Review of the 21st Century Truck Partnership, Second Report (2012) / Chapter Skim
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3 Engine Systems and Fuels
3 Engine Systems and Fuels
Pages 27-58
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From page 27... ...
Although diesel engines used in most trucks are the recovers some of the exhaust energy. Diesel engines operate most efficient on-road transportation power plants available at relatively low speeds, which reduce mechanical friction today, with diesel engines only approximately 42 percent of losses, and high power density is achieved primarily through the fuel energy is converted to mechanical work, resulting in high brake mean effective pressure (BMEP)
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From page 28... ...
with aftercooling and interintended by the EPA to be "aftertreatment-forcing." After cooling, and turbocompounding. The turbomachinery serves treatment technologies for PM were necessary in 2007, several purposes in engine performance and emissions control, and all new truck heavy-duty diesel engines were equipped including airflow for high BMEP and transient response, EGR with diesel particulate filters (DPFs)
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From page 29... ...
: The DOE and the heavy-duty engine industry have been • Advanced Combustion Engine working in public-private partnerships to develop and dem -- Combustion and Emission Control (shared between onstrate advanced diesel engine technologies and concepts light- and heavy-truck engines) that improve engine thermal efficiency while meeting the -- Heavy Truck Advanced Combustion Engine EPA's 2010 emissions standards.
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From page 30... ...
DE-FC26-05-NT42418 15 L engine: 16.4% improvement in brake thermal efficiency (2010 emissions with SCR NOx technology) 6.7 L engine: 14% improvement in fuel economy (Tier 2 Bin 8 emissions met without NOx aftertreatment)
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From page 31... ...
As the effective The objective of the WHR program is to improve engine ness of SCR is further improved, the use of EGR is likely to BTE by 10 percent (i.e., from 42 percent to 46 percent BTE) FIGURE 3-2 Cummins Waste Heat Recovery (WHR)
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From page 32... ...
. that this project is also reported as the Bilateral Program being conducted by Volvo Powertrain North America and Volvo AB of Sweden.6 It is jointly funded by the DOE and The nine diesel engine programs and projects reviewed above are examples of DOE public-private partnerships.
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From page 33... ...
It should be noted that the Programs and Projects Directed Toward Achieving 21CTP SuperTruck projects include efforts to reduce the load that Goal 2 the vehicle places on the engine as well as to improve the 21CTP Goal 2: Research and develop technologies which efficiency of the engine. By lowering the load on the engine, achieve a stretch thermal efficiency goal of 55% in prothe SuperTruck projects will actually make reaching the 50 totype engine systems in the laboratory by 2015 (DOE, percent efficiency goal at cruise conditions more difficult 2011a)
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From page 34... ...
LANL $290,000 $290,000 Computationally Efficient Modeling of High-Efficiency Clean LLNL $1.0 million $1.0 million Combustion Chemical Kinetic Research on HCCI and Diesel Fuels LLNL $400,000 $400,000 Stretch Efficiency for Combustion Engines: Exploiting New ORNL $250,000 $250,000 Combustion Regimes HCCI and Stratified-Charge Compression Ignition Engine Combustion SNL $750,000 $750,000 Research Heavy-Duty Low-Temperature and Diesel Combustion Modeling SNL $580,000 with $660,000 with $115,000 subcontract $115,000 subcontract to UW-Madison to UW-Madison Combustion Modeling Large Eddy Simulation Applied to LTC/Diesel/ SNL $450,000 $450,000 Hydrogen Engine Combustion Research Low-Temperature Diesel Combustion Cross-Cut Research SNL $570,000 $660,000 Optimization of Advanced Diesel Engine Combustion Strategies University of $360,000 $1.2 million Wisconsin–Madison NOTE: Acronyms are defined in Appendix I
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From page 35... ...
more robust computational design tools able to simulate the Higher efficiencies in heavy-duty truck engines have also full range of engine combustion approaches (conventional been shown in the laboratory. Implementation of diesel LTC mixing-controlled diesel combustion premixed and stratified approaches has begun in heavy-duty diesels for a portion of flame propagation, the LTC bulk ignition and combustion the fuel burned during moderate- to light-load parts of the engine operating range, providing significant engine-out 10 Gurpreet Singh, DOE, "Overview of the DOE Advanced Combustion emissions reduction.
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From page 36... ...
The DOE-funded research in advanced engine for the market. combustion at the national laboratories, in industry, and at The SuperTruck engine programs are discussed in this secuniversities is well managed and addresses important aspects tion; the vehicle programs are discussed in Chapter 8.13,14,15 for achieving an integration of advanced combustion processes that should be important enablers for achieving the • Daimler Trucks/Detroit Diesel: Technologies listed in 55 percent BTE goal as well as providing ongoing improve the September 9, 2010, presentation to the committee ments.
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From page 37... ...
The DOE should ensure that the PM-NOx balance; -- Friction reduction/insulation: engine R&D for the goal of 50 percent BTE at over-the-road Low friction, weight reduction, electrification of cruise conditions and the stretch goal of 55 percent BTE in engine accessories, drive mechanism improvements, an engine in a laboratory that will now be carried out under heat rejection reduction, insulated exhaust ports and the SuperTruck program receive the appropriate share of the manifolds; SuperTruck funding and benefit extensively from the DOE -- VVA: funded research programs in advanced engine combustion. Effective compression ratio control, cylinder deacti vation; ENGINE PROGRAMS OF THE ENVIRONMENTAL -- Dual fuel (gasoline and diesel)
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From page 38... ...
The EPA has demonstrated that optimized TABLE 3-6 EPA's Homogenous-Charge Compression Ignition (HCCI) Engine Features for a Series Hydraulic E85 alcohol-fueled engines using conventional three-way Hybrid Demonstrator Shuttle Bus catalysts for meeting 2010 emissions standards can achieve current diesel levels of BTE that can potentially provide Feature Description engine technology suitable for both conventional and hybrid Base engine 6.4 L base engine (base was a diesel engine)
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From page 39... ...
these unique operating conditions, NOx and PM are below the levels required by the 2010 emissions standards without aftertreatment; HC and CO emissions are controlled with Engine Progams oxidation catalysts. TARDEC conducts tests of high power density propulsion systems in which additional requirements of operating at DEPARTMENT OF DEFENSE ENGINE PROGRAMS high ambient temperatures (125°F)
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From page 40... ...
Army is launching a 4-year program to advance engines for use in Army ground vehicles. Targets for these the state of the art by developing new powertrain technologies programs are as follows: 48 percent BTE, brake specific heat that will improve overall efficiency by reducing fuel consumprejection (BSHR)
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From page 41... ...
Modified fuel specifications and new system in the laboratory for 2015. fuel formulations may facilitate expanding the operating r ange of new combustion regimes like homogeneousFUEL PROGRAMS charge compression ignition as well as improving the operation of conventional diesel engines.
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From page 42... ...
primarily bio-derived fuels. In addition, fundamental experi The remainder of this section addresses DOE fuels pro- ments are being done using advanced optical diagnostics to grams, DOD fuels programs, advanced petroleum fuels, evaluate the impact of nonpetroleum fuels on the combustion biofuels, alternative fuels, and lubricants.
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From page 43... ...
Coordinating Research ing diesel engines. TARDEC is concerned over fuel lubricity Council (CRC)
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From page 44... ...
Transition to such an optimal fuel and improvements in vehicle fuel consumption, total truck petro- engine combination would have to be facilitated through the leum consumption would continue to increase through 2035, development of engines that are capable of adjusting to the dominated by the increase for heavy-duty trucks.25 This will fuel characteristics. have major implications for refineries in the United States, which will see the ratio of gasoline to diesel fuel production Biofuels change from highly gasoline-biased to highly distillate-fuelbiased, and will necessitate changes in refinery configuration For many years, biofuels have been held out as the "holy and operation.
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From page 45... ...
With all of the above, what success has occurred, and Bio-mass derived dimethyl ether (DME) has received what is the outlook for biofuels, especially for biodiesel attention, especially in Europe, as a sulfur-free diesel fuel fuels that could be used in truck diesel engines?
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From page 46... ...
The DOE should reinstate its pro- diesel engines. The DOE should focus on processes likely to gram for advanced petroleum-derived fuels (they will be be commercially successful in the next 10 to 20 years.
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From page 47... ...
on emission-control-system performance, especially regard- The process for periodic enhancements of heavy-duty ing PM and NOx. diesel truck engine lubricating oil has been initiated, begin It is well known that reducing powertrain friction, through ning nearly a year ago as the EPA and DOT/NHSTA GHG design changes and the use of more efficient engine oils and emissions and fuel efficiency rule was anticipated (EPA/ transmission fluids, can reduce fuel consumption.
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From page 48... ...
for advanced • New 21CTP fuels and lubricants Goal 1: "Establish engines and new combustion regimes for the post-2010 the influence of fuel and lubricant sulfur on emission- time frame that enable further fuel economy benefits control technologies." and petroleum displacements while lowering emis Status: The 21CTP engine white paper dated August sions levels to near-zero, thus adding incentive for 30, 2010, states: "The sulfur and ash content of lubri- using non-petroleum fuels." cants are sufficiently high to be factors in degradation Status: The NRC Phase 1 report (2008) stated that this of performance of NOx adsorber catalysts and to influ- goal "was intended to emphasize the development of ence the cleaning intervals and regeneration phenom- non-petroleum fuel formulations beyond biodiesel," ena in DFPs, for example." No progress was reported previously addressed by Goal 1.
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From page 49... ...
, in addition to regional haze. Thus, conaftertreatment system, allowing for simpler, less expensive FIGURE 3-4 Emission control system architecture generally being applied to meet 2010 new engine emissions standards of the Environ 3-4.eps mental Protection Agency.
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From page 50... ...
Particulate matter aftertreatment in meeting its overall program goals and has emitted from modern diesel engines is typically in the size written a white paper specifying the role of aftertreatment range of 10 to 250 nanometers (µm)
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From page 51... ...
As part of the Phase 2 review, the DOE supplied to the • 21CTP Goal 6 related to aftertreatment technologies: committee a list of research programs that should be consid "Research pathways to post 2010 regulations for emis ered as part of the 21CTP. The names of these projects, the sions, such as toxics and carbon dioxide." lead agency performing the work, their DOE funding level, Comment: The regulation for carbon dioxide emis and a link to the most recent EERE merit review presentation sions from heavy-duty trucks will entail research into are presented in Table 3-11.
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From page 52... ...
However, versity of Houston is exploring optimal catalyst design and as new combustion processes, possibly using different fuels operating strategies for lean NOx reduction in a coupled ranging from petroleum-derived fuels to biofuels and synLNT/SCR system. Participants in this program include the thetics, are integrated into future engine operating maps, it University of Kentucky's Center for Applied Energy, Ford, is important to assess particulate size distribution characterBASF Catalysts, and ORNL.
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From page 53... ...
$892,000 pdfs/merit_review_2010/health_impacts/ace046_ lawson_2010_o.pdf NOTE: Funding levels represent DOE funds only. SOURCE: Information based on DOE Vehicle Technologies Program Merit Review (DOE, 2010b)
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From page 54... ...
CARB introduced regulations to limit the increase in NO2 emissions from DPF equipped diesel engines.) HIGH-TEMPERATURE MATERIALS • Certain liquefied natural gas (LNG)
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From page 55... ...
An example of this need for materials is that the higher efficiency, midterm goals for tensile strength will be thermal efficiency of the diesel engine is enhanced with the approaching 75,000 pounds per square inch, which exceeds ability to run the engine at higher peak cylinder pressures. the 65,000 pounds per square inch tensile strength for Higher cylinder pressures and temperatures will challenge compacted graphite cast iron.
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From page 56... ...
• Determine the effect of machining parameters on resid ual stress in ceramic diesel engine exhaust valves, Recommendation 3-10. The DOE should fund programs in • Study the residual stresses resulting from piercing the areas outlined in its "21CTP White Paper on Engines and truck frame rails, Fuels" (February 25, 2011)
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From page 57... ...
2011a. 21st Century Truck Partnership White Paper on Engines and Fuels.
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From page 58... ...
Long Haul Combination Truck Fuel Consumption and CO2 Emissions. Wijffels, H., and M.J.
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