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1 Iran Low Particulate Emissions Jorge Soria Galvarro, M.Sc David Raymand, PhD Senior Technical Adviser Senior Development Engineer Vehicle Regulations Scania R&D Catalytic converter and particulate filter performance Scania R&D Iran Low Particulate Emissions 4/27/2015 2 SCANIA since 1891 Iran Low Particulate Emissions 4/27/2015 3 EU Emissions Regulation – successively lower emissions in European legislation NOx g/kWh Particle number 5 Euro III Euro VI Euro III 4 Euro IV 3 Euro V 2 Regulated Fuel quality 1 Euro VI 0.02 0.04 0.06 0.08 0.10 Euro III 300 ppm S Euro IV 50 ppm S Euro V Euro VI 10 ppm S Particulate mass g/kWh Iran Low Particulate Emissions 4/27/2015 4 EU Emissions Regulation – successively lower emissions in European legislation 5 4 3 2 Euro III Euro III Euro III + DPF NOx g/kWh Particle number Euro VI Euro III+DPF Euro IV Euro V Regulated Fuel quality 1 Euro VI 0.02 0.04 0.06 0.08 0.10 Euro III 300 ppmS ppm S Euro IV 50 ppm S Euro V Euro VI 10 ppm S Particulate mass g/kWh Iran Low Particulate Emissions 4/27/2015 5 Challenges for EuVI • Stricter limits – as presented in previous slides • Stronger requirements on on-board diagnostics (two examples): • Correct on-board monitoring of NOX by continuous measurement of NOX using vehicle sensors • Euro VI step C adds continuous monitoring of PM-emissions (technology neutral – may be with soot sensor or otherwise equivalent method) All components affecting emissions have to be monitored by OBD • Both increases in engine emissions and decreases aftertreatment capability must be diagnosed and handled Iran Low Particulate Emissions 4/27/2015 6 OBD NOX-sensor Tempsensor Tempsensor UDS VGT Tempsensor NOX-sensor charge air DOC DPF EGR valve SCR dP-sensor High pressure fuel pump MAF Throttle Coolant temp Fuel pressure All components affecting emissions have to be monitored by OBD Iran Low Particulate Emissions 4/27/2015 Scania Proposal for approval of new type exhaust aftertreatment • Euro VI regulation is the first regulation in the world to regulate PN emissions. The PN measurement method was developed in Europe after eight years research program. • The PN measurement test procedure for Euro VI regulation is described in UNECE R49 rev 6 Annex 4 paragraph 10. • The PN measurement equipments requirements for Euro VI regulation is described in UNECE R49 rev 6 Annex 4 Appendix 8. • The test condition for engine with exhaust aftertreatment system described in R49 Rev. 4 Annex 4 section 6.6 shall be used. • Test cycles according to R49 Rev 5 Annex 4A for Euro IV • The method is so far the most robust method for PN measurement, with sufficient sensitivity and reliability. • We recommend that Iran adapt the R49 PN measurement method for a national PN related regulation, the same method will be used in a later stage when Iran will enforce Euro VI level regulations. • Base on the corresponding engine and aftertreatment technology and actual test cycle we propose particle number emission limit of 8x10e12 Iran Low Particulate Emissions 4/27/2015 7 8 What does Scania stand for? • • • • Low emissions Low fuel consumption High reliability High uptime Scania was the world’s first manufacturer to introduce serial production of Euro VI trucks and buses in 2011, the toughest environmental norm to this date. Resources corresponding to more than 5000 man years of development where invested in this achievement, ensuring the lowest fuel consumption and highest reliability ever measured on our product range The Scania Eu VI system offers passive regeneration and regenerates the DPF while in service Iran Low Particulate Emissions 4/27/2015 9 Scania Solutions • Developing fully integrated engine + after treatment is part of Scanias core competence • Scania has proved several times that we are able to meet stricter emissions regulation while improving customer business case => Lower emissions and lower operating cost • We currently have on-going collaborations with all of the principal catalyst suppliers • We are actively monitoring new technology to be able to supply our customers with the best possible solution Iran Low Particulate Emissions 4/27/2015 10 Main technical challenge for Iran • Solution must perform with current fuel quality and projected fuel quality • Secondhand value rely on that the used vehicle is competitive with newer offerings • Solution must be fully integrated There is no need to tamper with a EuVI system: It just works! • System must be fully integrated with vehicle diagnostics with clear driver alerts Iran Low Particulate Emissions 4/27/2015 11 Driver alerts for EuVI DPF-system The driver gets clear advice on what to do to protect the vehicle from low performance or damage. The indications cannot be ignored since they are presented directly in front of the driver. Iran Low Particulate Emissions 4/27/2015 Timeplan for new Aftertreatment System 2014 2015 2016 2017 2018 2019 2020 2021 Lead time for a completely new AT-system Research Finding and optimizing catalysts for available fuel Control strategy Service methods Product industrialisation 18 months of concept development Launch New AT-system Field trials - verification Optimization of production tooling Final calibration of engines for optimal fuel consumption Parts available in the market ~3.5 yrs needed for industrialization • For a new after treatment system specifically for Eu III/IV with DPF • Final product could have similar performance as current offerings Iran Low Particulate Emissions 4/27/2015 12 Timeplan for adapted Aftertreatment System 2014 2015 2016 2017 2018 2019 2020 2021 Lead time for a adapted AT-system Research Product industrialisation Finding and optimizing catalysts for available fuel Control strategy Service methods ~ 1 yrs of research Launch Adapted Scania AT-system for Eu III/IV Iran Field trials - verification Optimization of production tooling Final calibration of engines for optimal fuel consumption Parts available in the market ~1.5 yrs needed for development and durability testing • For a modified Scania system modified for Eu III/IV with DPF • Final product would have similar performance as current offerings • Final product would not affect load carrying capacity or chassi flexibilty Iran Low Particulate Emissions 4/27/2015 13 15 Exhaust treatment components • DOC – Diesel Oxidation Catalyst • Oxidizes hydrocarbons and carbon monoxide to water and CO2 • DPF – Diesel Particulate Filter • Removes particles from the exhaust. Breaks down PM to CO2 • UDS – Urea Dosing System • Injects liquid Urea to exhaust • Vaporization module • Turns liquid Urea to gaseous ammonia • SCR – Selective Catalytic Reduction Catalyst • Catalyst that breaks down NOX using ammonia • ASC – Ammonia Slip Catalyst • Removes excess ammonia from emissions Iran Low Particulate Emissions 4/27/2015 16 Scania Aftertreatment toolbox Components with verified performance DOC (max 10ppm S) DPF (max 10 ppm S) DPF Vaporization Module 1 Vaporization Module 2 SCR Volume A ASC ASC A Iran Low Particulate Emissions SCR Volume B SCR Volume C 4/27/2015 17 Scania Aftertreatment toolbox Components with verified performance Euro III DOC (max 10ppm S) DPF (max 10 ppm S) DPF Vaporization Module 1 Vaporization Module 2 SCR Volume A ASC SCR Volume B SCR Volume C ASC A Iran Low Particulate Emissions 4/27/2015 18 Scania Aftertreatment toolbox Components with verified performance Euro IV DOC (max 10ppm S) DPF (max 10 ppm S) DPF Vaporization Module 1 Vaporization Module 2 SCR Volume A ASC SCR Volume B SCR Volume C ASC A Iran Low Particulate Emissions 4/27/2015 19 Scania Aftertreatment toolbox Components with verified performance Euro V DOC (max 10ppm S) DPF (max 10 ppm S) DPF Vaporization Module 1 Vaporization Module 2 SCR Volume A ASC SCR Volume B SCR Volume C ASC A Iran Low Particulate Emissions 4/27/2015 20 Scania Aftertreatment toolbox Components with verified performance Euro VI DOC (max 10ppm S) DPF (max 10 ppm S) DPF Vaporization Module 1 Vaporization Module 2 SCR Volume A ASC ASC Iran Low Particulate Emissions SCR Volume B SCR Volume C 4/27/2015 21 Scania Aftertreatment toolbox Components with verified performance Euro IV Possible new additions DPF (S tolerant) DOC (max 10ppm S) DPF (max 10 ppm S) DPF Burner unit Vaporization Module 1 Vaporization Module 2 DOC (S tolerant) SCR Volume A ASC SCR Volume B SCR Volume C ASC A New demands require new additions to toolbox Iran Low Particulate Emissions 4/27/2015 22 Scania Aftertreatment toolbox Components with verified performance Euro IV + DPF DPF (S tolerant) DOC (max 10ppm S) DPF (max 10 ppm S) DPF Burner unit Vaporization Module 1 Vaporization Module 2 DOC (S tolerant) SCR Volume A ASC ASC A Iran Low Particulate Emissions SCR Volume B SCR Volume C 4/27/2015 23 Development method for adding catalyst to Toolbox Weeks 1 2 3 4 5 6 7 8 9 11 10 12 13 14 15 Design of experiment Sample manufacture of prototype catalyst Test – Engine/Lab. reactor Analysis Aftertreatment development 1 yrs Research 2015 J F M A M 1.5 yrs Industrialisation J J A S New legislation communicated O N D 2016 Q1 Q2 Q3 Q4 2017 Q1 typical 2 year lead time Q2 New legislation into effect Project definition Verification Catalyst development – iteration #1 Catalyst development – iteration #2 Optimization Concept FMEA Catalyst development – iteration #3 Service FMEA Industrialization Control strategy % Diagnostics Development Iran Low Particulate Emissions Q3 4/27/2015 Q4 24 Development method for adding catalyst to Toolbox Weeks 1 2 3 4 5 6 7 8 9 11 10 12 13 14 15 Design of experiment Sample manufacture of prototype catalyst Test – Engine/Lab. reactor Analysis The majority of the time is spent in industrialisation and verification Aftertreatment development 1 yrs Research 2015 J F M A M 1.5 yrs Industrialisation J J A S New legislation communicated O N D 2016 Q1 Q2 Q3 Q4 2017 Q1 typical 2 year lead time Software development takes the same amount of time as component development Q2 New legislation into effect Project definition Catalyst development – iteration #1 Catalyst development – iteration #2 Verification Optimization Concept FMEA Catalyst development – iteration #3 Service FMEA Industrialization Control strategy % Diagnostics Development Iran Low Particulate Emissions Q3 4/27/2015 Q4 25 Retro-fit solutions as factory option? • All components Scania delivers with the vehicle covered by warranty must meet our demands • All components on a Scania vehicle has passed our verification process. -> Retro-fit solutions is not necessarily a quicker path. Retro-fit solutions must be verified like any other component. Modifying an existing Scania system usually saves time since the majority of the verification is already finished, e.g. shake tests Iran Low Particulate Emissions 4/27/2015 26 Essential verifications • Emissions performance • Must meet legislation regardless the configuration. • Functional performance • Must work as an integrated component. OBD and other software functionality must be thoroughly tested. • Mechanical durability • Structural integrity must be guaranteed, even for very tough conditions – e.g. high speeds on bumpy roads • Climate durability • 1 year is required to perform one winter test and one summer test. Typical it requires two cycles, one for development and one for verification. Verification of factory-fit equipment is necessary regardless of whether system is retro-fit based or original equipment Iran Low Particulate Emissions 4/27/2015 27 Main message • Legislation should be technology neutral to allow for best possible solution for the customer. Therefore the test method in the legislation should be base on the regulation UNECE R49 • • • • R49 rev 6 Annex 4 paragraph 10 R49 rev 6 Annex 4 Appendix 8 R49 Rev. 4 Annex 4 section 6.6 R49 Rev 5 Annex 4A for Euro IV • Base on the corresponding engine and aftertreatment technology and actual test cycle we propose particle number emission limit of 8x10e12 ( Please note that the PN number level of 8x10e11 correspond to Euro VI engine technology and Euro VI test cycles) • Scania actively evaluates new advanced filtration concepts looking for superior DPFs. Development work already started to expand SCANIA modular toolbox Best solution may change as technology develops. Iran Low Particulate Emissions 4/27/2015
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