Embed Size (px)
Citation preview
Experiencias en la introducción de motores Diesel EURO V en Brasil – Ing. Nilton ShiraiwaBuenos Aires, 1º de setembro de 2015
Seminario AITA Tecnología Y Combustibles Diesel Euro V “Mejor combustible y
tecnología de los motores, mejor aire”
• Euro Emission limits evolution & environmental improvements• Technologies to meet EURO V• Transition P5 (Euro III) to P7 (Euro V) • South America requirements• Vehicles test • Preparation to launch Proconve P7• Fuel - S10 Diesel • ARLA32 (ARNOX32)• Field result • ARLA32 Emulators• Summary and Conclusion
Content
2
Euro Emission limits evolution & environmental improvements
3
CO HC NOx PM PN Smoke1/kWh 1/m
1992, ≤ 85 kW 4.5 1.1 8.0 0.6121992, > 85 kW 4.5 1.1 8.0 0.361996.10 4.0 1.1 7.0 0.251998.10 4.0 1.1 7.0 0.151999.10 EEV only 1.5 0.25 2.0 0.02 0.152000.10 2.1 0.66 5.0 0.10a 0.8
Euro IV 2005.10 1.5 0.46 3.5 0.02 0.5Euro V 2008.10 1.5 0.46 2.0 0.02 0.5Euro VI 2013.01 WHSC 1.5 0.13 0.40 0.01 8.0×1011
CO NMHC CH4a NOx PMb PNe
1/kWh1999.10 EEV only 3.0 0.40 0.65 2.0 0.022000.10 5.45 0.78 1.6 5.0 0.16c
Euro IV 2005.10 4.0 0.55 1.1 3.5 0.03Euro V 2008.10 4.0 0.55 1.1 2.0 0.03Euro VI 2013.01 WHTC 4.0 0.16d 0.5 0.46 0.01 6.0×1011
EU Emission Standards for Heavy‐Duty Diesel Engines: Steady‐State Testing
Stage Date Testg/kWh
Stage Date Testg/kWh
Euro I ECE R‐49
Euro II
e ‐ for diesel engines ; PN l imi t for pos i tive i gni tion engines TBD
EU Emission Standards for Heavy‐Duty Diesel and Gas Engines: Transient Testing
d ‐ THC for diesel enginesc ‐ PM = 0.21 g/kWh for engines < 0.75 dm3 swept volume per cyl inder and a rated power speed > 3000 min‐1b ‐ not appl icable for gas fueled engines at the Euro I I I‐IV s tagesa ‐ for gas engines only (Euro I I I‐V: NG only; Euro VI: NG + LPG)
Euro III ETC
Euro III ESC & ELR
a ‐ PM = 0.13 g/kWh for engines < 0.75 dm3 swept volume per cyl inder and a rated power speed > 3000 min‐1
Euro Emission limits evolution & environmental improvements
4
EURO III to EURO V, 60% reduction of NOx and 80% reduction of PM
Equivalent emission PM1 E0 = 37 EV1 EI = 18 EV1 EII = 7 EV1 EIII = 5 EV
Technologies to meet EURO V
5
PM & Fue
l con
sumption
NOx
NOx x PM & FC Trade‐off
11
EGR
33DPF
22
22
Combustion
SCR
SCR vs. EGR
Technologies to meet EURO V
6
Trucks & Busses manufactures’ choices for Euro V (Proconve P7)3,5 ton 16 ton
‐ Gross Vehicle Weight +
SCR
SCR
SCR
SCR
SCR
SCR
SCREGR
EGR
EGR
EGR
EGR
Key market driver: advanced emission standards for diesel engines require the use of Selective Catalytic Reduction (SCR) technology, which consumes AdBlue/DEF/ARLA32/ARNOX 32
Source: Integer
SCR is the more used technology to meet the Euro V limits
Transition P5 (Euro III) to P7 (Euro V)
7
Publication of Brazilian Emission Regulation vs. implementation dates
Transition P5 (Euro III) to P7 (Euro V)
8
Source: Anfavea
Scaled Emission limit introduction, no pre-buy
effect.
Source: Gilberto Leal – Integer Brazil 2013
Transition P5 (Euro III) to P7 (Euro V) –Licensing Trucks and Buses in Brazil
South America requirements
9
Brazil has 1,712 million km of highways, 12,4 % of which are paved, 79,9% unpaved and 7,7% is under construction or already planned. AltitudeUp to 5000 m (Andes‐South America)Bad Fuel – Sulphur cont. (2010)Brazil –500 and 2000 ppmParaguay ‐ 2000 ppmUruguay ‐ 5000 ppm
AdBlue/DEF/ARLA32:Not available, need to build infrastructure(It is not available in all cities)Engine Oil: Only Mineral oil
Unpaved79,9%
In Construction
7,7%
Paved12,4%
Highway – Long distanceUnder high temperature and long time in full load
Unpaved roadOften impassable during the rainy season; very fine dust suspended in the atmosphere.
Urban trafficHard stop and go.Application of small engine in bus and truck
High altitude Altitude up to 5.000 m o.s.l.
South America requirements are not comparable to European
Vehicles test
10
With European Euro IV and V experience and Brazilian requirements, MBBras planned and tested the Proconve P7 products during 5 years (3 y. vehicles test).
10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6
C
B
C
B
C
C
C
C
C
B
B
C
C2.392.532 2.972.000 81%
end
end
end
Highway - Track 5 212.922 300.000 71%
Highway - Track 5 120.000
O500 RS 1836 (85R)
300.000 40%O500 RSD 2743 (83R)
Highway - Mexico 307.880 300.000 103%CBC 1830/30 65RM
City - Mexico 129.000 160.000 81%XBC 1519 43UM
City - Track 2 90.000 160.000 56%XBC 1621 6UM
City - Track 2 85.000 160.000 53%OF 1721 26UM
City - Track 2 129.000 160.000 81%OF 1721 25UM
City - Track 2 114.000 160.000 71%OF 1721 24U
City - Track 2 142.396 160.000 89%MBCO 1116/44 16UM
City - Mexico 122.000 160.000 76%XBC 1519 44UM
Highway - Mexico 304.364 300.000 101%CBC 1830/30 66RM
Highway - Track 5 204.673 182.000 112%O500 RS 1836 (86RM)
City - Track 2 150.000 150.000 100%O 500 2836 UA GLE 4U
City - Track 2 161.000 160.000 101%CBC 1826 64UM
City - Track 2 120.297 160.000 75%MBCO 1116 11UM
Engine TrackMileage
done(km)
3
4
5
6
7
8
9
10
2012Pos.
1
2
2008 2009 2010 2011Plan - Mileage
Total(km)
% done
OM 926LA
OM 457LA
OM 924LA
Vehicle
15
11
12
13
14
10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3
end
end
end
end
end
end
end
end
end
end
end
end
end
end
end
5.665.117 7.146.418 79%
Muffler Sample C 1.107.730
92720 180.000 52%5 Atego 1419 / 48 (4x2) L979 V54 Highway - Track 5
Engine Vehicle number
City - Track 10
Track Mileage done(km)
OM 924LA
OM 926LA
Atego 1719 / 48 (6x2) L958 V168
% done
City - Track 10 210.564 96%
2012Pos. 2008 2009 2010 2011Vehicle
OM 457LA
Accelo 1016 C / 44 (4x2) L979 V41
Accelo 1016 C / 44 (4x2) L979 V42
Atego 1726 S (4x2) L958 V165
230.203 105%
Atego 1719 / 48 (6x2) L958 V161 Highway - Track 5 394.225
Highway - Track 5 307.767
99%
Highway - Track 5 305.864 102%
100%
Highway - Track 5 104.598 35%300.000
FPN 2729 P (6x4) L693 V12
Atego 2426 (6x2) L958 V170
Atego 1729 S / 36 (4x2)
Customer (sugar cane) 84.479 84%100.000
AXOR 2831 P (6x4) L958 V177 Customer (sugar cane) 51.083 24%210.000
AXOR 1933 S (4x2) L958 V196 Highway - Track 5 307.674 103%300.000
AXOR 1933 S (4x2) L958 V197 Highway - Track 5 249.610 83%300.000
HSK LS 1635 L695 V32 Off-road 50.275 71%71.000
Axor 2036 S / 36 (4x2) L958 V179 Highway - Track 5 304.000 60%506.312
Axor 2540 S / 36 (6x2) L958 V185 Highway - Track 5 280.094 93%300.000
Axor 3340 P / 48 (6x4) L958 V184 Customer (sugar cane) 215.891 75%286.235
Axor 2544 S / 33 (6x2) L958 V186 Customer (milk) 402.113 82%489.481
Axor 2644 S / 33 (6x4) L958 V180 Highway - Track 5 286.225 63%457.342
Axor 3344 S / 33 (6x4) L958 V187 Customer (wood) 301.673 66%459.141
Accelo 1016 C / 44 (4x2) L979 V50 Customer 83.190 52%
Accelo 1016 C / 31 (4x2) L979 V49 Off-road 95.336 106%
Atego 1419 / 48 (4x2) L958 V164 City - Track 10 161.696 101%160.000
Atego 1719 / 48 (6x2) L958 V167 Off-road 97.684 112%
L958 V171 Highway - Track 5 30.719 61%
HPN L 1620 L695 V29 Highway - Track 5 308.501
Highway - Track 5 247.851 83%300.000 HSK LS 1635 L695 V28
Off-road 43.268 62%HPN L 1319 (4x2) L695 V30
FPN 2729 K (6x4) L693 V13 Customer 20.787 21%100.000
51%FPN 2729 B (6x4) L693 V14 60.000
70%AXOR 1933/36 S (4x2) L958 V175 50.000
107%100.000 Axor 2040 S / 36 (4x2) L958 V181
110%96.440 Axor 2036 S / 36 (4x2) L958 V182
3
4
Off-road 105.938
Off-road 107.030
Off-road 35.238
Customer 30.558
11
12
13
6
7
8
9
14
15
16
17
18
19
20
21
22
23
24
25
30
31
32
26
27
28
29
Plan - Mileage Total (actual)
(km)
220.000
98%10 Atego 1726 (4x2) L958 V162 Off-road 118.263
1
2 220.000
90.000
160.000
87.153
396.307
300.000
120.211
307.302
103%
50.168
69.326
300.000
planneddelay / accidentperformed with Muffler Sample A or B / Cat Bperformed with Muffler Sample B / Cat Dperformed with Muffler Sample C/ Cat Dperformed with Muffler Sample D/ Cat D
7.146.418 km planned5.665.117 km done
79%
2.972.000 km planned2.392.532 km done
81%
In 3 years of test were accumulated:
+ 8.0 million km (endurance)
+ 40,000 h engine bench test
Preparation to launch Proconve P7
11
• Trained the Engineers in ATS technology.• Made the production staff aware that we need the
manufacture with more accuracy than older product.• Trained After-Sales & dealers • Defined the strategy of Spare parts (initial stock,
logistic, etc)• Homologated the Training Centers (Mercedes Training
Centers, Homologated Training Centers, SESI and SEST-SENAT)
• Prepared the Mercedes dealers to sell ARLA32.• Built a direct channel between the Warranty/After-sales
and Development.• Trained the front- and back-office of 0800 (SAC).• Made aware campaigns: PROCONVE P7 vehicles must
use only ULSD and ARLA32.
What was done before SoP to prepare our plant, our dealers and our customers for the arrival of new products PROCONVE P7?
Fuel ‐ S10 Diesel
12
S10 Diesel (ULSD) until now is not yet available in most Brazilians’ cities and S500 will still be available until 202x.
source: ANP
preço médio
preço mínimo
preço máximo
Sao Paulo 2,72 2,49 3,10 S500Sao Paulo 2,92 2,57 3,40 S10
Mato Grosso 3,18 3,15 3,20 S500Mato Grosso 3,27 3,19 3,34 S10
estadoPreço ao Consumidor
tipo de Diesel
Síntese dos Preços Praticados ‐ BrasilRESUMO II ‐ Diesel S10 x S500 R$/l
Período : 2015 ‐ Abril
ARLA32 (ARNOX32)
13
ARLA32 is still expensive, some customers require vehicles with big tanks. Start to sell fractionated volume
Gas station => ARLA32/Diesel price= 1,1 (20l container)For big fleet => ARLA32/Diesel price = 0,50 (in Europe 0,40)
ARLA32 specification NBR ISO 22241
ARLA32 (ARNOX32)
14
Inappropriate /adulterated ARLA32ARLA32 samples from field
Examples of ARLA32 (AdBlue) collected from customers. Blends made with agricultural Urea and common water, cause damages to the
environment and irreversible damage to the SCR
ARLA32 (ARNOX32)
15
Consequences of use the inappropriate/ adulterated ARLA32
Chromatographic analysis of waste on the SCR and ARLA32 nozzle show high presence of Mg, S, Si, Ca, Na, etc.
Use of inappropriate /adulterated ARLA32 causes damage to the environment and can cause irreversible damage to the SCR.
Field result
16
European experience + 3 y. vehicles test in Brazil, Mexico & Chile
Based on the European experience during these 3-year tests failures were mitigated and a rugged components were developed, resulting in a robust
product. Field failure rate of ARLA32 metering unit in Brazil was 4x less than in Europe.
Brazil
Europa
Field result
17
Brazilian Application effectDevelopment phase
Project
Loose tip brazing material (ARLA32 leakage)
Failure mode SolutionField failure modes/root cause
1) Clogging / Contaminated ARLA32
2) Loose flange brazing material / high temperature (consequence: ARLA32 leakage)
Series phase
Failure rate of ARLA32 injector remains high as a consequence of Brazilian application, high S and the lack of attention on OBD from the
user, these failures almost did not occur in Europe.
ARLA32 Emulators
18
Brazilian Application effect
source: http://www.tudosobrechapeco.net/index.php/desc_noticias/empresas_que_fraudavam_arla_32_saeo_multadas_pelo_mpsc
ARLA32 Emulators are an environmental crime that require law enforcement.
With this kind of cheating the engine will emit up to 5 times more
NOx.!! => 6… 10 g/kWh.
Summary and Conclusion
19
• Euro V improve a lot of air quality and for MD & HD application SCR technology is the better solution to control the engine emission
• Should be preferred to apply at first where it has higher emission (cities)
• South America application is more severe than the European, therefore test in SA is required.
• We took 5 years to develop PROCONVE P7, of which 3 years were to test in vehicles, it was fair enough.
• It’s mandatory to use all experience and know how. Important point is training the involved staff in the new technic and technology.
• Clarify/train the customer to handle this new technology.• There are “smart” people in the world, therefore it is necessary
“police control” and Inspection and Maintenance Program.• To improve the availability and quality of ULSD and ARLA32 in all
cities is necessary to avoid problems in ATS system and EGR (ULSD).
20
AEA appreciates your attention
Nilton Mitsuro ShiraiwaManager
MD Engines Performance & Emission and After-treatment Systems Performance
+55 11 4173-6003
