SELECTIVE CATALYTIC SELECTIVE CATALYTIC REDUCTIONREDUCTION

“Nuking the NOx”

Ed SaxmanArkansas Trucking AssociationNovember 11, 2008

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Emission DevelopmentEmission Development

Particulate Reduction

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regeneration

NOx Reduction

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Massive EGR

SCR+EGR

Emission DevelopmentEmission Development

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“The technology does not exist to achieve 0.2 without regeneration”

Regulated EmissionsRegulated Emissions

COCarbon Monoxide

HCHydrocarbons

PMParticulate Matter

Carbon (Soot)

NOxOxides of Nitrogen

NEAR ZERO

NEAR ZERONEAR ZERO

NEAR ZERO

NEAR-ZERO EMISSIONS

With EPA’10, using Selective Catalytic Reduction (SCR), we will have achieved a 99% reduction

in all regulated pollutants from untreated levels.

99% Fewer Pollutants99% Fewer Pollutants

• Why use SCR?– SUPERIOR fuel economy, compared to other solutions for EPA’10.

Total fuel costs will be significantly reduced, even allowing for the DEF.– Improved engine performance. Less EGR needed, less heat rejection

into cooling system results, greater power density, and higher efficiency.– Very little maintenance required– Reliable, proven approach (High volume production in other markets)

• What additions to the truck will be included?– DEF tank, on the driver’s side. Heated. Various sizes depending on fuel

capacity. Includes pump and filter.– Heated lines, pump to injector– DEF injector, mounted to today’s frame-mounted Diesel Particulate

Filter– SCR catalyst, behind DPF or vertically mounted

All About All About Selective Catalytic ReductionSelective Catalytic Reduction

EPA’10 HardwareEPA’10 Hardware

EPA’10 HardwareEPA’10 Hardware

EPA’10 HardwareEPA’10 Hardware

PLAIN AND SIMPLEPLAIN AND SIMPLE

WITH UREA YOU SIMPLY “NUKE THE NOx”WITH UREA YOU SIMPLY “NUKE THE NOx”

YOU CAN MAKE ALL THE ENGINE-OUT NOx YOU WANTYOU CAN MAKE ALL THE ENGINE-OUT NOx YOU WANT

AND NUKE IT IN THE AFTERTREATMENTAND NUKE IT IN THE AFTERTREATMENT

YOU CAN TUNE THE ENGINE TIMING AND PRESSURE RATIOS YOU CAN TUNE THE ENGINE TIMING AND PRESSURE RATIOS THE WAY THEY USED TO BE AND STILL HAVE A GENUINE THE WAY THEY USED TO BE AND STILL HAVE A GENUINE

NEAR-ZERO EMISSION COMPLIANT ENGINENEAR-ZERO EMISSION COMPLIANT ENGINE

• The after-treatment system utilizes an injection of a solution of urea.

• Urea is a compound of nitrogen that turns to ammonia (NH3) when heated. When a urea solution is injected into the exhaust stream and passed over a catalyst, the urea reacts with the NOx to form just nitrogen and water vapor – both clean components of ‘air’.

In essence, NH3 + NOx = N2 + H20

Diesel Exhaust Fluid (Urea)Diesel Exhaust Fluid (Urea)

• The main component of DEF is an organic nitrogen-rich compound called urea.

• Urea is synthesized from natural gas and carbon dioxide.• Urea is very widely used in agriculture as a fertilizer, most often distributed

in wax-coated pellets. (Not a water solution)• Urea is a compound of nitrogen that turns to ammonia (NH3) when heated.• Why call it DEF?

– Automotive industry wanted a generic name

• What is Diesel Exhaust Fluid made from?– 32.5% urea, 67.5% demineralized water– Must be kept extremely pure

• Why 32.5%?– Water solution with lowest freezing point, 12oF.– AUS32. Will also be an API standard.

Diesel Exhaust Fluid (Urea)Diesel Exhaust Fluid (Urea)

• The main component of DEF is an organic nitrogen-rich compound called urea.

• Urea is synthesized from natural gas and carbon dioxide.• Urea is very widely used in agriculture as a fertilizer, most often distributed

in wax-coated pellets. (Not a water solution)• Urea is a compound of nitrogen that turns to ammonia (NH3) when heated.• Why call it DEF?

– Automotive industry wanted a generic name

• What is Diesel Exhaust Fluid made from?– 32.5% urea, 67.5% demineralized water– Must be kept extremely pure

• Why 32.5%?– Water solution with lowest freezing point, 12oF.– AUS32. Will also be an API standard.

Freezing Point of Urea/Water Solutions

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• DEF Freezes at 12oF.

• You can walk up to a truck that has been standing over a frigid weekend and drive it away with no additional warm-up time.

• A few cc’s will melt immediately due to the heat from the exhaust.

• The tank heater will eventually melt the rest as you drive.

• Oh, by the way – one of the other uses for urea is as a de-icer. Google it.

So This Stuff Freezes?So This Stuff Freezes?

• For every $1.00 of Diesel Exhaust Fluid you put in your truck with SCR technology, your diesel fuel costs will be reduced by nearly $2.00.

• "The total COST of fuel PLUS Diesel Exhaust Fluid for EPA'10 will be 5% LESS than our EPA’04 engine, under similar conditions."

How Much Extra How Much Extra Does That Stuff Cost?Does That Stuff Cost?

Quick,Quick,Gimme a BuckGimme a Buck

How much Diesel Exhaust Fluid is required?

• Volvo is optimizing the amount of Diesel Exhaust Fluid (DEF) to be injected for US’10 standards, but the rate will probably fall in the 2-4% range.

• The more DEF, the lower the diesel fuel consumption. The less DEF, the more diesel fuel consumption. We will optimize for the lowest total cost.

What will be the price of Diesel Exhaust Fluid?

• According to Volvo’s information, it is estimated at about 3/4 the price per gallon of diesel fuel. The exact price will, as always, be set by the market.

Can the UREA infrastructure meet the additional demand?

• Easily. Globally over 100 million tons of urea were produced last year, primarily for agriculture, and also for cosmetics.

DEF Q&ADEF Q&A

What about the base engine?• Base engine will only experience minor changes.

– Same proven injection system– Same camshaft– Same cylinder head– Same block

Changes for EPA’10Changes for EPA’10

NOx: At Odds withNOx: At Odds with Fuel Economy Fuel Economy

EFFICIENCY vs. NOx

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In general, the more efficient the combustion, the higher the NOx output.

The lower the NOx output, the lower the efficiency

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NOx Reduction, %

Major improvements in NOx came with ultra high pressure fuel injection.

• Higher fuel injection pressure gives finer atomization for better combustion

• Shaped fuel injection delivery allows pressure rise to be controlled for best possible release of power.

• Proven Delphi Dual Solenoid fuel injector used since EPA’02 now delivers 35,000 psi for EPA’07

How Have We Been AbleHow Have We Been Ableto Reduce NOx andto Reduce NOx and

Still Maintain Fuel Economy? Still Maintain Fuel Economy?

Dual SolenoidDual SolenoidFuel InjectorFuel Injector

Exhaust Gas RecirculationExhaust Gas Recirculation

• The big step in the evolution of the low-emission diesel was Exhaust Gas Recirculation. Some of the exhaust gas is recycled back through the engine under certain circumstances.

• The purpose of the EGR is not to ‘re-burn the exhaust’ • EGR dilutes the amount of oxygen in the intake charge. This

reduces the temperature of combustion and lowers formation of NOx.

EGR CoolerEGR Cooler

Hydraulic Actuator

Pressure balanced poppet design

Solenoid hydraulic control valve

G. W. Lisk Co., Inc.

D11, D13, D16 EGR Valve

Near zero force to open, combined with powerful actuator => the valve will never stick

October 2, 2007 -- FIRST FIVE EPA’10

TEST TRUCKS DELIVERED

EPA’10 Testing EPA’10 Testing ExperienceExperience

• About Twenty EPA’10 Customer Function Trucks ~ Well Over a Million Miles • 23 SCR Evaluation Trucks since 2002

~ 9 Million Miles• ~150,000 SCR Euro IV and Euro V trucks globally

• We know what we’re doing

EPA’10EPA’10Testing ExperienceTesting Experience

Engine

EGR Fuel

Fuel Mixing zone

DPF

Diesel Exhaust FluidReservoir

Sensors:3 Temperature sensors 1 Differential Pressure sensor2 NOx-sensors

OBD

DEF Mixing zone

SCR

Exhaust Outlet

On Board Diagnostics (OBD)On Board Diagnostics (OBD)

Selective Catalytic ReductionSelective Catalytic Reduction

Ready For COReady For CO22

In March, we exhibited seven CO2-Neutral trucks, each powered by a totally fossil carbon-free fuel (plus a diesel electric hybrid) at the Washington International Renewable Energy Conference (google WIREC).

The message was to policymakers was, “pick the RIGHT alternative fuel for the future, and we will develop an engine for it.”

Ready For COReady For CO22

• Thank you. Questions?