Heavy Duty Truck Engine

Achieving High Efficiency at 2010 Emissions

Christopher R. Nelson Cummins Inc.

DEER Conference August 23rd, 2006

Program Goals and Timing

Phase I Phase IIA

Demonstrate Demonstrate

� 45% BTE � 45% BTE

� 2002 Emissions � 2007 Emissions • 2.5 gm • 1.2 gm BSNOx

BSNOx • 0.01 gm BSPM

• 0.1 gm

BSPM

Phase IIB

Demonstrate � 50% BTE

� 2010 Emissions • 0.2 gm

BSNOx • 0.01 gm

BSPM

August 23rd, 2006 2

August 23rd, 2006 3

Advanced Combustion + Cooled EGR

0.2 1.2 2.5 8.0

45%

50%

40%

Project PhaseProject PhaseIIBIIB

IIAIIAII

NOx [g/hpNOx [g/hp--hr]hr]

Engi

ne B

rake

The

rmal

Engi

ne B

rake

The

rmal

Effic

ienc

y [%

] @ C

ruis

e Sp

eed

Effic

ienc

y [%

] @ C

ruis

e Sp

eed

4.0

EPAEPA--9898Technology Roadmaps and OptionsTechnology Roadmaps and Options

Cooled EGR

HPCR Fuel System, Hi-Cap. EGR Cooling, Advanced Air Handling, Particulate Aftertreatment

Other Fuel Economy Countermeasures: Engine Parasitic Reduction, Low Temperature, Hi-Cap. EGR Cooling

No EGR SCR Aftertreatment

Previous Deliverables

1.2 2.5 4.0

EPAEPA--9898

August 23rd, 2006 4

0.2 8.0

45%

50%

40%

Project PhaseProject PhaseIIBIIB

IIAIIAII

NOx [g/hpNOx [g/hp--hr]hr]

Max

imum

Eng

ine

Bra

keM

axim

um E

ngin

e B

rake

Th

erm

al E

ffici

ency

[%]

Ther

mal

Effi

cien

cy [%

]

Technology Roadmaps and OptionsTechnology Roadmaps and OptionsWaste Heat Recovery (Rankine Cycle) and reduced parasitic loads at this condition

Base engine efficiency taken at PhIIA A100 operating condition. Highest efficiency with highest quality energy for recovery.

Application of Optimized SCR A/T allows us to make necessary NOx reduction.

Phase IIB Approach

Phase IIB ISX Base Engine Ultra-Low NOx ISX: Phase IIB Demo - Base Engine Architecture

CHARGE AIR COOLER

BASE ENGINE 15L Displacement

Low Temperature EGR Cooling

Aftertreatment

HPCR Fuel System

To Exhaust Stack Typical Linehaul Application 450 Hp at 2000 Rpm Rating

1650 ft-lbf Torque Peak at 1200 rpm

EGR Valve

August 23rd, 2006 5

Aftertreatment

NOx Reduction Technique � Urea-SCR

• A Urea-SCR Aftertreatment System operating at 85% Efficiency was assumed present in the high-efficiency test and demonstration

PM Reduction Technique � Very similar to technology applied to Phase IIA. � Robust RPF (DOC and PF)

• An RPF operating at 90% Efficiency was assumed present in the high efficiency test and demonstration.

August 23rd, 2006 6

HDTE – WHR Pugh Concept Selection Matrix

CONCEPT

CRITERIA

RA

NK

INE

CYC

LE

RA

NK

INE

CYC

LE

(REH

EAT)

THER

MO

ELEC

TRIC

SYST

EMS

ELEC

TRIC

TUR

BO

CO

MPO

UN

DSY

STEM

S

RA

NK

INE

CYC

LE

+TH

ERM

OEL

ECTR

ICSY

STEM

1 2 3 4 5 1. Power Generated S S - - + 2. System Complexity. S - + - -3. Resistance to temperature. S S - S S 4. Fuel economy increase obtained. S - - - + 5. Compatibility with actual engines. S S S S S 6. Number of components. S S + S -7. Effect over the emissions. S S S S S 8. Weight of the system S S + + -9. Size of the system. S S + + -10. Durability of the system S S S S S 11. Price S + - - -12. Ease of maintenance. S S + + S 13. Ease of installation. S S + + -14. Power consumption S S + + S

TOTAL + 0 1 7 5 2 TOTAL ­ 0 2 4 4 6

TOTAL S 14 11 3 5 6 Best possible choice… 14 10 6 6 2

*No direct effect over emissions. Decrease emissions due to fuel economy increase.

August 23rd, 2006 7

Working Fluid Research

Net Work Produced (kW)

23.83 23.36 22.57

16.82 16.03

11.14 11.08 9.656 9.471

7.34

kW

Wnet Wp

August 23rd, 2006 8

Fluo

rinol

50(T

1=10

0°C

)

Isop

enta

ne

Fluo

rinol

85(T

1=66

.8°C

)

R24

5fa

R11

R11

4

R50

0

R12

R22

R13

4a

Fluorinol-50

Fluorinol or 2,2,2 Trifluoroethanol and water � CAS No. 75-89-8 � Molecular Weight 100.04 � Chemical Formula – F3CCH2OH � Flammable Liquid/Vapor � More toxic than Ethlyene Glycol � Used in previous ORC DoE demonstration

Excellent heat transfer properties with a high thermal stability - >550F

Fluorinol-50 (50-50 molal mix of Fluorinol and Water) provided the best performance -

August 23rd, 2006 9

August 23rd, 2006 10

Electricity

ISX Engine Dyno

Comp

Turb

Condenser

EGR

Exh.M

anifold

Charge Air

Exhaust Out

Air In

Exhaust Gas

Generator

Turbine

EGR

Inta

ke M

anifo

ld

Pum

p

Exhaust

Engine Coolant

High BTE Lab Demonstration Schematic

TC Engine Cooler

TC Charge Air Cooler

EGR Valve

Hot Well

Resistor Bank

ORC Fluid

Lift Pump

Turbine Generator

August 23rd, 2006 11

Designed and built by Barber Nichols, Inc.

Radial Inflow Turbine coupled to a Unison high-speed 4-pole generator

Capable of 60+kW

Generator cooled with process water

Integrated Feedpump

Hermetically sealed system

Approximately 10” diameter by 16” length (without diffuser)

August 23rd, 2006 12

Turbine and Rotor

Permanent Magnet rotor Hybrid-Ceramic, self-lubricated bearings cooled with F-50.

Axial impulse turbine 50krpm design speed 77% Efficiency Predicted 93 blades, 15 nozzles 17-4 PH Steel Bar/Forging

August 23rd, 2006 13

Turbine Rotor dynamics and Stress Analysis

Integral Feedpump

•Small Impeller Feed pump•Hollow Shaft for Bearing Supply •6 bladed pump •Aluminum •470 psia at 50 krpm

August 23rd, 2006 14

Heat Exchangers

Procured from FlatPlate, Inc.

Stacked Plate type. Copper brazing on jacket water, condenser and charge air coolers. Nickel brazing on Exhaust and EGR coolers.

August 23rd, 2006 15

Controls and Data Acq.Turbine speed was controlled by PWM control of generator amperage to the resistive load bank.

Turbine speed was determined from measured AC voltage.

WHR System operating temperatures and pressures were monitored with the Labview data acquisition system.

Electric power was measured with a Flex-Core Watt Meter calibrated to our target generator frequency and voltage (1600 Hz and 500VAC).

Electric power was also measured by monitoring cooling water flow and temperature rise across our resistive load bank.

Good agreement between the two power measurements was observed.

August 23rd, 2006 16

HDTE Phase IIB Results on 5/11/06

A100 Engine Condition – Engine Load – 378 Hp Engine Speed – 1200 rpm

Engine bsfc – 0.322 or 43.2% BTE Engine Out bsNOx – 1.39 gm/Hp-hr

– SCR Aftertreatment achieves 0.2 gm BSNOx

42.5 kWe / 57 Hp Recovered Power

Combined Cycle bsfc – 0.279 or 50.0%BTE

Peak WHR Cycle Efficiency was 21.0%

August 23rd, 2006 17

HDTE and ISX Engine Architecture

Combustion Optimization

Electronic Controls Exhaust

Aftertreatment

Fuel System Development

Optimized/Electric Parasitics

Cooling System Optimization

Air Handling

Base Engine Updates

August 23rd, 2006 18

Thanks to our Sponsor!

Cummins Inc. thanks –

The United States Department of Energy

for their support throughout this program

August 23rd, 2006 19