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The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12 th Diesel Engine-Efficiency and Emissions Research Conference, Detroit, August 20-24, 2006

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Page 1: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

The Potential of GTL Diesel to Meet Future Exhaust Emission Limits

Paul Schaberg, Sasol Technology

12th Diesel Engine-Efficiency and Emissions Research Conference, Detroit, August 20-24, 2006

Page 2: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

Co-authors

DaimlerChrysler AGHans-Otto HerrmannStefan KeppelerWalter Friess

SasolChevron Consulting Ltd Mark Schnell

Sasol Technology

Johan Botha

Page 3: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

Presentation overview

Status and availability of GTL diesel fuel

Impact of GTL diesel fuel on performance and emissions

Without engine modifications

With software adaptation

With hardware adaptation

GTL Demonstration Vehicle

Conclusions

Page 4: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

GTL diesel fuel production Oryx GTL, Qatar

330 MM 1 000 bpdSCF/d

LPGnatural gas 24 000 bpd

diesel

9 000 bpd naphtha Commercial

production in 2006

ProductProduct workupworkup UtilitiesUtilities pipepipe rackrack GasGas feedfeed

Page 5: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

CurrentCurrentglobal marketglobal market13,500,00013,500,000

GTL diesel Fuel Meeting diesel demand growth

GTL industry potential GTLGTL industry potential GTL diesel capacity ~600 000diesel capacity ~600 000

Cumulative additionalCumulative additionalglobal demandglobal demand

~4 600 000~4 600 000

20052005 20152015

AnnualAnnualglobal growthglobal growth

(at 3%)(at 3%)

4%4%13%13% ofof NEWNEW demanddemand

ofof TOTALTOTAL demade ndmand

Sasol Chevron potential GTLSasol Chevron potential GTL diesel capacity ~300 000diesel capacity ~300 000

Oryx GTLOryx GTL24 00024 000

Global dieselGlobal diesel demanddemand

~13.5 million~13.5 million

((~~ 1 500 ppm S)1 500 ppm S) (volumes in bpd)(volumes in bpd) (~ 50 ppm S)(~ 50 ppm S)

5

Page 6: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

Properties of SasolChevron GTL diesel fuel

Clear, almost odourless liquid

Highly paraffinic (total aromatic content <1%, polycyclic aromatic content < 0.05%)

Density ~ 0.77 kg/l

H/C ratio ~ 2.10 mol/mol

Energy content ~ 47.1 MJ/kg

Cetane number >>70

Very low sulphur (< 1ppm)

Good thermal stability

Page 7: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

Impact of GTL diesel fuel on performance and emissions : Review

40 40

-100

Heavy Duty

Part

icul

ates

(%)

Light Duty

MB C220 CDI vehicle with EU3 and EU4 calibrations

With software adaptation

20 20

0

-20

-40

-60

-80

0

-20

-40

-60

-80

-100 -40 -30 -20 -10 0 10 20 -40 -30 -20 -10 0 10 20

NOx (%) NOx (%)

Potential reductions in all regulated emissions (HC, CO, NOX, PM), as well as in CO2 and other unregulated emissions

Part

icul

ates

(%)

Source : SAE Paper 2003-01-0763, NREL

Page 8: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

Impact of GTL diesel fuel on engine performance and emissions

No engine modifications

+ • HC reduction potential 90% • CO reduction potential 90% • PM reduction potential 35%

• Limited NOX-reduction

- • Slightly reduced power • Higher volumetric

fuel consumption

Vehicle: MB E220 CDI

GTL diesel fuel offers high emission reduction potential for non-adapted engines. These benefits can be utilized in existing vehicle fleet.

Page 9: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

Impact of GTL diesel fuel on engine performance and emissions

Software adaptation only

+

-

• Simultaneous particulate and NOX reduction of up to 35%

• Must still meet emission limits with conventional diesel

• Higher volumetric fuel consumption

Software adaptation would facilitate NOX reduction from engines operated with GTL diesel fuel. However, potential is limited by certification requirements.

Page 10: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

Impact of GTL diesel fuel on engine performance and emissions

Hardware adaptation offers maximum potential to reduce emissions at lower cost. This scenario requires dedicated GTL engines.

Hardware and software adaptation

+ • Potential to reduce all engine-

out emissions • No power loss • Reduced overall cost

- • Dedicated engine • Requires new standard

to utilize full potential

Project Target: 0.08 g/km NOx (NEDC) without active NOx aftertreatment

Baseline EU4 Engine

GTL fuel + hardware adaptation Requires ~ 70% NOx-Reduction

Page 11: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

Engine and vehicle data

Vehicle details : Mercedes Benz E320 CDI Model year : 2005

Gearbox : 7-speed automatic transmission

Emission status : EU 4 (baseline)

Emission test cycle : New European Driving Cycle NEDC 2000

Vehicle weight class : 4000 lbs

Engine details : Mercedes Benz OM642 Configuration : 3 litre, 6 cylinders, 72 degree V

Compression ratio : 18:1 (baseline)

Fuel management : Common rail, direct injection, piezo injectors, 1600 bar peak pressure

Air management : VGT turbocharged, intercooled

Emission control : Cooled EGR, inlet swirl control, closed coupled DOC, DPF

Rated torque : 510 Nm from 1600 to 2800 rev/min

Rated power : 165 kW at 3600 rev/min

Page 12: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

Hardware optimization strategy

Relative NOx (%)

Rel

ativ

e So

ot (%

) EU 4 Engine

CR = 15:1 + recalibration

Adapted injector configuration + recalibration

Two-step hardware optimization strategy:

Step 1: Reduction of compression ratio (CR=15:1)

Step 2: Adaptation of injector parameters

Due to availibility of a DPF, main focus of engine

optimization was reduction of nitrogen oxide

emissions

Page 13: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

Smok

e

Impact of compression ratio on emissions

NOX relevant engine operating point

HC relevant engine operating point

CR 16:1 GTL Diesel Fuel

1800 rpm bmep = 8.9 bar

CR 15:1 GTL Diesel Fuel Optimized Injection Strategy

CR 15:1 GTL Diesel Fuel

Hyd

roca

rbon

Em

issi

ons

CR 16:1 GTL Diesel Fuel

1000 rpm bmep = 4.2 bar "cold conditions"

CR 15:1 GTL Diesel Fuel Optimized Injection Strategy

Oxides of Nitrogen Oxides of Nitrogen

GTL diesel fuel + compression ratio reduction offers significant improvement potential for NOx at higher load, while maintaining low HC emissions at low

temperature operating conditions

Page 14: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

-20

100

Crank Angle [deg]

10

20

30

40

50

60

-20.0

0.0

20.0

40.0

60.0

80.0

100.0-4-20246

0

20

40

60

80

100

-6.0

-2.0

2.0

6.0

-20.0

20.0

60.0

100.0

140.0

-20

100

Crank Angle [deg]

-4-20246

Impact of GTL diesel fuel on combustion parameters

1000 rpm, bmep = 4 bar, CR = 16:1 1800 rpm, bmep = 8,9 bar

EU Diesel EU Diesel, CR = 16:1 GTL Diesel Fuel

GTL Diesel Fuel CR = 15:1

Cyl

inde

r Pre

ssur

eH

eat R

elea

se R

ate

Rat

e of

Cyl

. Pre

ssur

e R

ise

Inje

ctor

Sig

nal

Inje

ctor

Sig

nal

Rat

e of

Cyl

. Pre

ssur

e R

ise

Cyl

inde

r Pre

ssur

eH

eat R

elea

se R

ate

-30 -20 -10 0 10 20 30 40 50 -30 -20 -10 0 10 20 30 40 50

Crank Angle [deg] Crank Angle [deg]

Page 15: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

GTL Demonstration VehicleEmissions and performance

120

Part

icul

ate

Filte

r

0.08 g/km

0.5 g/km 0.05 g/km

0.005 g/km

Result

0 NOx CO THC PM

Exhaust Emissions

100

80

60

Rel

ativ

e Le

vel (

%)

40 EU4 limit EU4 production vehicle Project target20

Page 16: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

EU4 Limit

Project TargetEU4 Production Vehicle

Result

GTL Demonstration VehicleEmissions and performance

0

20

40

60

80

100

120

Rel

ativ

e Le

vel (

%)

Part

icul

ate

Filte

r

0.08 g/km

0.5 g/km 0.05 g/km

0.005 g/km

165 kW

EU4 limit

Project target EU4 production vehicle

Result

NOx CO THC PM CO2 Vol FC Maximum

Exhaust Emissions Fuel Consumption Power

Project emission targets were achieved without compromising maximum power or energy efficiency.

Page 17: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency

Conclusions

GTL diesel fuel is an enabler for cost-efficient reductions in exhaust emissions

Engine efficiency and performance need not be compromised by the adaptation for GTL diesel fuel.

The results corroborate that clean fuels are one means to comply with future, more stringent emission regulations in a cost-effective manner.

Potential future development of such dedicated “GTL diesel engines” will be determined by the widespread availability and the cost of GTL diesel fuels. Also, a standard for such fuels would have to be developed.

Page 18: The Potential of GTL Diesel to Meet Future Exhaust ...€¦ · The Potential of GTL Diesel to Meet Future Exhaust Emission Limits Paul Schaberg, Sasol Technology 12th Diesel Engine-Efficiency