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8. September 2007
HDV Emissions Retrofit Kit11th ETH-Conference on Combustion Generated Nanoparticles
Yves Hohl, Alois Amstutz
© ETH Zürich | Measurement and Control Laboratory
28. September 2007
Measurement and Control Laboratory
Outline of the presentation
Introduction and objectives of the project
The Heavy Duty Vehicle emissions retrofit kit
Phase 1: Investigation on the engine test bench
Phase 2: Field tests on the garbage truck
Field test results
38. September 2007
Measurement and Control Laboratory
Introduction
Community trucks have a life time between 10 to 20 yearsMany of them are EURO 3
48. September 2007
Measurement and Control Laboratory
Objective of the project
EGR
coo
ler
• 50% reduction of the NOX emissions• 99.5% reduction of the PM emissions• without producing secondary emissions as NO2
NOX (g/kWh)
1 765432 98
0.1
0.2
0.3
0.4PM (g/kWh)
EURO 11990
EURO 2
EURO 3
EURO 4EURO 5
EGR NO
X
Reduction > 50%DPF PM
Reduction > 99%
Trade-offPM - NOX
build a retrofit kit
Retrofit Kit
58. September 2007
Measurement and Control Laboratory
Objectives
(2006)(2009)
NOx-reduction by closed loop controlled EGR
Diesel particulate filter for PM reduction
DPF regeneration by thermodynamical means
68. September 2007
Measurement and Control Laboratory
Schematic representation of the kit
particulate trap
turbine
throttle „2"
intercooler
compressor
EGR
-coo
ler
EGR-valvewith
throttle „1"
λ-sensorNOX-sensor
rpm
timpim
pos. gas pedal
pb. comp.
tb. DPFta. DPF
pb. DPF pa. DPF
8. September 2007
Investigation on the engine test bench (phase 1)
88. September 2007
Measurement and Control Laboratory
Components and characteristics of the engine test bench
Mercedes OM 611
• 4 cylinders, 4 valves
• with turbocharger and Common-Rail
• 2150 cm3
• compression ratio 19:1
• 92 kW @ 4200 rpm
• 300 Nm from 1600 rpm to 2600 rpm
particulate trap
throttle „1“
EGR valve
EGR-cooler
NOX & Lambda-Sensor
turbocharger
98. September 2007
Measurement and Control Laboratory
EGR control system
PartikelfilterTurbine
Klappe „2"
Ladeluftkühler
Verdichter
AG
R-K
ühle
r
AGR-VentilMit
Klappe „1"
pin
pout
mA
GR
mLuft
mLuft + mAGR
λ-Sonde
108. September 2007
Measurement and Control Laboratory
EGR control system
Regelstrecke
AGR-Ventil Motor
Motortemp.,...
PI-Regler
Lambda-Sonde
Kennfeld Lambda Soll
VorsteuerungAGR-Ventil
• w: Führungsgrösse (Kennfeld Lambda)• e: Regelabweichung• u(R): Stellgrösse von Regler• u(0): Stellgrösse von Vorsteuerung• u: Stellgrösse• z: Störung (Motortemperatur, Ladedruck, Abgastemperatur, Genauigkeit von Klappe)• y: Regelgrösse (Lambda)
118. September 2007
Measurement and Control Laboratory
Control System for Regeneration
PartikelfilterTurbine
Klappe „2"
Ladeluftkühler
Verdichter
AG
R-K
ühle
r
AGR-VentilMit
Klappe „1"
mLuft
λ-Sonde
PI-Regler Klappe 2 Motor
u0 Kl 2
λsoll +
-+
+
λist
eKl 2
rpm
u GP
1.5
Regnerationsstrategie
Δp DPF
T vor DPF
mAbg
128. September 2007
Measurement and Control Laboratory
Regeneration control system
Regelstrecke
AGR-Ventil Motor
Motortemp.,...
PI-Regler
Lambda-Sonde
Lambda soll
• w: Führungsgrösse (Kennfeld Lambda)• e: Regelabweichung• u(R): Stellgrösse von Regler• u(0): Stellgrösse von Vorsteuerung• u: Stellgrösse• z: Störung (Motortemperatur, Ladedruck, Genauigkeit von Klappe)• y: Regelgrösse (Lambda)
Regenera-tions-strategie
138. September 2007
Measurement and Control Laboratory
Effect of the EGR and DPF
1000 1250 1500 1750 2000 2250 2500 2750 30000
2
4
6
8
10
12
14
16
18
engine speed [rpm]
pme
[bar
]
NOX reduction [%]
0
10
20
30
40
50
60
70
80
1000 1250 1500 1750 2000 2250 2500 2750 30000
2
4
6
8
10
12
14
16
18
engine speed [rpm]
pme
[bar
]
reduction of elementar carbon [%]
99
99.1
99.2
99.3
99.4
99.5
99.6
99.7
99.8
99.9
100
148. September 2007
Measurement and Control Laboratory
Effect of the throttling with throttle 2
1400 1600 1800 2000 2200 2400 26000
2
4
6
8
10
12
14
16
temperature before DPF without throttling [°C]
engine speed [rpm]
pme
[bar
]
200
220
240
260
280
300
320
340
360
380
1400 1600 1800 2000 2200 2400 26000
2
4
6
8
10
12
14
16
Lambda without throttling [-]
engine speed [rpm]
pme
[bar
]
1.5
2
2.5
3
3.5
1400 1600 1800 2000 2200 2400 26000
2
4
6
8
10
12
14
16
engine speed [rpm]
pme
[bar
]
temperature before DPF with throttling [°C]
360
380
400
420
440
460
480
500
520
1400 1600 1800 2000 2200 2400 26000
2
4
6
8
10
12
14
16
engine speed [rpm]
pme
[bar
]
Lambda with throttling [-]
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
158. September 2007
Measurement and Control Laboratory
Effect of the EGR during cycle 1
0 20 40 60 80 100 120 140 160 180 200 220 2401
2
3
4
NO
x [g
/kW
h]
original enginewith the kit with EGR
0 20 40 60 80 100 120 140 160 180 200 220 2400
20
40
60
redu
ctio
n of
NO
x [%
]
0 20 40 60 80 100 120 140 160 180 200 220 24005
1015202530
time [s]
engi
ne s
peed
[rpm
] p
me
[bar
]
engine speed/100pme
mean value during cycle 1
100 %
- 30 %
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
1
conc
entr
atio
n of
NO
X [g
/kW
h]
original engine with the kit with EGR
mean value during cycle 1
168. September 2007
Measurement and Control Laboratory
Effect of the DPF
0 20 40 60 80 100 120 140 160 180 200 220 2400
1
2
3
4
5
6
7
8
9
10
time [s]
elem
enta
r car
bon
[mg/
kWh]
with the kit with EGRwith the kit during the regeneration
Comparison w/wo regeneration
0 20 40 60 80 100 120 140 160 180 200 220 2400
20
40
60
80
100
120
140
160
180
200
220
240
260
time [s]
elem
enta
r car
bon
[mg/
kWh]
with the kit with EGRwith the kit during the regenerationoriginal engine
Comparison w/wo DPF
8. September 2007
Field test on the garbage truck (phase 2)
188. September 2007
Measurement and Control Laboratory
Field test: Vehicle
Hersteller: Mercedes-BenzTyp: Econic 2628-LMotor: OM 906 LA.III/4 (6-Zylinder)Abgas-Normen: Euro 3Leistung: 205 kW (280 PS) @ 2'200 rpmHubraum: 6'374 ccm
198. September 2007
Measurement and Control Laboratory
Implementation on the truck
208. September 2007
Measurement and Control Laboratory
Typical route of the waste collection (truck n° 64)
218. September 2007
Measurement and Control Laboratory
Week analysis, DPF data
228. September 2007
Measurement and Control Laboratory
Statistics on how the truck is used
65.2
14.7
13.0
2.7
0.1
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
500 ≤ rpm < 1000
1000 ≤ rpm < 1500
1500 ≤ rpm < 2000
2000 ≤ rpm < 2500
2500 ≤ rpm
frequency [%]
73.3
5.0
5.9
3.7
12.2
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
0 ≤ GP < 20
20 ≤ GP < 40
40 ≤ GP < 60
60 ≤ GP < 80
80 ≤ GP < 100
frequency [%]
85.8
10.4
3.6
0.2
0.0
0 10 20 30 40 50 60 70 80 90 100
0 ≤ v truck < 20
20 ≤ v truck < 40
40 ≤ v truck < 60
60 ≤ v truck < 80
80 ≤ v truck < 100
freqeuncy [%]
engine speedgas pedal
truck speed
238. September 2007
Measurement and Control Laboratory
Statistics on how the truck is used
68.2
15.9
4.0
1.2
1.1
0.3
0.1
0.0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
0 ≤ p < 40
40 ≤ p < 80
80 ≤ p < 120
120 ≤ p < 160
200 ≤ p < 240
240 ≤ p < 280
320 ≤ p < 360
360 ≤ p
frequency [%]
3.5
14.6
52.6
19.4
5.4
0.7
0.2
0.1
0.1
0 5 10 15 20 25 30 35 40 45 50 55 60
100 ≤ T < 200
200 ≤ T < 250
250 ≤ T < 300
300 ≤ T < 350
350 ≤ T < 400
400 ≤ T < 450
450 ≤ T < 500
500 ≤ T < 550
550 ≤ T
frequency [%]
5.3
13.4
45.3
22.7
7.5
3.0
1.1
0.2
0.0
0 5 10 15 20 25 30 35 40 45 50
100 ≤ T < 200
200 ≤ T < 250
250 ≤ T < 300
300 ≤ T < 350
350 ≤ T < 400
400 ≤ T < 450
450 ≤ T < 500
500 ≤ T < 550
550 ≤ T
frequency [%]
temp. before DPF temp. after DPF
pressure diff. on DPF
248. September 2007
Measurement and Control Laboratory
Regeneration analysis
16.4 16.45 16.5 16.55 16.6 16.65 16.7 16.75 16.8 16.85 16.912345
time [h]
lam
bda
[-]
16.4 16.45 16.5 16.55 16.6 16.65 16.7 16.75 16.8 16.85 16.900.20.40.60.8
1
time [h]
th. 2
[-]
16.4 16.45 16.5 16.55 16.6 16.65 16.7 16.75 16.8 16.85 16.9100200300400500600
time [h]
tem
p. [°
C]
16.4 16.45 16.5 16.55 16.6 16.65 16.7 16.75 16.8 16.85 16.9050
100150200250300
time [h]
p D
PF [m
bar]
before DPF
after DPF
258. September 2007
Measurement and Control Laboratory
EGR analysisWithout EGR With EGR
8. September 2007
Exhaust gas measurements
278. September 2007
Measurement and Control Laboratory
Description of the stationary measurements
load
[%]
Modified ESC test cycle
288. September 2007
Measurement and Control Laboratory
Description of the dynamic measurements
Waste collection cycle City-cycle
298. September 2007
Measurement and Control Laboratory
Results of the gas analysis I
0
100
200
300
400
500
600
700
1 2 3 4 5 6 7 8 9 10 11 12 13
operating points [-]
NO
X [p
pm]
measurement 1 (before DPF, wo EGR)measurement 4 (after DPF, w EGR)
1 3 5 7 8 9 11 a b c d e f0
25
50
75
100
Load
[%]
Idle speed A B C46
70 65 53
50 50 50
0 0 0
0 0 0
1375 rpm 1750 rpm 2125 rpm600 rpm
75
67667562
47
NOX reduction [%] Comparison of NOX emissionswith/without the Kit
308. September 2007
Measurement and Control Laboratory
Results of the particle analysis
PM reduction [%]
0
25
50
75
100
Load
[%]
Idle speed A B C99
99 99 99
99 99 99
99 99 99
99 99 99
1375 rpm 1750 rpm 2125 rpm600 rpm
99
99999999
99
Size distribution and penetration
318. September 2007
Measurement and Control Laboratory
NO2/NOX ratio
05
101520253035404550
100 150 200 250 300 350 400 450 500 550exhaust gas temperature before DPF [°C]
NO
2/NO
X [%
]
sinter-metal DPF + FBC + EGRwo DPF, wo EGR, w FBC
328. September 2007
Measurement and Control Laboratory
Results of the gas analysis II
CO increasing [%]Comparison of CO emissionswith/without the Kit
0
25
50
75
100
Load
[%]
Idle speed A B C50
336 190
0 0 0
0 0 0
1375 rpm 1750 rpm 2125 rpm600 rpm
354
207
263218178173
133
200 200200
0200400600800
10001200140016001800
1 2 3 4 5 6 7 8 9 10 11 12 13
operating points [-]
CO
[ppm
]
measurement 4 (after DPF, w EGR)measurement 1 (before DPF, wo EGR)
1 3 5 7 8 9 11 a b c d e f
338. September 2007
Measurement and Control Laboratory
Waste collection cycle
0
10000
20000
30000
40000
50000
60000
0 10 20 30 40 50 60 70 80 90 100 110 120time [s]
PAS
2000
[μgE
C/m
3 ] before DPF
after DPF
-100%
-80%
-60%
-40%
-20%
0%
20%
NOx PM CO
effe
ct o
f the
HD
V Em
issi
ons
Ret
rofit
Kit,
w
aste
col
lect
ion
cycl
e
auxiliary drive system is turned on
348. September 2007
Measurement and Control Laboratory
City-cycle
-100%
-80%
-60%
-40%
-20%
0%
20%
40%
60%
NOx PM CO
effe
ct o
f the
HD
V Em
issi
ons
Ret
rofit
Kit,
city
-cy
cle
0 20 40 60 80 100 120 140 160 180 2000
100
200
300
400
500
600
700
800
900
1000
time [s]
NO
X [ppm
]
NOX wo EGR
NOX w EGR
358. September 2007
Measurement and Control Laboratory
ConclusionsHDV Emissions Retrofit Kit consisting of
- DPF- EGR system- Additive for regeneration
finds on a truck room to be installedproved to be very reliablecosts about 6000 CHF w/o DPFachieves
is a suitable solution for retrofitting heavy duty vehicles in communitiy applicationsProject should be extended to a bigger fleet
• 45% reduction of the NOX emissions• 99.5% reduction of the PM emissions• without producing secondary emissions
8. September 2007
HDV Emissions Retrofit Kit11th ETH-Conference on Combustion Generated Nanoparticles
Yves Hohl, Alois Amstutz
© ETH Zürich | Measurement and Control Laboratory
Thank you for your attention!
Andreas MayerThomas Lutz