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7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
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Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved. Detroit Diesel Standard Template.ppt
Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010Emissions Regulations
Craig Savonen, Guangsheng Zhu, Houshun Zhang, Sandeep Singh, Rakesh AnejaAugust 23, 2006
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
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Detroit Diesel Standard Template.ppt 1Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Presentation Outline
Technical Status Towards Project Objectives
Technology Development Methodology
Technology Building Blocks Example Case Studies
9 Combustion
9 Fuel Injection System
9Air and EGR System
9 Controls
9 System Integration
Conclusions
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
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Detroit Diesel Standard Template.ppt 2Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Presentation Outline
Technical Status Towards Project Objectives
Technology Development Methodology
Technology Building Blocks Example Case Studies
9 Combustion
9 Fuel Injection System
9Air and EGR System
9 Controls
9 System Integration
Conclusions
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
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Detroit Diesel Standard Template.ppt 3Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Project Objectives
Develop and validate on-highway truck engine technologies for 50% thermal efficiency and near-zero emissions (NZ-50) that are viable for subsequent product development and eventualcommercialization
Project Duration CY2000-CY2006
Project Sponsorship U.S. DOE, Office of Vehicle Technologies
Emphasis on Enabling Sub-system Technologies
9 Low Emissions Combustion Processes
9Fuel Injection Events Flexible, Precise, Repeatable, Distributed, Modulated Pressure / Rate-shape
9 Engine Charge Efficient Charging and EGR Cooling; Efficient, Variable Breathing
9 Controls and Automated Calibration Techniques Model-based, Adaptive, Closed-Loop
9 Basic Aftertreatment and System Integration Vehicle Boundary Conditions
NZ-50 Multi-cylinder Test-bed
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
5/23DetroitDiesel StandardTemplate.ppt 4Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Representative Over-the-Road Truck Route
0
10
20
30
40
50
60
70
80
90
100
Speed [rpm]
400 600 800 1000 1200 1400 1600 1800 2000 2200
14
14
10
10
10
6
6
6
6
Percent Time Spent as a Function of Engine Speed and LoadTypical Over-the-Road Operation - Class 8 Truck with 80,000 lbs. GVW
Detroit, MI to Carlisle, PA
Load
[%]
In addition to the project objective of peak thermal efficiency at a single operating condition, emphasis
placed on fuel economy (equivalent thermal efficiency) during over-the-road representative cycles
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
6/23Detroit Diesel Standard Template.ppt 5Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Thermal Efficiency StatusIntegrated Experimental and Analytical ResultsPeak Thermal Efficiency at a Single Operating Condition
Phase II-A
Out-of-Box with 07 Emissions
Phase II-A Interim
Result
FY05 Joule
Milestone
Demonstration
Phase I
Current ProductionEngines
NZ-50 Phase I
Demonstration
Technologies to Achieve 50.2% Thermal Efficiency Demonstrated
? Roadmap for >50% Equivalent Thermal Efficiency Being Developed
Phase II-B Interim
Results
PhaseII-B
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
7/23Detroit Diesel Standard Template.ppt 6Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Thermal Efficiency Roadmap - Key Building BlocksPeak Thermal Efficiency at a Single Operating Condition
Combustion OptimizationDistributed Injection EventsEGR Cooling System OptimizationCharging and Breathing Efficiency ImprovementBasic Exhaust Recovery
Selective Implementation of Low Emissions CombustionBasic NOx Aftertreatment Integration
Higher Compression Ratio (Higher Peak Firing Pressure)High Efficiency NOx AftertreatmentExhaust Energy Recovery (Turbo-compounding)
Increased Turbo System EfficiencyVariable BreathingAftertreatment Back-pressure Reduction
Parasitic Loss Reduction
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
8/23Detroit Diesel Standard Template.ppt 7Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Progress Towards Near-zero EmissionsExperimental Multi-Cylinder Engine Results
System-out Emissions Demonstrated to be Below 2010 EmissionsLevels over Representative Over-the-road Conditions
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
9/23Detroit Diesel Standard Template.ppt 8Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Progress Towards Near-zero EmissionsExperimental Multi-Cylinder Engine Results
Integrated System/Controls Optimization
ConventionalCombustion Optimization
Selective Implementation
of Low Emissions Combustion
EPA 2010 System-out Emissions LevelsDemonstrated over Transient FTP
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
10/23Detroit Diesel Standard Template.ppt 9Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Presentation Outline
Technical Status Towards Project Objectives
Technology Development Methodology
Technology Building Blocks Example Case Studies
9 Combustion
9 Fuel Injection System
9Air and EGR System
9 Controls
9 System Integration
Conclusions
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
11/23Detroit Diesel Standard Template.ppt 10Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
DDCs Integrated System Development Approach
2010+ Technology
Conceptual Targets
Identified via Analysis
Steady-state Multi-cylinder
Development Validates Analysis;
Simulates Transient
Transient Multi-cylinder
Development Validates
Steady-state Development;
Simulates Vehicle
Vehicle Development Validates
Transient Development; Identifies
Baseline for Next-generation
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
12/23Detroit Diesel Standard Template.ppt 11Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
NZ-50 Phase II-B Technology IntegrationBuilds on Phase I, Phase II-A
Advanced Transient
Combustion &
Emissions
Model-based Control
Strategies
Fuel System Flexibility
Next Generation
EGR System &
Exhaust RecoveryConcepts
Integration of
Aftertreatment
Technologies
Phase IIPhase II--BB
Phase I, II-A Demo
Transferable
Technology
2010+ System-level
Boundary Conditions
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
13/23Detroit Diesel Standard Template.ppt 12Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
NZ-50 Phase II Multi-cylinder Test-beds
NZ-50 Phase II Test-beds based on Multi-cylinder Series 60-2007 (shown above) and PrototypeHeavy-duty Engine
Prototype Heavy-duty Engine Test-bed Equipped with Exhaust Energy Recovery Hardware andIncreased Peak Firing Pressure Capability
Test-beds Equipped with Multiple-leg Exhaust System with Bypass to Provide Flexibility for TestingEngine-out and Tailpipe-out Configurations
Test-beds Equipped with Multiple Emissions Sampling Capability to Provide Spatial and Temporal
Resolution of Exhaust Species for Low Emissions Combustion
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Detroit Diesel Standard Template.ppt 13Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Presentation Outline
Technical Status Towards Project Objectives
Technology Development Methodology
Technology Building Blocks Example Case Studies
9 Combustion
9 Fuel Injection System
9 Air and EGR System
9 Controls
9 System Integration
Conclusions
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
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Detroit Diesel Standard Template.ppt 14Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Example Combustion System ResultLow Emissions Combustion Development on NZ-50 Phase II-B EngineDemonstrated Up to 70% Load (~15bar BMEP)
Low
Emissions
Combustion
Technical Demonstration of EPA 2010 Emissions
Engine-out
However, Technology not Viable for
Commercialization in the Near-to-Mid Term due
to Significant Thermal Efficiency Deterioration
In-cylinder Spatial Distribution of Temperature
and Equivalence Ratio forTraditional Diffusion
Limited Combustion and Low Emissions
Combustion
DOE-DDC Light Truck Program CY2002
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
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Detroit Diesel Standard Template.ppt 15Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Example Fuel Injection / Controls System ResultTechnology Demonstration of Precise, Distributed Injection Events
TDC
720CA
Injector #1
Injector #3
240CA
Cam Signal
Crank Signal
Simulated NZ-50
engine cam/crank
timing configuration
5 injection events
with 360 to 360 CA
injection timing span
There is overlapping
of injection among
six cylinders
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
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Detroit Diesel Standard Template.ppt 16Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Example Air and EGR System ResultVariable Breathing Optimization of Exhaust Valve Event and Intake Valve EventUsing Design of Experiments
0
1
2
3
4
5
6
7
8
9
10
A25 B25 C25 B50 A75 C75 A100 B100
BS
FCImprovement(%)
Various Engine Operating Modes
BSFC
BSFC
Comprehensive Engine Cycle Simulation Model Developed and Calibrated
Model Coupled with Design of Experiments and being Utilized to Analytically Optimize Engine Breathing Events to Reduce PumpingLosses, for Thermal Management and for In-cylinder Temperature Control for Low Emissions Combustion
Initial Application of the Model over Steady-state Operating Conditions, Followed by Application over Transient Conditions
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
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Detroit Diesel Standard Template.ppt 17Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Example Controls and Calibration System ResultModel-Assisted Total System Calibration and Optimization
Demonstrated improvement in FTP emissions
(NOx, CO) and fuel economy
Method emerging as a promising tool for calibrating
and optimizing increasingly complex total system
comprising engine, aftertreatment (NOx and PM)and vehicle systems
The next step involves 2nd iteration of model
generation and experimental validation over steady
state and transient
Optimized window showingimprovement in NOx, Smoke and
BSFC
Baseline
Analytical example shown here
demonstrates ~6% reduction in fuel
consumption and over 20% reduction inNOx and smoke emissions
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
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Detroit Diesel Standard Template.ppt 18Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Example System Integration ResultDemonstration of Transient EPA 2010 Emissions over FTP CycleExperimental Multi-Cylinder Engine Results
Integrated System/Controls Optimization
ConventionalCombustion Optimization
Selective Implementation
of Low Emissions Combustion
EPA 2010 System-out Emissions LevelsDemonstrated over Transient FTP
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
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Detroit Diesel Standard Template.ppt 19Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Presentation Outline
Technical Status Towards Project Objectives
Technology Development Methodology
Technology Building Blocks Example Case Studies
9 Combustion
9 Fuel Injection System
9 Air and EGR System
9 Controls
9 System Integration
Conclusions
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
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Detroit Diesel Standard Template.ppt 20Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
2004 vs. 2007 DDC Fuel Economy Comparison
Testing showed EPA07 engine to be within 1% of the EPA04 engine.
All runs were within 2% variance.
This test was a preliminary look at EPA07 vs. EPA04 Fuel Economy.
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
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Detroit Diesel Standard Template.ppt 21Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Conclusions
Demonstrated Technologies, via Integrated Experiments and Analysis, to Achieve the
Technical Objectives of the DOE-DDC Heavy Truck Project (NZ-50)
950.2% Peak Thermal Efficiency at a Single operating Condition
9 EPA 2010 Emissions Regulations over Steady-state and Transient Operation
Significant Risks and Challenges Remain for Application and Commercial Viability of
Some of the Technology Enhancements
However, Collaborative DOE-Industry Programs Lay a Strong Technology Foundation
for Subsequent Industry-led Product Development to Address These Challenges
Forward Engineering Methodologies Enabled by Analytical Tools were Beneficial to
Develop and Validate the Technical Roadmap to Enhance Thermal Efficiency and
Reduce Emissions
7/29/2019 Aneja (2006) - Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions Regulations
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Detroit Diesel Standard Template.ppt 22Confidential and Proprietary to Freightliner LLC. Freightliner LLC. All rights reserved.
Acknowledgements
DOE-DDC Collaborative Heavy-Truck Project (NZ-50)
Department of Energy, HQ
9 Gurpreet Singh
9 Roland Gravel
National Energy Technology Laboratory
9 Carl Maronde
9 Jeffrey Kooser