Download - SCR Engine Development at VOLVO
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
1
SCR Engine Development at VOLVO
• Presentation Content
Volvo Environmental CareEuro # engine developmentEGR and VolvoEGR v SCR decision criteriaSCRT experienceSCR System TechnologySCR engine DevelopmentAdblue & LogisticsConclusions
Maurice BrownEuropean City bus Product ManagerVolvo Bus Corporation
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Our Core Values
Quality Safety Environment
We use our expertise to create transport-related products and services of high quality, safetyand environmental carefor demanding customers.
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Euro 1
1993
Certificationof the engine
Euro 2
1996
Conformity of production
Euro 3
Oct2001
Defeat device language
Euro 4
Oct2006
Durability, On Board Diagnostics No. 1, Anti-tampering, In-use testing programme
Euro 5
Oct2009
On Board Diagnostics No. 2. NTE, In-use compliance
Legislation – not only emission levels
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
42005 2006 2007 2008
Euro 4 step IMandatory
Driver warning if:
• > 5 g. NOx/ kWh
40% torque reduction if:
• > 7 g. NOx/ kWh
Euro 4 step IIAdditional
requirement
Driver warning if:• AdBlue tank is empty• Dismounted catalyst • Lack of AdBlue dosing
Certificationbefore Oct 1 -05
Oct 1 Oct 1 Oct 1
Euro 4 legal requirement
Certify new engines for Euro 4
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Exhaust Emission Standards
PM (P
artic
ulat
e M
atte
r) [g
/kW
h]
Euro 3 (2001)
Euro 2 (1996)
Euro 4 (2006)Euro 5 (2009)
2012NOx [g/kWh]
Euro 6 (2012?)
Legislative Demands
Increased injection pressure & retarded engineWhich lowers efficiency but suppresses NOx formation
Phase out 10 litre engineDevelop lower friction components2 new engines 9 & 12 litre with unit injectors
SCR/EGR?
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Volvo 7 & 10 litre VEC system (EGR)
EGR was pioneered by Volvo
2000 – 2003 with over 400 buses built
Conclusion:
Difficult to achieve acceptable PM emission to
allow CRT regeneration at low load/temp cycles
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
GasGas system + EGRsystem + EGR MG9 CNG EGR Solution
P2/T2 sensorEGR valve
Cooled EGR
Lambda 1Stoechiometric engine3-way catalyst to treat NOx, HC and COUse of EGR (Exhaust gas recirculation) in
order to reduce exhaust temperatures
Advantages:Advantages:Durable concept: Possibility to have EURO6
Emissions levelDevelopment based on a advanced
engineering projectEngine able to adapt with different Natural gas
3-way catalyst
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Volvo EGR solution for USA
• 80,000 EGR’s in service across the USA since introduction in 2002
V Pulse EGR similar the the MG9 CNG engine
+ 4- 5% fuel consumption penalty
Use of an additive is prohibited in the legal framework due to lack of trust on Operators compliance
• To fulfil US ‘O7Volvo will utilise cooled EGR with PM after treatment
This solution has also been introduced in Japan due to late agreement for use of an Additive – The next generation Japanese engines to be introduced in 2008 are likely be SCR according to statements by two domestic manufacturers.
VGT (variable geometry turbocharger) will be used in the new generation engines
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
SCR technologySCR technology
SCR - Selective Catalytic Reduction
Selective
Removes NOx in the presence of oxygen
Catalytic
Decreases the activation energy for the chemical reaction which Enables reaction at + 200 °C when amonia is released from the Adblue solution
Reduction
Reduces NOx by 75% - 95%
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Incentive Euro 5 SCRT 340 bhp 12 litre
• Introduced in April 2003 with 27 test buses on the Swedish west coast
• Denox 1 system with air assisted injection and non cooled injector
• 100 buses equipped with this solution and are all operating well
• Adblue consumption is approx 2 – 2.5% due to the lower Nox reduction of the base Euro 3 engine
• Good solution for Euro 3 – 5 due to lower Nox reduction
• No reduction of fuel consumption + Adblue cost
Note: 1% Adblue = -1 gm NOx approx
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Volvo CRT™/SCR system
• Meets the proposed Euro 5 emission standard• 27 buses in field test since April 2003• Market introduction in late 2004• 12 l Euro 3 engine 340 Hp for city/intercity
application
Modular after treatment system
CRT
Clean up catalyst
SCR
AdBlueinjection
Open loop system
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Part
icul
ates
–g/
kWh
NOx – g/kWh0 104 6 8 12 142
0.10
0.08
0.06
0
0.04
0.02
Trade-offPresent
HD Diesel
CooledEGR
EU4EU5
DPF
SCR η=80%
EU3
SCR η=65%
Exhaust Emission Strategy - HD Diesel - Europe
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
Comparison SCR vs. Cooled EGRComparison SCR vs. Cooled EGR
EGR SCRFuel EconomyGreen House Gases (~Fuel Economy)Heat rejection and Chassis CoolingPackaging (installation dependent)WeightEngine durabilityFuel flexibility (Sulphur)Urea need (On-Board and Infrastructure)Oil Drain IntervalChassis System CostDevelopment cost
Source: Volvo Powertrain, September 2005
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Power plantsEstablished technology since 1970. Possibility to reach 95% NOx-conversion with NH3 .
Marine applicationsCatalytic converters for marine applications to meet NOx-emission levels <2 g/kWh.
Heavy duty vehiclesTest around the world, mainly Europe.Meet legal requirement of NOx-emission <3,5 →2 g/kWh.
SCR - Selective Catalytic Reduction
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Chemical reaction with SCR (simplified)
In hot exhaust:2NH3
In SCR catalyst:2N2 + 3H2O
From engine:NO + NO2
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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• 32.5 % urea solution in desalinated water pH value of 9.0-9.5
• A stable, colourless water-like fluid
• Urea is made of ammonia and CO2
• AdBlue composes slowly to ammonia and carbon dioxide in room temperature
• Freezing point = -11°C
• DIN 70070 standard to ensure consistent quality
• AdBlue is not a hazardous substance
• There are no known health hazards related to handling of AdBlue solution
• Urea is produced in large volumes, stable price levels
• AdBlue ¢ 50 € - ¢ 80 € per litre
AdBlue
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Global production of Heavy Duty Diesel Engines 2004*
Volvo Powertrain
DC Powersystems
Weichai Power
Caterpillar
Cummins
Scania
MAN
Yaroslavl
* Engine Production 2004, 9 - 18 litre (excluding licensees / JV’s)
161.000
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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New Heavy Platform - common technology
• One Cylinder Head• Overhead Camshaft• Four Valves per Cylinder• Central Vertical Injector• Electronic Unit Injectors• Electronic Management System• Rear End Transmission• Integrated Engine Brake• Wet Liners
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
19-202468
101214161820222426g
7 0 6 5 6 0 5 5 5 0 4 5 4 0 3 5 3 0 2 5 2 0 1 5 1 0 0 5 0 0 0 5 1 0
Euro 4 Engine Features
Injection system
• Injector Type : E3
• Same packaging as former E1 version.
• Injection pressure : 2000bar
• Opening and closing pressure : flexible
• Multiple injection capability
• Rate shaping and multiple injection capability
Benefits:
• Euro 4 ultra low particulate emissions levels can be reached without filter.
• Reduced noise and improved cold startabilitythanks to pilot injection capability.
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Electronically controlled Turbocharger
• Water cooled - Insulated
• Machined from solid compressor wheel
• Closed loop electronic control of the waste gate, replacing the former mechanical boost pressure control.
Benefits:
• Full flexibility to control waste gate opening and thus boost pressure
• Precise adjustment of the air quantity into the engine in all operating conditions, for improved transient response, better fuel economy and lower emissions.
Air valve unit
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
Mapped for city bus & coach applications
Volvo EURO4 Engine
Specific needs of a city bus and coach applications have been integrated in the performance development
• Using detailed analysis of bus and coach driving conditions the engine was optimisedwhere it is used, leading to decreased fuel consumption.
-500
0
500
1000
1500
2000
0 500 1000 1500 2000
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
- 3 0 0
-1 5 0
0
1 5 0
3 0 0
4 5 0
6 0 0
7 5 0
9 0 0
1 0 5 0
1 2 0 0
1 3 5 0
1 5 0 0
1 6 5 0
S P E E D
T O R Q U E
London driving duty cycle analysis
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Clean-up catalyst for removal of NH3 to avoid smell
AdBlue injector+ temp sensor
AdBlue
AdBlue tank
SCR catalyst & muffler
AdBlue pump and injectionsystem control unit
NOx sensor
AdBlue level & temp sensor
SCR - Selective Catalytic Reduction
Upstream catalytic converter
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Temperature sensor
AdBlue pump and dosing unit
NOx sensor
Components for SCR system – AdBlue Pump and Dosing Unit and sensors
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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AdBlueInjectionnozzle
Temp sensor
SCR – Muffler and AdBlue injection
Pre Catalyst -Standard on all 9 litre engines and 340bhp 12 litre engines
NOx sensor
AdBlue injection nozzle
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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AdBlue tank and filling neck
The industry has agreed on a automotive AdBlue tank filling neck insert standard to facilitate sealed depot system
Filling neck insert drawing.B = 43.5 -/+0.1 mmC = > 26.8 mm
B
C
AdBlue tanks 40 60 l
Level Sensor & temp sensor
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
SCR technologySCR technology
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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AdBlue Usage Range
COACH• 40 litre tank based on 4% usage and diesel consumption of 28.2 l/100km
(30l x 94%) = 28.240 x 25 / 28.2 x 100 = 3546km max range
• 60 litre tank based on 4% usage and diesel consumption of 28.2 l/100km60 x 25 / 28.2 x 100 = 5319km max range
GENERAL• 40 litres of AdBlue is equivalent to 960 litres of diesel fuel consumption for
Euro 4 and 950 litre for Euro 5
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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• Rapid expansion of public systems
throughout Europe• Major oil companies develops
infrastructure (Total, Shell, OMV)• Spill free filling
AdBlue filling – Fuel stations
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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• Several suppliers of AdBlue within Europe • Tailor made solutions for depot filling• Volvo partner YARA can support customers with
infrastructure and AbBlue supplies• Spill-free coupling offers AdBlue filling integrated in
atomised depot system for diesel fuel
AdBlue filling – Depot option
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Emission levels Euro 4
0.46
1.5
3.5
0.020.0040.12
2.41
0.0110.01 0.04
2.02
0.0130.010.10
3.01
0.0150
0.5
1
1.5
2
2.5
3
3.5
4
HC CO Nox Pt
g/kw
H Euro 4 normsD7E levelD9B levelDH12E level
Euro 4 Emission Levels
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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Future Euro 5 development
Lower Consumption & Emissions• Rate shaping and multiple injection with E3 injector• Higher injection pressure at lower revolutions• Higher efficiency SCR from 80% to 90+%• Improved gas exchange within the exhaust and inlet systems
Lower Fuel consumption• Higher combustion peak pressure + 200bar
Stronger base engine block & cyl. Head
Lower Emissions• More optimised control with additional engine and SCR sensors
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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In Summary - No Compromise
• SCR delivers
Low emissionsLower Fuel consumption min 3 – 7% Longer maintenance IntervalsEuro 5 capability from production start in 2006Euro 4 upgradeable to Euro 5 without hardware changesWith Euro 6 generation even better fuel economy
Volvo Bus Corporation
Volvo Bus Corporation - M Brown2005-11-24, Israel SCR
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and finally….
….Thank you for your kind attention