Cummins 2010
Update
EPA NA Emission Standards
5.0
4.5
NOx – g/hp-hr
4.0
EPA ’98
3.5
3.0
2.5
EPA ’02
2.0
1.5
EPA ’07
1.0
0.5
EPA ’10
0.0
0.0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
Particulate – g/hp-hr
2
0.09
0.10
0.11
0.12
0.13
Global On-Highway Standards
5.0
4.5
NOx – g/hp-hr
4.0
U.S. ‘98
3.5
EURO IV
3.0
2.5
EURO V
2.0
U.S. ‘02
Japan 05
Japan 09
1.5
US ‘07
1.0
0.5
U.S.10
0.0
0.0
0.01
0.02
0.03
0.04
0.04
0.05
0.06
0.07
Particulate – g/hp-hr
3
0.08
0.09
0.10
0.11
0.12
Diesel Exhaust Fluid
(DEF)
Diesel Exhaust Fluid (DEF)
 Diesel Exhaust Fluid is 32.5% strength urea water
solution with high purity requirements. The
specification of Diesel Exhaust Fluid is currently
defined according to the DIN 70700 and the ISO
22241-1 specifications.
 Water purity: ISO grade 3, produced for example by
single distillation, de-ionization, ultra-filtration or
reverse osmosis.
5
DEF Specifications
 ISO 22241-1 Quality and handling requirements: Standard used for
bidding specifies the quality characteristics of DEF needed to operate the
SCR system on your vehicle. It is a final, published International Standard.
 ISO 22241-2 Test methods, specifies test methods required for
determination of the quality characteristics of DEF. It is also a published
International Standard.
 ISO/DIS 22241-3 Handling, transportation and storing, describes how to
deal with DEF in practice. It is much like the CEFIC QAGD above. It is also
a published International Standard.
 ISO/DIS 22241-4 Refilling interface, describes elements relating to refilling
components. Draft has been submitted for approval and final version is due
in 2009.
6
Why 32.5% for DEF?
 The eutectic 32.5% wt
urea-water solution is the
preferred form for use in
SCR
- A eutectic mixture is a
mixture of two or more
phases in a composition that:
1) has the lowest freezing point
and 2) where the phases
simultaneously crystallize to
maintain the solution’s
concentration
7
32.5% urea/water solution has
the lowest freezing
temperature -11°C (11°F)
Why 32.5% for DEF?
 The 32.5% solution provides the lowest crystallization
point while also maintaining the solution in constant
phase
– Urea and water freeze together at 11° F so the frozen solution
has the same 32.5% wt
– When thawed it will remain at the same concentration of urea
solution feeding the SCR system
 What happens at different concentrations of Urea …
– Greater concentrations → Urea freezes before water
– Reduced concentrations → Water freezes before Urea
8
DEF Properties
 Non-toxic and non-flammable
 Safe to handle and store
 Poses no serious risk to humans,
animals, equipment or the
environment if properly handled
 The product is slightly alkaline
with a pH of approximately 9.0
9
Acidic pH
Cummins Aftertreatment System
Architecture
DEF Dosing Valve sprays a fine
mist of DEF into hot exhaust stream
Cummins Particulate Filter
Selective Catalytic Reduction (SCR)
Catalyst
Decomposition occurs in 3 steps
within the Decomposition Reactor
•
Step 1: Evaporation
•
Step 2: Thermolysis
•
Step 3: Hydrolysis
10
DEF Storage
 Shelf life of DEF is a function of ambient storage
temperature
 ISO Spec 22241-3 details the Storage, Handling
and Shelf Life minimum expectations for DEF
throughout the distribution chain
 Expectations for shelf life as defined by ISO
Spec 22241-3 are the minimum expectations for
shelf life when stored at constant temperatures
11
DEF Storage Data
 With extrapolation, the
storage viability for
DEF stored at
temperature higher
than 70ºC (158ºF) is
short
 Although certain
storage data exist, the
decomposition data at
elevated temperature is
still necessary and is in
progress
12
DEF Freeze Point
 Freezing of DEF begins at about 11°F
 Once the DEF has melted, it can be used without
problem. The first melted drop has the same
consistency as defined in the Diesel Exhaust Fluid
specification
 The SCR system is designed to provide heating for the
DEF tank and supply lines which will reduce the
melting time for frozen DEF
 If DEF freezes, start up and normal operation of the
vehicle is not inhibited so the operator is not impacted
13
DEF Storage & Handling
Recommendations
 Storage temperature below 86° F is recommended
to maintain shelf life
 Storage temperature above 11° F is recommended
to avoid freezing
 The maximum temperature of stored diesel exhaust
fluid on the vehicle should not exceed 122º F
14
DEF Storage & Handling
Conclusions
 DEF will degrade in time and this is dependent on
temperature and exposure to sun light
 Stated shelf life is based on continuous exposure to
heat and sunlight. In reality, continuous exposure is
unlikely
 Concerns over ‘shelf-life’ have been over-stated
15
DEF Quality System API Certification
 Currently, the mark has not yet
been approved.
 Most likely it will feature the full
name American Petroleum
Institute in a square quality
symbol
 Website address likely a form of
'API-DEF.org/.com/.net'
– Licensing renewal on an
annual basis
– Fees still TBD
16
DEF Service Tool
 A service tool called a refractometer is in
development.
 The refractometer measures the concentration
of urea in the DEF.
 May provide one quick, simple way for urea
quantification.
17
DEF Infrastructure
 Major investments in DEF production, pump and
container equipment, transportation and
distribution channels to serve the on-highway
market are being made now and will be in place
by 2010
 Pilot Travel Centers recently announced their
intent to carry DEF at the pump
18
Urea Producers
2007 Domestic Urea Capacity
PCS Nitrogen
12%
CF Industries
40%
Terra Industries
16%
Agrium
11%
Others
21%
8.2 Million Tons
19
 Terra Environmental Industries
 Potash Corporation / PCS
 CF Industries
 Agrium
 Other Market Players
– Industrial Services Solutions
– Yara
– Dyna Nobel
DEF Producers
 Terra Environmental Industries
– Considered to have a leadership position in the market
– Currently manufacture a DEF product: TerraCair™
UltraPure DEF (urea liquor)
– Has 4 manufacturing plants
– Currently pursuing partnerships to create North American
Distribution network
20
DEF Producers
 Yara
– Global chemical company that produces and sells
industrial gases and chemicals primarily in Europe,
but also has a presence in several Asian and African
countries
– Largest producer of AdBlue in Europe and interested
in the US DEF market
– Brenntag is their European distribution counterpart
21
DEF Producers
 Dyno Nobel
– Leading supplier of industrial explosives and blasting
services to the mining quarrying and construction
industries
– Produces DEF under the name DYNOx32
– Announced distribution agreement with CervantesDelgado, a marketing and distribution company
focusing on urea solutions for SCR systems, in 2007
22
DEF Producers
 PotashCorp / PCS
– Integrated producer of fertilizer, industrial and animal
feed products
– Claim to be the world’s largest fertilizer producer
– Currently manufacture high purity granular urea
– Exploring partnerships for distribution
23
Potential DEF Producers
 Agrium
– Major supplier of specialty fertilizers in the US
– Has been investigating the DEF opportunity
 Industrial Solution Services
– Has been in the industrial urea business and has storage and
distribution capacity in the US
– Is taking steps to supply the mobile market in the US
 CF Industries
– Major Urea producer in the US
– Interest in the DEF market is currently unknown
24
Example of a Major Distributor’s DEF
Infrastructure System
 Brenntag is the world’s leading chemical
distribution company
Blending
Blending, stocking, and /or
repackaging the bulk
material.
Inventory
Product arrives from
the manufacturer by
rail or truck to one of
our many hubs
located across North
America.
Product is delivered from the
hub directly to the customer.
or delivered closer to the
customer for JIT delivery.
25
Specialized Urea
 New reagent “Denoxium”
– Developed by Kemira Oyj Industrial
Chemicals in Finland
– Mixture of urea, ammonium formate and pure
water, and meets the DIN 70070 standard
– Claims to be “fully compatible and
interchangeable with DEF”
– Usable down to -30oC (-22oF) which may
eliminate the need for heating systems on
DEF tank and lines
– Performance difference between DEF and
Denoxium not understood - manufacturers
own data shows differences in NOx
conversion performance
– Not approved by CES due to corrosion issues
in DEF doser pump
26
What is the Real Price for Engine
Quality DEF?
 Automotive quality DEF is only slightly more expensive
to produce as it requires a higher purity urea base stock
and deionized water
 Higher prices are associated with small containers and
low volume suppliers
 DEF prices loosely follow natural gas commodity prices
so these numbers will change if there is a significant shift
in NG
 Also, we have heard some suppliers may have
aggressive discounting initially to gain market share
27
Diesel Exhaust Fluid (DEF)
Availability and Accessibility
 Cummins plan for DEF availability and accessibility
– We will use the existing Cummins Customer Assistance
Center 1-800-DIESELS
• Ensure they have the tools to locate DEF for customers
– Dealer/distributor DEF stocking locations
– DEF locator websites
• Offer shipment of DEF to a
customer, who is not able to
obtain DEF locally, by putting
the customer in touch with the
closest Cummins
distributor/dealer
(shipping/handling at the
expense of the customer)
EPA 2007 Dealers
28
Current DEF Existence in
North America
 Cummins Filtration
 The products are blended with high purity
synthetic Urea dissolved in deionized water
 The finished formulation is further filtered to
protect internal SCR system components and
enhance catalyst life
29
SCR System Review
Cummins Aftertreatment System
Selective
Catalytic
Reduction
(SCR)
Catalyst
Cummins
Particulate
Filter
31
Decomposition
Reactor
Diesel Exhaust
Fluid (DEF)
Dosing Valve
32
Cummins Aftertreatment System
33
Cummins Aftertreatment System
DEF Dosing Valve
Cummins Particulate Filter
Decomposition
Reactor
Selective Catalytic Reduction (SCR)
Catalyst
ENGINE-OUT
EGR
PM
NOx
PM
PM
Filter
Filter
ENGINE-OUT
SCR
SCR
0.01
34
TAIL-PIPE OUT
0.2
TAIL-PIPE OUT
Cummins Aftertreatment System
 Cummins Emissions Solutions:
– Particulate Filter / Decomp Reactor / SCR Catalyst
– Control Module / DEF Pump / DEF Valve / NOx sensor
 Certification includes specified SCR system
and controls.
 OEM's are required to install the system
defined in the certification process.
35
Low DEF Warning & Inducement
DEF (Urea) Tank Level
Notification*
Lamp
>10% full
E
F
Stage 1
<10% full
E
F
Stage 2
<5% full
E
<2.5% full
Stage 4
E
F
F
Empty, after the engine
has been shut down
36
*Preliminary
Message
None
None
None
DEF lamp solid
Warning message
None
DEF lamp flashing
Increasing
message
duration and/or
frequency
None
F
Stage 3
E
- or -
Inducement
DEF lamp flashing
Amber warning lamp solid
DEF lamp flashing
Red lamp solid
Maintenance
derate
(12 -17%
torque derate)
Inducement
message
Vehicle speed
limited to 5 mph
Incorrect DEF Warning & Inducement
Notification*
DEF (Urea Mixture)
Lamp
- or -
Inducement
Message
Correct DEF
None
None
None
Incorrect DEF
Amber Lamp Solid
Warning
message
None
Incorrect DEF
+ 10 hrs
Amber Lamp Solid
Inducement
message
Incorrect DEF
+ 20 hrs, after engine
has been shut down
37
*Preliminary
Red Lamp Solid
Maintenance
derate
(12 -17%
torque derate)
Vehicle speed
limited to 5
mph
How Can I Determine how Much DEF
I will Use?
Example…Heavy duty
Annual miles for average truck = 120,000 miles
MPG for average truck = 6 mpg
120,000 miles / 6 mpg = 20,000 gallons diesel fuel per year
DEF usage @ 2% of fuel consumption = 400 gallons of DEF / year
400 gallons / 20 gallon tank (average size) = 20 DEF fill-ups / year
38
Example Only
How Can I Determine how Much DEF
I will Use?
Example…Medium Duty
Annual miles for average truck = 50,000 miles
MPG for average truck = 10 mpg
50,000 miles / 10 mpg = 5,000 gallons diesel fuel per year
DEF usage @ 2% of fuel consumption = 100 gallons of DEF / year
100 gallons / 10 gallon tank (average size) = 10 DEF fill-ups / year
39
Example Only
How Much DEF Will I Use?
 Approximately 2% DEF consumption
40
2010 Aftertreatment Dash Lamps
 HEST Lamp
– High Exhaust Temperature
 DPF Lamp
– Diesel Particulate Filter
 Diesel Exhaust Fluid Lamp
– Low level warning
MIL Lamp
 Malfunction Indicator Lamp
– OBD (On-board Diagnostics)
– Emissions non-compliance indication
41
2010 Engine
Platforms
2010 Engine Platforms & Ratings
43
 ISB6.7
200-325 HP
 ISC8.3/ISL9
260-380 HP
 ISX11.9
310-425 HP
 ISX15
400-600 HP
2010 Technology
 MidRange & Heavy Duty Platforms
– ISB6.7, ISC8.3/ISL9, ISX11.9 (new), ISX15
– All utilize common subsystems, e.g. ECM, VGT, EGR, Aftertreatment
 XPI fuel system – High Pressure Common Rail
– Ultra high injection pressure
– Multiple injections per cycle
 SCR aftertreatment - MR & HD 2010
– Breakthrough SCR Technology
– NOx conversion efficiency 90% on-highway
44
Cummins XPI Fuel System
 Common rail system
 Ultra high injection pressure
 Pressure available on demand
 Multiple injections per cycle
45
2010 MidRange
 Comparable Fuel Economy relative to 2007
 Reliability improvement
– Regeneration capability in broad range of duty cycles
 NOx/PM ratio favorable for DPF passive regeneration
 Same service intervals
– Oil change interval same as 2004 & 2007
– Ash cleaning interval 200K-400K miles
– Crankcase breather interval 120-150K miles
– DEF supply pump filter 200K miles
46
2010 Heavy Duty





Up to 5% MPG advantage versus ’07 HD engines
No increase in EGR rates
No increase in heat rejection
NOx/PM ratio favorable for DPF passive regeneration
Same service intervals
– Oil change interval same as 2004 & 2007
– Ash cleaning interval 200K-400K miles
– Crankcase breather interval 120-150K miles
– DEF supply pump filter 200K miles
47
Our Commitment
 Right Technology
 On Time
 Depend On Cummins
48