & OBD issues need to be resolved
13
Navistar, HTUF 10/2009
HILS – Making its way into MD/HD Homologation Procedures
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J-MLIT at ACEA Mtg Dec.3, 2009: A Global Approach to Sustainable Freight Transport
Outlook: Waste Heat Recovery in combination with Hybrids
“Integrated Powertrain and Vehicle Technologies for Fuel Efficiency Improvement and CO2 Reduction”, DDC, DEER 2009
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Aftertreatment Design
Considerations
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Multiple drivers for aftertreatment requirements
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A/T Impact of Hybridization on Freightliner M2
DPF Regeneration Interval
increases
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Freightliner, HTUF 10/2009
A/T Impact of Hybridization on Freightliner M2
DPF Regeneration Interval
increases
19
Freightliner, HTUF 10/2009
Series Electric Class 8 Truck & City Bus w/ Range Extender
-Freightliner Columbia (Parker-Artisane-Capstone), ZEM (Italy)
Emissions are very low…
aftertreatment likely not
needed.
Parker, HTUF 2010; http://zemplc.com/technology.php
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LD Example (Prius III, 1.8l ICE) -Intermittent ICE Operation, Lower
exhaust gas temps & aggressive catalyst heating
Aggressive Catalyst Heating in Prius
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Umicore, 4/2010
Market dynamics
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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)
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Current offerings (NAFTA)
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http://www.afdc.energy.gov/afdc/vehicles/heavy/hybrid_systems
Hybridization Market Triggers
Fuel prices
-some anticipate $4++(US)
CO2 regs
-getting into place
Tax incentives
-key to mitigate
Cost reduction
-significant effort needed
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Three areas that could affect A/T for the ICE
Time frame
Enabler
A/T - Impact
Short /
Medium
Serial Hybrid,
Downsizing, NR:
possible avoidance
(kW-segment specific)
ICE 1.
Downsizing
High battery capacity
Parallel Hybrid:
medium potential
2. Modified ICE ops cycle
3.
Homologation
/ Certification
Medium /
Long
Above and OE
focused effort
Functional shift
Long
Regulatory
approaches, new cert
cycles / limits
Potential functional
reduction
Light-off, heat retention
importance
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Heat Energy Recovery
Approaches
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Context: Engine based fuel economy levers
Reduced pumping losses
-intake
-exhaust (e.g. A/T)
Heat Energy
Recovery
38.7%
Engine Hard/Software,
NOx calibration,
A/T Efficiency
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Energy Flow Chart @ B50 point of a 290kW engine, Behr, Wien 2009
Stanton, Deer 2009
Heat Energy Recovery Approaches
Turbo
Turbo
Process Heat
Thermoelectric
Charging
Compounding
(e.g. Rankine Cycle)
Series production
Series production
Emerging
Emerging
LD & HD
HD
HD
LD
e.g. 1953 on DC-7, Wright 3350
and later up to today on HD as
well (CAT, Cummins, DAF, Hino,
Scania, Volvo, DDC/DAG)
MAN’s
Thermo Efficiency System,
Marine & Stationary
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BMW’s TEG in EGR Loop
4 cyl Diesel engine
EGR Cooling
TEG
Suggested to move to exhaust
system location for higher recovery
(500W rather than 100W on EGR)
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Ref: BMW, 5th Emission Control, Dresden, 6/10
Mechanical/Electrical Turbocompounding
-extracting heat upstream of aftertreatment
DDC Mechanical Turbocompounder
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Bowman Industries, SAE ComVec 2009
Cummins Example
-showing R245fa working fluid
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Cummins, SIAT Jan. 2011
Iveco Glider
-Concept Vehicle
•Condensor
• Expander:Turbine
• Boiler
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Lastauto Omnibus 12/2010
Expander machines
under consideration
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R&D ongoing for expander machines
Turbine
 High rpm speeds
Piston
 e.g. Voith’s “Steam Expander”

2 cylinder, ~0.75l displacement
Rotary/Sliding Vane
Axial piston rotary
Considerations:
 Expansion ratio
 Ability to handle wet vapor (X<1), i.e. two-phase flow with droplets
 Working fluid compatibility
 GWP
 other
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Working Fluids under
Consideration
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Rankine Working Fluid candidates
R245fa, Ethanol, Water, Water/Ethanol, other
Choice based upon:
•Critical point
•Decomposition temperature
•Slope of saturated vapor line
•Environmental/Safety aspects
•other
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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
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Technologies emerging that will have an impact on aftertreatment
design -> 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
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Thank you for your
kind attention!
Questions are welcome!
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