advanced egr 2010 emission compliant

8/10/2019 Advanced EGR 2010 Emission Compliant

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ADVANCED EGR2010 Emission Compliant

MF_Advanced_EGR_Book[p].indd 1 12/17/08 10:13 AM


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EPA Regulations

EPA regulations for NOx(Oxides of Nitrogen) andPM (Particulate Matter or soot) have tightened.

In 2010 NOxemissions must be reduced from 1.2 g/bhp-hr

(grams per brake horsepower hour) to 0.2 g/bhp-hr.

WHAT IS NOx?The atmosphere is 78% Nitrogen. High combustiontemperatures inside an engine form NOx. Once in theatmosphere, NOxresults in ground level ozoneformation and smog.

5.0

500 PPM(6/93)

SULFURContentIn Fuel

NOx

(g/bhp

-hr)

Particulate Matter (g/bhp-hr)

ULSD

15 PPM(6/06)

4.0

2.5

1.2

0.20.0

0.0 0.01 0.10

How can we control NOxemissions? Either by addingmore equipment to the exhaust system to clean them

up, or by reducing combustion temperatures to avoidcreating the NOxin the first place.



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EPA vs. Euro Standards

EPA regulations in the US are alsotypically adopted by Canada.

The European Unions latest standardsare referred to as Euro V.

European manufacturers began usingSCR to meet Euro IV emissions levelsin 2005 and many will continue to doso in 2008.

We have been able to meet thechallenge of our stricter US EPA

emissions levels that went into effectin 2004 and 2007 with EGR systems.

NOTE: Euro requirements are typically lessstringent than the EPA requirements.

5.00

EPA941994

Euro II EPA98 Euro III EPA04 Euro IV EPA07 Euro V EPA10 Euro VI1996 1998 1999 2004 2005 2007 2008 2010 2013

EPA941994

Euro II EPA98 Euro III EPA04 Euro IV EPA07 Euro V EPA10 Euro VI1996 1998 1999 2004 2005 2007 2008 2010 2013

NOx

(g/bhp-

hr)

PM(

g/b

hp-

hr)

5.22

4.00 3.73

2.50 2.61

1.20 1.49

0.200.37

0.10

0.186

0.10 0.075 0.10

0.015 0.01 0.015 0.01 0.007

NOx

PARTICULATE MATTER

SCR was adopted when competing technologies were not ready to meet thestandards. It was presented and pushed by manufacturers of the technology,and the infrastructure to support SCR was mandated by European legislation.

Manufacturers now have competing technology solutions available, and thestricter requirements of EPA 2010 mean that Euro V experiences are not

directly applicable.

EPARegulations&Stamdards




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T

T

DieselParticula

teFilter

EGR - Cooler

OxidationCatalyst

T

P

NOxNOxT Urea Doser

Tank must beinsulated and

heated

Clean Air

Level Sensor

Urea TankNH3Slip Cat

ChargeAirCo

oler

SCR Catalyst

Urea

Tank

One method of moving from the 2007 to 2010 emissions level is to take the current EGRsystem and add SCR, Selective Catalytic Reduction, to clean up the NOxemissions and

meet the 2010 standards.

The engine includes an EGRsystem, much like todays engines,and it creates exhaust whichincludes particulate matterand NOx

Exhaust passes through theoxidation catalyst and on to theDPF, which cleans the soot. Fromthere, the exhaust passes to theSCR catalyst

There is a urea tank located nearthe exhaust system. This tank mustbe continuously monitored forurea level. The tank must also beinsulated and heated.

Pump supplies urea to the SCRinjection system

The injector sends the urea into theSCR catalyst

Urea mixes with the exhaust gasesand turns into ammonia and carbondioxide, then reacts with NOxtoproduce nitrogen and water vapor

The end result of this process islowered levels of NOxto meet theEPA 2010 emissions standards

EGREGR

SCRSCR

2007 NOxLevel

2010 NOxLevel

Emissions Solutions

SCR



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An alternative solution involves refining the EGR (Exhaust Gas Recirculation) systemcurrently in place to provide an in-cylinder solution. Rather than continuing to create NOx

and then having to clean it up, an in-cylinder solution is designed to prevent the NOxfrombeing formed in the first place.

SCR systems are projected to offer a slight improvement in fuel mileage, since they can allow theengine to run dirtier and then clean up the emissions later. However, they also require the addition of

diesel exhaust fluid or DEF, so the costs of operating the engines are similar.

In-CylinderEGR

2007 NOxLevel

2010 NOxLevel

In-CylinderEGR

EGR

Navistars 2010 compliantengines will be very similar tothe 2007 compliant engines,with no additional aftertreatmentcomponents or fluids required

Emis

sionsSolutions




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Urea + Deionized water = DEF(Diesel Exhaust Fluid)

The mix of urea used foragricultural applications willNOT work for diesel engines.

Contamination, Temperature and Storage ConcernsUrea is temperature sensitive and easily contaminated. Storage and dispensing

tanks must be heated and cooled. Vehicle tanks will need to be insulated and heated.

60 to 70F

50 to 60F

40 to 50F

30 to 40F

20 to 30F

10 to 20F

0 to 10F

10 to 0F

Below 10F

Winter AverageLow Temperature

Above 110F

100 to 110F

90 to 100F

80 to 90F

70 to 80F

60 to 70F

50 to 60F

Summer AverageHigh Temperature

12F / -11C

32F / 0C

85F / 30C

122F / 50CUrea begins to emitammonia gas

Urea begins tobreak down

Urea freezes

Above 85 F, the storage life of urea decreases rapidly.

Temperature (F)

StorageLife(months)

30

20

86 95 104 122 140

10

0

Deionized Water67.5%

Chemical Urea32.5%

All About Urea



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Urea Tank

Because Urea is temperature sensitive,this tank must be insulated AND heated.

SCR Hardware

Urea weighs 9.1 pounds pergallon. The complete SCR systemand fluid will add 300-400

pounds of weight to the vehicle.

What does it take to makean SCR system work?Trucks utilizing SCR for emissions reductionswill require significant additional hardwarebeyond todays exhaust packaging, resulting

in reengineering work for TEMs.

Additional parts, components andcomplex electrical interfaces couldreduce SCR system reliability.

48 36 24 12

0

12 24 36 48 60 72 (IN)

Urea Injector Supplyand Heating Lines

Urea Tank; Power Supply;Heating Unit; Pump

Battery Box &Air Tank Module

SCR CatalystAMOX CatalystShown canned including: Temperature Sensors; NOxSensor Electrical Clipping Bar and Mounts

Urea Injector

Added SCR Hardware

DPFDOC

Current Hardware

DEF Pump

TemperatureSensors

CatalyticConverter

UreaInjector

AftertreatmentControl Module



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EPA Requirements for SCR Systems

SCRHardwa

re&EPARequirements

You can think of urea as afuel because without it thevehicle cannot run legallyand must shut down,rendering the vehicle

useless to the customer.

UREA = FUEL

Without Urea, the Vehicle WILL NOT RUN

In March of 2007, the EPA issued a letter containing guidelines for the design and operation of SCR systems to be used onvehicles. Among these guidelines were a requirement that the SCR system be tamper-proof to prevent operation of the vehiclewithout fully functioning emissions controls in place, or with a fluid other than urea in the tank.

Although not final, EPA vehicle

compliance requirements indicatevehicles will have to be equippedwith sophisticated sensors to detectNOx in exhaust. If the sensors detectthat there is a bad urea solution orno urea is available, there will be four

progressive stages of warning andvehicle response.

DPF

HEST

UreaSolution

Urea Solution lamp added to already

complex EPA07 package

With a low urea level,a warning light will

appear which shouldbe augmented by anaudible warning.

1Next, the enginewill de-rate and

the driver willfeel a power loss.

2As the issueprogresses,

vehicle speedwould be limitedwell below typicaloperating levels.

3Finally, when thevehicle is shut

down, there will bea no start condition.

4




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The Advanced EGR Solution

How will MaxxForceand Navistarmeet the new emissions

Step 1Advanced Fuel Injection TechnologyOur next-generation fuel injection systems are capable of deliveringfuel into the cylinder multiple times per cycle and at higher pressures.Utilization of one or more pre- and post-injections along with themain injection event means combustion can take place over a

longer period and be more complete, resulting in less creation ofNOxemissions.

Step 2Proprietary Combustion Bowl DesignOur redesigned combustion bowl combines with the higher fuelinjection pressure to break the fuel up into a finer mist spreadmore evenly inside the cylinder, resulting in a more complete andcleaner burn.

Early Injection

Main Injection Event

TDC BDC

Post Injection

Extra Exhaust Hardware Extra Fluid

OLD DESIGNFuel not distributed evenly,burns inconsistently

NEW DESIGNFuel is a finer mist for a

smoother, more complete andcleaner burn



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Other Manufacturers Strategies

CaterpillarCaterpillar has announced that they are exitingthe on-highway engine market as of 2010.

Freightliner / Detroit DieselDetroit Diesel is driving towards commonengine platforms with parent companyMercedes and will be utilizing SCR to meetEPA 2010 emissions.

Peterbilt / KenworthIn addition to DAF engines from Europe thatutilized SCR, Peterbilt and Kenworth will utilizeSCR on their PX-6 and PX-8 engines based onthe Cummins ISB and ISC platforms.Cummins

Although they originally were going to useEGR, Cummins recently changed course andhas now announced they will add SCR systemsto their engines to comply with 2010 emissionsrequirements. The ISM will no longer be produced.

Mercedes-BenzMercedes has used SCR in Europe since2004, and is introducing it in the US forEPA 2010 as well as continuing to use it tomeet EuroV emissions.

Scania and MANWhile Scania and MAN have previouslyutilized SCR to meet EuroIV standards, bothcompanies recently announced a transitionto EGR technology to meet EuroV standardsgoing forward.

Volvo/MackVolvo and Mack will be utilizingcommon engine platforms in the future,

and Volvo will be carrying over theirSCR technology from Europe for usehere in the United States.



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OtherMan

ufacturersStretegies

EGR SCRFUEL ECONOMY:SCR may offer slightly improved fuel economy, but

the savings will be offset with the need to add Urea.

PRICE: The engineering and hardware costs of EGR andSCR are expected to be competitive.

MAINTENANCE: No extra fluids to fill, no additional systems to breakor parts or fluids to stock, and no new techniciantraining required.

DRIVERS: Nothing new to learn, no additional fluids to fill orworry about.

WEIGHT: With an SCR system weighing in at 300-400 poundsor more, EGR has a significant advantage at only70-100 pounds.

PACKAGING: No additional aftertreatment hardware means noreengineering for TEMs.

TRADE VALUE: If the rest of the industry begins utilizing advanced

EGR, what will SCR trucks be worth at trade-in?

The Choice is ClearAdvanced EGR from MaxxForce is the best solution

to meet the 2010 EPA emissions requirements. ADVANCED EGR2010 Emission Compliant



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But They Said...

The competition is making a lot of statements about NavistarsAdvanced EGR strategy. Here are some of their claims and the actual facts:

Navistar is using credits to meet the requirementsActually, this is true, but heres the rest of the story: the EPA supports the collection and use of

credits because it actually contributes to cleaner air. No company that collects and uses credits getall the credits back [one for one]. A percentage of them are held back. In other words if a companygenerated 100 credits, they are only able to use 80 of those credits in the future. The balance is thatcompanys contribution to the environment.

EGR is just temporary, theyll switch to SCR in 2012Navistar is committed to the path of EGR, now and in the future. As of 2012, credits will no longerbe allowed to certify engines to the 0.2g/bhp-hr standard. By that time, we will have fine-tuned ourengine systems and calibration to meet the standard at the tailpipe without credits or other additionalaftertreatment hardware.

Navistar is building a dirty engineNavistar has been a leader in clean diesel technology on many fronts; we were the first to marketwith electronic emissions controls in 1994, the first to introduce Green Diesel Technologyin 2000,with the first diesel engine with emissions equal to natural gas and most recently the first to mass-

produce a diesel-hybrid electric vehicle. The fact is, Navistar will be fully compliant with the clean airstandards in 2010 without the use of additional complex aftertreatment.

Navistar is the only manufacturer using creditsNavistar is the only manufacturer that builds enough engines cleaner than the current standard togenerate a surplus of credits that we can use in the future. All engine manufacturers have usedcredits over the last few years to achieve compliance across their product lines, and some will

continue to use credits after 2010.

SCR will cost less since it getsbetter fuel mileage

Remember that you also need to addthe cost of urea, so operating costs willbe comparable.

And its not just us saying that



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MaxxForceBig Bore Value Drivers

The company that has been a leader in diesel engine technology for years now offers big-bore power!

MaxxForce Big Bore atings

HP Torque (lb-ft)

330 1,250370 1,350

390 1,400

410 1,450

430 1,550

75 1,700

Special EquipmentAdds Versatility Optional engine

compressionretarder brake

Optional integral REPTOfor mixer applications

Programmable electronicparameters for increasedfuel economy

Optional FEPTO for snowplow applications



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MaxxForce

BigBoreValueDrivers

High Strength Without Added WeightNo engine offers a higher power-weight ratio thanthe MaxxForce big bore engine with compactedgraphite iron cylinder block.

Excellent Power Characteristics

Twin turbos and high-pressure injection system helpdeliver peak torque at 1000 rpm vs. typical 1300 rpmfor competitors.

Upshift at lower speeds

Fewer downshifts

Outstanding Fuel Economy Common rail fuel system

Low friction design

Very Low Noise, Vibration

and Harshness Advanced block design and high-pressure multi-shot injection

combine to produce a 30% lower noise level inside the cab.

CGI Strength Margin(vs. gray iron)

+75% tensile

+40% stiffness

+200% fatigue

CGI molecules intertwine providing greater strength withthinner casting walls.

Conventional Gray Iron Compacted Graphite Iron




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advanced egr 2010 emission compliant

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