2010 Nuking The N Ox

SELECTIVE CATALYTIC SELECTIVE CATALYTIC REDUCTIONREDUCTION

“Nuking the NOx”

Volvo Trucks North America

Emission Development Emission Development

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1974 1988 1991 1994 1998 10'02 2007 2010E

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NOx

Particulates

Series3NOx with Credits


Particulate Reduction

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Reducing ParticulatesReducing Particulates

Units: g/hp-hr


NOx Reduction

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Massive EGR

SCR+EGR

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aftertreatment

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

Reducing Oxides of Nitrogen (NOx)Reducing Oxides of Nitrogen (NOx)

Units: g/hp-hr


COCarbon Monoxide

HCHydrocarbons

PMParticulate Matter

Carbon (Soot)

NOxOxides of Nitrogen

NEAR ZERO

NEAR ZERONEAR ZERO

NEAR ZERO

Near-Zero Emissions from Truck DieselsNear-Zero Emissions from Truck Diesels


Exhaust Gas RecirculationExhaust Gas Recirculation

A 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. But how much is too much?

EGR CoolerEGR Cooler


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

Higher fuel injection pressure gives finer atomization for better combustion, reducing the soot

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 & ‘10

How Have We Been Able to Reduce NOxHow Have We Been Able to Reduce NOxand Still Maintain Fuel Economy?and Still Maintain Fuel Economy?

Dual SolenoidDual SolenoidFuel InjectorFuel Injector


Industry Industry DefinitionDefinition

EGR FlowEGR Flow

Light EGR 10% - 20%

Heavy EGR 20% - 35%

Massive EGR 35% - 50+%

MoreMore Exhaust Gas Recirculation?? Exhaust Gas Recirculation??


Keeping Everything in Balance is a Keeping Everything in Balance is a Challenge…Challenge…

Peak Cylinder Pressure

NOx to Soot Ratio

Displacement

Fuel Injection Pressure

Air/Fuel ratio

Regeneration

Power Density

“Not to Exceed” Emission Window

Boost Pressure


The Solution for 2010:

Ultra High Pressure Fuel Injection to Reduce the Soot

Light-Heavy EGR to knock Down the NOx

DPF aftertreatment for Near-Zero Soot

SCR aftertreatment for Near-Zero NOx

How Do We Meet The Near-Zero Levels How Do We Meet The Near-Zero Levels of 2010 with Good Fuel Economy??of 2010 with Good Fuel Economy??


Why use SCR? (NOx Aftertreatment)

– 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 Selective Catalytic ReductionAll About Selective Catalytic Reduction


EPA’10 Hardware: Injector and CatalystEPA’10 Hardware: Injector and Catalyst


EPA’10 HardwareEPA’10 Hardware


DEF Indicator – a Real GageDEF Indicator – a Real Gage


Volvo In-Tank Heater / PickupVolvo In-Tank Heater / Pickup

Fits inside DEF tank from top

Circulates engine coolant through the Diesel Exhaust Fluid to maintain proper temperature – 60oF

All stainless steel, high-quality

DEF level gage float (in center), with wiring harness

DEF pickup with intake filter

No tank insulation is required

By the way – Volvo Group has already delivered over 150,000 of this part. Like the rest of the SCR system, it’s proven. It works.


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 REDUCE THE EGR AND TUNE THE ENGINE TIMING YOU CAN REDUCE THE EGR AND TUNE THE ENGINE TIMING AND PRESSURE RATIOS THE WAY THEY USED TO BEAND PRESSURE RATIOS THE WAY THEY USED TO BE

AND STILL HAVE A GENUINE NEAR-ZERO EMISSION AND STILL HAVE A GENUINE NEAR-ZERO EMISSION COMPLIANT ENGINECOMPLIANT ENGINE


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

Volvo is the only manufacturer who is going into 2010 with essentially the same engine as 2007


MASSIVE MASSIVE EGREGR

EGR + SCREGR + SCR

Power Density LESSLESS MOREMORE

Heat Rejection MOREMORE LESSLESS

Fuel Efficiency LESSLESS MOREMORE

Comparing EGR & SCRComparing EGR & SCR


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’.

Ammonia + NOx react to make N2 + H20 – nitrogen and water vapor – nothing left over.

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. DEF is governed by DIN 70700 and the ISO 22241-1 specifications.

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


Freezing Point of Urea/Water Solutions

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Diesel Exhaust FluidDiesel Exhaust Fluid

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Ice


DEF Freezes at 12oF.

THERE IS NO DELAY IN DRIVING A TRUCK WITH A FROZEN DEF TANK.

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?


Los Angeles

New York

Here are the NumbersHere are the Numbers

(Worst Case, as of this date)(Worst Case, as of this date)

13 gallons DEF

You can travel coast to coast

And still have 1/3 tank of DEF left over


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


Potential DEF Sale LocationsPotential DEF Sale Locations


Diesel Exhaust Fluid DispensersDiesel Exhaust Fluid Dispensers


As Close As Your NearestAs Close As Your Nearest Travel Center Convenience Store Travel Center Convenience Store

D


October 2, 2007 -- FIRST FIVEEPA’10 TEST TRUCKS DELIVERED

EPA’10 Testing ExperienceEPA’10 Testing Experience


• About Twenty EPA’10 Customer Function Trucks ~ Well Over 1.5 Million Miles • 23 SCR Evaluation Trucks since 2002

~ 10 Million Miles• ~150,000 SCR Euro IV and Euro V trucks globally

~ 2+ Billion Miles

• We know what we’re doing

EPA’10 Testing ExperienceEPA’10 Testing 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)


Feature Benefit

1. Fuel Economy SCR more efficient than Massive EGR Including DEF, lower by $3000 (or more)

2. Weight D13 with SCR several hundred pounds less than 15L

3. Power Power density with SCR is higher, not lower

4. Complexity Volvo adds a tank, with coolant line heater and pump

5. Durability / Reliability

Volvo has the benefit of implementing a proven technology – 150,000 on road already, 2x+ by 2010

6. Cost of Operation

Due to the lower fuel costs, and to higher reliability, SCR will clearly provide the customer’s lowest cost of operation.

Volvo for EPA’10Volvo for EPA’10


Thank you. Questions?

2010 Nuking The N Ox

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