Technologies for the Future

(HD Diesel) Engine Technologies for the Future Dr. John C Dr C. Wall Vice President - Chief Technical Officer Cummins Inc. University of Wisconsin ERC...
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(HD Diesel) Engine Technologies for the Future Dr. John C Dr C. Wall Vice President - Chief Technical Officer Cummins Inc. University of Wisconsin ERC Symposium June 8, 2011

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Our Products Must Meet Customer Requirements High Performance

Low Noise and Emissions

Reliable FuelLow Efficient Emissions

Durable

Low Maintenance

Low Initial Cost

Connected and Integrated Systems y TM

2

6/7/2011

Cummins Confidential

Cummins Engines 109 to 3,500 HP 3 500HP 3,500HP

109 HP

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Cummins Engines 109 to 3,500 HP 3 500HP 3,500HP

109 HP

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“Fuel Economy” isn’t “BSFC” and it isn’tt at a “point” isn point - Duty Cycle Matters Average Fuel Rate (Gallon/h):

9.04

1710 1620

Engine Performance Curve

1530

2.29

10.12

0.27

0.03

0.16

2.70

0.08

0.50

1440

0.00

0.04

0.10

0.50

3.09

0.14

0.24

1350

0.02

0.01

0.06

0.37

3.50

0.02

0.05

1260

Engine Torque ( ft-lb)

0.26

0.00

1170 1080 990

0.01

900

0.00

0.01

0.01

0.00

0.00

720

0.00

630

0.22

0.45

0.00

0.00

0.06

0.46

3.90

0.05

0.07

0.04

0.27

0.07

0.02

0.00

0.00

0.05

0.47

5.14

0.04

0.08

0.04

0.01

0.11

0.03

0.01

0.06

0.50

4.63

0.04

0.04

0.04

0.04

0.01

0.01

0.01

0.05

0.47

7.65

0.03

0.03

0.01

0.01

0.02

0.00

0.00

0.07

0.40

10.24

0.04

0.01

0.03

0.02

0.03

0.01

0.07

0.47

8.63

0.07

0.05

0.04

0.02

0.02

0.01

0.01

0.06

0.34

8.82

0.07

0.03

0.02

0.03

0.02

0.01

0.01

0.05

0.29

5.87

0.03

0.02

0.02

0.00

0.00

810

0.42

0.00

0.00

0.00

0.00

0.00

0.01

0.00 0.01

0.01

0.01

0.05

0.24

3.79

0.11 0.08

0.02

0.03

0.03

450

0.00

0.02

0.00

0.00

0.01

0.00

0.04

0.27

2.28

0.03

0.02

0.02

0.03

0.02

360

0.00

0.02

0.01

0.01

0.01

0.01

0.02

0.18

1.56

0.05

0.01

0.02

0.02

0.01

270

0.00

0.02

0.00

0.02

0.02

0.01

0.02

0.14

1.17

0.03

0.01

0.01

0.00

180

0.00

0.01

540

0.01

0.00

0.00

0.03

0.01

0.01

0.01

0.02

0.03

0.12

0.77

0.04

0.01

0.01

0.01

90

0.82

0.08

0.03

0.03

0.03

0.05

0.10

0.58

0.06

0.02

0.02

0.02

0.00

0.00

0

0.02 700

0.02 800

0.00 900

0.00 1000

0.01 1100

0.01 1200

0.03 1300

0.18 1400

0.08 1500

0.00 1600

0.01 1700

0.01 1800

0.00 1900

2000

500

600

Engine Speed (RPM)

Line Haul

School Bus

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Ultra-Low Emission HD Diesels It’s It s ALL about Technology Integration Air Handling & EGR

Combustion Aftertreatment

Electronic Controls Fuel Systems

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Evolution of HD Diesel Technology

Selective Catalytic Reduction 15 ppm S

Diesel Particulate Filter

Cooled Exhaust Gas Recirculation 500 ppm S

Electronic Fuel Systems

Aft Aftercooling li 7

1990 6/7/2011

2000 2010 Cummins Confidential

2020

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Evolution of HD Diesel Technology 98% Reduction in NOx and Particulate Selective Catalytic Reduction 15 ppm S

Diesel Particulate Filter

Cooled Exhaust Gas Recirculation 500 ppm S

Electronic Fuel Systems

Aft Aftercooling li 8

1990 6/7/2011

2000 2010 Cummins Confidential

2020

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Stable Product Architecture  Cost  Quality Q lit  Reliability  Customer acceptance

 Requires a long-term view

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Evolution of Cummins Heavy-Duty P d tA Product Architecture hit t P NOX

Fuel Injection

NOX

P

T

T

Urea T

Diesel Particulate Filter

DOC

T

T SCR

Urea Doser Mixer

A M O X

Cu Zeolite

0.2g Tail Pipe Out

EGR R-Cooler

VGT

CAC

XPI Fuel System High Efficiency Nozzle & Pump

2002 1998 2010 2007

Engine Mixer

EGR V l Valve

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Heavy Duty Engine Efficiency 60

Brake Thermal Efficiency (%)

55

50

SCR 45

40

EGR

35

1990

1995

2000

2005

2010

2015

2020

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Evolution of Diesel Technology NOx, PM

CO2

Selective Catalytic y Reduction Diesel Particulate Filter Cooled Exhaust Gas Recirculation Electronic Fuel Systems Aftercooling 12

1990

6/7/2011

2000Cummins Confidential 2010

2020

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Reducing CO2

Idle Reduction

Low Low Carbon “Net Carbon” Fuels Fuels

Hybrids

Low Temp Aftertreatment

High g Efficiency y Clean Combustion Waste Heat Recovery

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Energy gy Source * Solar

Gas

Geothermal

“Fossil” Coal

Natural Gas Gasoline

Water (Gravity)

H2

Oil

Diesel Bio-derived

Wind

Renewable HC Nuclear * “Not to scale”

Bio-produced TM

Reducing CO2 Low Carbon Fuels Hybrids

Idle Reduction

CO2

Fuel Efficiency Low Temp Aftertreatment

High g Efficiency y Clean Combustion Waste Heat Recovery

TM

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Heavy Duty Engine Efficiency 60

Brake Thermal Efficiency (%)

55

50

45

40

35

1990

1995

2000

2005

2010

2015

2020

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2010 HD Engine Energy Balance Fuel Energy 100%

Indicated Power 50%

Gas Exchange 4%

Friction 1.5%

Heat Transfer 26%

Accessories 2.5%

Exhaust 24%

Brake Power 42%

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Enabling Technology for Efficiency Improvement TOR RQUE (ft-lbs)

Lifted Flam e D iffusion Controlled

Fuel Energy 100%

PCCI Sm okeless Rich SPEED ((rpm )

Advanced Combustion (Mixed Mode) • Stoichiometric

Indicated Power 55.5%

Heat Transfer 23.5%

Exhaust 21%

• Early PCCI • Lifted Flame

Gas Exchange 2%

Friction 1.0%

Accessories 2.5%

Brake Power 50%

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Enabling Technology for Efficiency Improvement

Fuel Energy 100%

Advanced Combustion •Higher Inj.Pressure, Multiple Inj

Indicated Power 55.5% • Flexible Air Handling • Cooled EGR

Heat Transfer 23.5%

Exhaust 21%

• High Cylinder Pressure • Closed Loop Combustion Control

Gas Exchange 2%

Friction 1.0%

Accessories 2.5%

Brake Power 50%

TM

Enabling Technology for Efficiency Improvement Fuel Energy 100%

Indicated Power 55.5%

Gas Exchange 2%

Friction 1 0% 1.0%

Heat Transfer 23.5%

Accessories 2 5% 2.5%

Exhaust 21%

Brake Power 50%

Low Temperature Aftertreatment • lower soot loading • low pressure drop • regeneration controls/strategyTM

Enabling Technology for Efficiency Improvement Fuel Energy 100%

Indicated Power 55.5%

Gas Exchange g 2%

Friction 1.0%

Heat Transfer 23.5%

Accessories 2.5%

Exhaust 21%

Brake Power 50%

Gas Exchange • Electrically assisted turbo • EGR pump • Variable valve actuation

TM

Enabling Technology for Efficiency Improvement Fuel Energy 100%

Indicated Power 55.5%

Gas Exchange g 2%

Friction 1.0%

Heat Transfer 23.5%

Accessories 2.5%

Exhaust 21%

Brake Power 50%

Friction Reduction • Piston and rings • Bearings • Surface treatment

TM

Enabling Technology for Efficiency Improvement Fuel Energy 100%

Indicated Power 55.5% (+5.5%)

Gas Exchange g 2% (-2%)

Friction 1.0% (-0.5%)

Heat Transfer 23.5% (-2.5%)

Accessories 2.5%

Exhaust 21% (-3%)

Brake Power 50% (+8%)

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Reducing CO2 Low Carbon Fuels Hybrids

Idle Reduction

CO2

Fuel Efficiency Low Temp Aftertreatment

High g Efficiency y Clean Combustion Waste Heat Recovery

TM

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Waste Heat Recovery vs. Hybrid Waste Heat Reco er Recovery

Fuel Economy Benefit

Hybrid

Heavy Duty High Horsepower

Seldom Start/Stop

Frequent Start/Stop y Cycle y Duty

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Waste Heat Recovery Fuel Energy 100%

Indicated Power 55.5%

Heat Transfer 23.5%

Exhaust 21%

Waste Heat Recovery

Gas Exchange 2%

Friction 1.0%

Accessories 2.5%

Brake Power 50%

TM

Waste Heat Recovery

Pump

Boiler Waste Heat

Engine

Power Turbine

Waste Heat

Power Additional Power

Waste Heat

Condenser

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ISX Engine with EGR

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ISX Engine with WHR

WHR Power Turbine

Preserve EGR Control System

Boiler Replaces EGR Cooler and Integrates with EGR system TM

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Energy Balance for Waste Heat Recovery and Electric Accessories Fuell Energy F E 100%

Indicated Power 55.5%

Gas Exchange 2%

Friction 1.0%

Accessories 1.0%

Brake Power

57% (+ 15%)

Heat Transfer 19.5%

Exhaust 19.5%

EGR Source (ORC) 4%

EGR + Exhaust Source 1.5%

Electric Accessory Drive

TM

Heavy Duty Engine Efficiency 60

Advanced Combustion Waste Heat Recovery And Vehicle Electrification

Brake e Thermal Effficiency (%)

55

50

45

Waste Heat Recovery 40

35

1990

1995

2000

2005

2010

2015

2020

TM

31

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Cummins Confidential

Reducing CO2

Idle Reduction

Low Low Carbon “Net Carbon” Fuels Fuels

Hybrids

Low Temp Aftertreatment

High g Efficiency y Clean Combustion Waste Heat Recovery

TM

32

6/7/2011

Cummins Confidential

Prod cer Gas 1 MW Producer-Gas Power Generation Plant Coimbatore, India

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TM

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35

6/7/2011

Cummins Confidential