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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
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SCANIA since 1891
Iran Low Particulate Emissions
4/27/2015
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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