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MD/HD COMD/HD CO22 Reduction by Reduction by

Hybridization & WHRHybridization & WHRTechnology Impact on Emission ControlTechnology Impact on Emission Control

Dr. Uwe Zink, Dr. Uwe Zink, Corning IncorporatedCorning Incorporated

Director, Emerging Industry TechnologyDirector, Emerging Industry Technology

April 4, 2011April 4, 2011

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Agenda

COCO22 Context Context

HybridizationHybridization

MotivationMotivation

Powertrain implicationPowertrain implication

Aftertreatment design considerationsAftertreatment design considerations

Technology sortingTechnology sorting

Heat Energy Recovery Approaches in IndustryHeat Energy Recovery Approaches in Industry

Rankine cycle considerationsRankine cycle considerations

SummarySummary

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COCO22 Context & Context &

considerationsconsiderations

On-Road focusOn-Road focus

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HD CO2/Fuel Consumption Reduction: Different approaches JP: Fuel consumption, EU: CO2 focus(?), EPA: GHG focus

New EU Regs CO2 (assumption)

2011 2012 20142013 2015 2016 2017 2018 2019 20212020 2022 2023 2024

EPA CO2e (CO2; N2O, CH4 caps; BC)

JP: Fuel cons. -12% vs 2002 Tighter JP Regs (assumption)

(*): www.Daimler.com, MTZ 1-’09, http://www.cat.com/sd2009, http://www.deere.com/en_US/globalcitizenship/stewardship/metrics.html

DoE SuperTruck

Vehicle fuel eco demo

ACEA: 20% reduction goal (*)

DoE: +50% freight efficiencyPrototype demo

CO2/Fuel Eco - Government / OE Initiatives

DAG’s “Shaping Future Transportation” (*)

“Road to Emission Free Mobility (LD & HD)”(*)

Tighter EPA Regs

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Fuel consumption evolution in EuropeACEA’s Goal(*): 20% Fuel consumption reduction by 2020 –Assume vehicle

-20%

(*) MTZ 1-’09, Daimler SAE Gothenborg 9-’10

10 mpg per CCJ 3/31/10 quoting DTNA @ MATS

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CO2 & fuel consumptions measures-Aerodynamics, vehicle weight, engine, tires, drivetrain

Ref.: Technologies and Approaches to Reducing the Fuel Consumption of Medium- and Heavy-Duty Vehicles, April 2010; http://www.nap.edu/catalog/12845.html

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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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MD/HD-Vocational Applications are Targets for Hybridization High Potential for Braking Energy Recovery

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11

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65

4

31

59

18

23

18

35

47

0%

20%

40%

60%

80%

100%

Delivery Bus Refuse Class 8

Kinetic Energy Loss Comparison of Various Types of Medium and Heavy Vehicles

Rolling

Aero

Braking

5/07 Michigan Clean Fleet Conference

Vehicle Type

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Targeting combustion engine operation at optimum BSFC points

Ref: Hydraulic Hybrid Vehicle System Panel

10Ricardo, SIAT Jan 2011

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Hybridization impact on conventional powertrain -Combustion engine selection (“downsized”) & operation (less transient”)

Ref: DTF 3-08 Volvo

“Hybridization”

Transient

Steady State

Diesel Engine Operation

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Combustion Engine “Downsizing” -Example (MB Citaro G)

Conventional:Conventional:

12l, OM 457 LA12l, OM 457 LA

Hybrid:Hybrid:

4.8l, OM 924 LA4.8l, OM 924 LA

Compensation for torque & Compensation for torque & powerpower

4 wheel hub electric 4 wheel hub electric motors, ea. @motors, ea. @

60 kW continuous60 kW continuous

80 kW peak 80 kW peak 1000 1400 1800 2200 rpm

400

800

1500

1900

OM 457 LA

OM 924 LA

OM 457 LA

OM 924 LA

Mercedes Benz Website http://www.mercedes-benz.de

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Cost, Certification & OBD issues need to be resolved

Navistar, HTUF 10/2009

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HILS – Making its way into MD/HD Homologation Procedures

J-MLIT at ACEA Mtg Dec.3, 2009: A Global Approach to Sustainable Freight Transport

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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 Aftertreatment Design ConsiderationsConsiderations

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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

Freightliner, HTUF 10/2009

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A/T Impact of Hybridization on Freightliner M2

DPF Regeneration Interval increases

Freightliner, HTUF 10/2009

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Series Electric Class 8 Truck & City Bus w/ Range Extender-Freightliner Columbia (Parker-Artisane-Capstone), ZEM (Italy)

Parker, HTUF 2010; http://zemplc.com/technology.php

Emissions are very low… aftertreatment

likely not needed.

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LD Example (Prius III, 1.8l ICE) -Intermittent ICE Operation, Lower exhaust gas temps & aggressive catalyst heating

Umicore, 4/2010

Aggressive Catalyst Heating in Prius

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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)

http://www.afdc.energy.gov/afdc/vehicles/heavy/hybrid_systems

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Hybridization Market Triggers

Fuel pricesFuel prices -some anticipate $4++(US)-some anticipate $4++(US)

CO2 regsCO2 regs -getting into place-getting into place

Tax incentivesTax incentives -key to mitigate-key to mitigate

Cost reductionCost reduction -significant effort needed-significant effort needed

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Three areas that could affect A/T for the ICE

ICE -ICE -

Time frameTime frame EnablerEnabler A/T - ImpactA/T - Impact

1.1. DownsizingDownsizing Short / Short / MediumMedium

Serial Hybrid,Serial Hybrid,

High battery capacityHigh battery capacity

Parallel Hybrid: Parallel Hybrid: medium potentialmedium potential

Downsizing, NR: Downsizing, NR: possible avoidance possible avoidance (kW-segment specific)(kW-segment specific)

2. Modified ICE ops cycle2. Modified ICE ops cycle Medium / Medium / LongLong

Above and OE Above and OE focused effortfocused effort

Functional shiftFunctional shift

Light-off, heat retention Light-off, heat retention importanceimportance

3.3. Homologation Homologation

/ Certification/ Certification

LongLong Regulatory Regulatory approaches, new cert approaches, new cert cycles / limitscycles / limits

Potential functional Potential functional reductionreduction

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Heat Energy Recovery Heat Energy Recovery ApproachesApproaches

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Context: Engine based fuel economy levers

Reduced pumping losses

-intake

-exhaust (e.g. A/T)

Heat Energy

Recovery

Engine Hard/Software, NOx calibration,

A/T EfficiencyStanton, Deer 2009

38.7%

Energy Flow Chart @ B50 point of a 290kW engine, Behr, Wien 2009

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Heat Energy Recovery Approaches

Turbo Turbo

ChargingCharging

Turbo Turbo

CompoundingCompounding

Process HeatProcess Heat

(e.g. Rankine Cycle)(e.g. Rankine Cycle)

ThermoelectricThermoelectric

Series productionSeries production

LD & HDLD & HD

Series productionSeries production

HDHD

EmergingEmerging

HDHD

EmergingEmerging

LDLD

e.g. 1953 on DC-7, Wright 3350e.g. 1953 on DC-7, Wright 3350

and later up to today on HD as and later up to today on HD as well (CAT, Cummins, DAF, Hino, well (CAT, Cummins, DAF, Hino,

Scania, Volvo, DDC/DAGScania, Volvo, DDC/DAG))

MAN’s MAN’s

Thermo Efficiency System, Thermo Efficiency System,

Marine & StationaryMarine & Stationary

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BMW’s TEG in EGR Loop4 cyl Diesel engine

Ref: BMW, 5th Emission Control, Dresden, 6/10

TEG

EGR Cooling

Suggested to move to exhaust system location for higher recovery (500W rather than 100W on EGR)

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Mechanical/Electrical Turbocompounding-extracting heat upstream of aftertreatment

BSFC simulation data for from a “typical” heavy duty engine, >10ltrs and with 2010+ emissions compliance

DDC Mechanical Turbocompounder

Bowman Industries, SAE ComVec 2009

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Cummins Example-showing R245fa working fluid

Cummins, SIAT Jan. 2011

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Iveco Glider-Concept Vehicle

•Condensor

• Expander:Turbine

• Boiler

Lastauto Omnibus 12/2010

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Expander machines Expander machines under considerationunder consideration

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R&D ongoing for expander machinesTurbineTurbine

High rpm speedsHigh rpm speeds

Piston Piston

e.g. Voith’s “Steam Expander”e.g. Voith’s “Steam Expander” 2 cylinder, ~0.75l displacement2 cylinder, ~0.75l displacement

Rotary/Sliding VaneRotary/Sliding Vane

Axial piston rotaryAxial piston rotary

Considerations:Considerations:

Expansion ratioExpansion ratio

Ability to handle wet vapor (X<1), i.e. two-phase flow with dropletsAbility to handle wet vapor (X<1), i.e. two-phase flow with droplets

Working fluid compatibilityWorking fluid compatibility

GWPGWP

otherother

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Working Fluids under Working Fluids under ConsiderationConsideration

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Rankine Working Fluid candidatesR245fa, 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 characteristicsChemical and physical characteristics

E.g. decomposition temperatureE.g. decomposition temperature

Achievable system pressure Achievable system pressure

cost for pumps, condensor, heat exchanger along with pressure levelcost for pumps, condensor, heat exchanger along with pressure level

Environmental considerations Environmental considerations

GWPGWP

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Technologies emerging that will have an impact on aftertreatment design -> A/T industry needs to prepare for

HybridizationHybridization

ICE downsizingICE downsizing

Shift in operating pointsShift in operating points

Certification/Homologation proceduresCertification/Homologation procedures

Exhaust Heat Energy RecoveryExhaust Heat Energy Recovery

New processesNew processes

Additional componentsAdditional components

WeightWeight

SpaceSpace

BackpressureBackpressure

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Thank you for your Thank you for your kind attention!kind attention!

Questions are welcome!Questions are welcome!