Euro4, Euro5 and EEV MAN Engine Technology for Today and Tomorrow
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dec 2008
1
New emission standard Euro5 / EEV Overview
Introduction of MAN Group Once and Today: A Comparison Development of exhaust gas stages NOx or PM: How to influence the Combustion Combustion with reduced NOx amount: The MAN way Euro 5 Concept for D0834 Euro 5 Concept for D0836 Euro 5 Concept for D20/26 Advantages for the Customer Strategy for future technology Summary
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
2
MAN Group Sales in 2007: €15.5 billion (No. 375 in Fortune 500)
69%
Commercial Vehicles
10% 7% 14%
Industrial Services
Turbomachinery (plus industrial cooperations and financial services)
Diesel Engines MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
3
MAN Nutzfahrzeuge Group Sales in 2007: €10.4 billion
13% 87%
Buses and Coaches Trucks
Buses & Coaches
Trucks
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
4
Truck Division
Light/Medium Range
Heavy Range
Special-purpose Vehicles MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
5
Truck Production in 2007 Total: 93,260 units 60,500
TGA
TGL
3,120
23,041
TGM
6,599
Special-purpose Vehicles
TGX/TGS MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
6
Bus Division
Coaches
Coaches / Inter-city Buses
City Buses
Chassis
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
7
Components
Axles
Engines
Pressings MAN Nutzfahrzeuge AG
Transfer Cases H. Gossner, M. Bayer
MN
Euro4/Euro5/EEV
12. Dez 2008
8
Product Innovations
Optimised Tractors for Europe
TGL MAN Nutzfahrzeuge AG
NEOPLAN Starliner D20 Common-Rail Euro 4 with PM-Kat®
D 08 H. Gossner, M. Bayer
TGX/TGS Euro4/Euro5/EEV
MAN PriTarder 12. Dez 2008
9
New emission standard Euro5 / EEV Once and Today: A Comparison
Engine D0834 LFL
Displacement 20 ltr,. 15 kW (20 HP) 4,5 to
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Displacement 4,6 ltr,. 151 kW (206 HP) 480 kg
Euro4/Euro5/EEV
12. Dez 2008
10
New emission standard Euro5 / EEV Energy Mix of the future 100
Hydrogen Natural gas LPG
Market shares %
80 Petrol (fossil) 60 Renewable energy 40 Diesel (fossil) 20 GTL fuels 0
2000
MAN Nutzfahrzeuge AG
2004
2008
2012
H. Gossner, M. Bayer
2016
2020
Euro4/Euro5/EEV
2024
2028
(Gas to Liquid)
12. Dez 2008
11
Development of the Euro-Stages Timeline
2003
2004
2005
2006
2007
2008
2009
2010
2011/12
Euro 3 -> 01.10.2005 01.10.2006
Euro 4 Type approval
Euro 4
01.10.2008
Registration
Euro 5 new homologation
01.10.2009
Euro 5
2011/12?
Registration
Euro 6 new homologation
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
12
Development of the Euro-Stages What it means in terms of NOx and PM 0.8
16
Euro 0 14.1
Euro 1
Euro 2
Euro 3
Euro 4
Euro 5
0.7
14
0.7 0.6
12
PM Reduction
E0 to E4: 85% E0 to E5: 97% NOx Reduction E0 to E4: 75% 9 E0 to E5: 85%
10
0.4
8
0.4
7
0.3
NOx (g/kWh)
PM (g/kWh)
0.5
6
5 0.2
4
3.5
0.15 0.1
2
0.1
2
0.02
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
2010
2009
2008
2007
2006
2005
2004
2003
2002
2001
2000
1999
1998
1997
1996
1995
1994
1993
1992
1991
1990
1989
0
1988
0
12. Dez 2008
13
MAN’s engine technology: Soot – NOx - Tradeoff
Soot-Emission
λ1
NOx-Emission MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
14
MAN’s engine technology: EGR function schematic
MAN-engine
airfilter
EGR-valve
Pressure peak-valve EGR-Cooler Air charging cooler Regulated exhaust gas recirculation increased EGR-ratio in comparison to Euro 3 improved EGR- cooling unit Exhaust gas
Exhaust gas is fed into the EGR-cooler where it is cooled and fed into the intake air again
Effect: Lower combustion temperature and thus less NOx MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
15
MAN’s engine technology: Catalyzer Chemistry
V
P
PM = Particulate matter
V
Pre -oxidation Pt,Pd,Rh cat: 2NO + O22 2NO22 Pre-oxidation
P
Soot Soot particle particle separator separator: C+2NO22 CO22+ 2NO C+ O22 CO22
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
16
MAN’s engine technology: PM-Catalyzer Type BC
Composition of the BC-Type
Particleseperation during flow through the fleece
As a result of the open structure, the PM-Kat cannot be mechanically blocked in normal use! MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
17
MAN’s engine technology: PM-Catalyzer
Catalyzer element cut open Detail: Open Cell Structure MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
18
MAN’s engine technology:
Separationrate as function of the particle size
100
80
6
60
before PM-KAT after PM-KAT Separation
4
40
2
20
0 5
10
50
100
Separation [%]
8
13
dN/dlog Dp[ x10 Particle/cm3 ]
10
0 300
‘electrical mobility diameter’ [nm] MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
19
From Euro 4 to Euro 5 Overview
Common Rail System 2nd generation Exhaust-gas recirculation system 2-stage turbo charging Indirect inter- and main charge air cooling PM-Kat
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
20
Euro 5 features Common Rail System Injector 1800bar with 8 pinhole nozzle
Welded rail
HDP fuel lubricated
Injection pipes Ø8x2,5
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
21
Euro 5 features Exhaust-gas recirculation system
• Dual exthaust system • Water cooled EGR-module
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
22
Euro 5 features 2-stage turbo charging
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
23
Concept D20 / 26 LOH Euro 4 / EEV Coolant systems Euro 5 / EEV Euro 5 EEV NT Coolant circuit
1
3 2
4
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
24
Concept D0834 LOH Euro 5 / EEV Coolant systems D0834 cooling circuit Euro 5
Cooling Air
DPF
1
2
Main coolant circuit Exhaust Gas Charged Air
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
25
Concept D0834 LOH Euro 5 / EEV Comparison to Euro 4 D0834 LOH 52/53 Euro 4
D0834 LOH 60/61 Euro 5 / EEV
1
1
2
MAN Nutzfahrzeuge AG
2
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
26
Concept D0836 LOH Euro 5 / EEV Coolant systems D0836 cooling circuit Euro 5
Cooling Air
DPF
2
1
LLK
Main coolant circuit Exhaust Gas Charged Air
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
27
Concept D0836 LOH Euro 5 / EEV Comparison to Euro 4 D0836 LOH 55/56 (SAE 1) Euro 4
D0836 LOH 64/65 (SAE 1) Euro 5 / EEV
1 1
2
3
2
3
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
28
Concept D20 / 26 LOH Euro 4 / EEV Coolant systems Euro 4 Euro 4 Coolant circuit
Cooling Air
DPF
1
Main coolant circuit Exhaust Gas Charged Air
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
29
Concept D20 / 26 LOH Euro 4 / EEV Coolant systems Euro 4 Euro 4 Coolant circuit 1
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
30
Concept D20 / 26 LOH Euro 4 / EEV Coolant systems Euro 5 / EEV
HT Circuit
DPF NT Circuit
Cooling Air
Euro 5 EEV NT Kühlkreislauf / Euro 5 EEV NT Coolant circuit
4
3
2
1
HD-LLK
ND-LLK
Main coolant circuit (HT-Circuit) Exhaust Gas Low Temperature Water Circuit (NT-Circuit) MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
31
Concept D20 / 26 LOH Euro 4 / EEV Coolant systems Euro 5 / EEV EEV NT Coolant circuit 3
1
2
4
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
32
Concept D20 / 26 LOH Euro 4 / EEV Exthaust System Euro 4 D2066 LOH 01/02/03/04 Euro4
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
33
Concept D20 / 26 LOH Euro 4 / EEV Exthaust System Euro 5 / EEV D2066 LOH 26/27/28 EEV
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
34
MAN’s engine technology: How to achieve Euro 4 limits
Combustion chamber and injection: Compression ratio raised from 19:1 to 20,5:1 Optimization of combustion chamber Use of improved injection nozzles (7-hole) for optimised combustion Injection pressure was raised to 1600 bar Useage of postinjection to reduce formation of soot
Useage of an optimized EGR-system: EGR-rates of up to 20 % Lower temperatures of the recirculated exhaust gas The formation of NOx is in-line with E4 regulations
Useage of the PM-catalyzer to reduce the soot output Maintenance free, price-winning system that keeps the PM output inline with E4 regulations MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
35
MAN’s engine technology: How to achieve Euro 5 limits
Injection: Usage of 2nd generation CommonRail system Use of improved injection nozzles (8-hole) for optimised combustion Injection pressure was raised to 1800 bar (for E6 pressure of up to 2400 bar is planned)
Further optimized EGR-system: EGR-rates of up to 30 % Double-fold exhaust system to achieve high EGR-rates Lower temperatures of the recirculated exhaust gas due to a better cooling unit The formation of NOx is in-line with E5 regulations
Turbo charger and cooling system Double turbo charger Elaborate cooling system with air-water-intercooling for both turbos MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
36
MAN’s engine technology: Comparison of old and new engine generation 1900 Torque D2066 (Nm, E4) Torque D2066 (Nm, E5) Torque D2866 (Nm, E3)
1800
kW
1700
1600
1500
1400
2000
1900
1800
1700
1600
1500
1400
1300
1200
1100
1000
900
800
1300
RPM MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
37
MAN’s engine technology: Comparison of old and new engine generation 280 270 260 250
kW
240 230 220 210
Output D2066 (kW; E4) 200
Output D2866 (kW; E3)
190
Output D2066 (kW; E5; EGR)
2000
1900
1800
1700
1600
1500
1400
1300
1200
1100
1000
900
180
RPM
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
38
MAN’s engine technology: Comparison of old and new engine generation 240 235
Consumption D2066 (g/kWh; E4)
230
Consumption D2066 (g/kWh; E5; EGR)
225
Consumption D2866 (g/kWh; E3)
220
g/kWh
215 210 205 200 195 190 185
2000
1900
1800
1700
1600
1500
1400
1300
1200
1100
1000
900
180
RPM
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
39
Euro 4/5 Technology with MAN PM-KAT® Advantages for the customer Lower weight and reduced installation space (compared to SCR-solution) No increased consumption compared to Euro3 (D28) Robust and maintenance-free system No reduction-agent necessary no urea heating or seperate tank is needed No complex metering system needed
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
40
Overview MAN Euro5 / EEV Engines
Engine Type
Rated Power Charging kW / HP
D0834LOH60 D0834LOH61 D0836LOH65 D0836LOH64 D0836LOH61 D0836LOH60 D2066LOH26 D2066LOH27 D2066LOH28 D2066LUH46 D2066LUH47 D2066LUH48 D2066LUH32 D2066LUH33 D2066LUH34 D2676LOH26 D2676LOH27 D2676LOH28
MAN Nutzfahrzeuge AG
132 / 180 132 / 180 184 / 250 213 / 290 184 / 250 213 / 290 235 / 320 265 / 360 294 / 400 206 / 280 235 / 320 265 / 360 235 / 320 265 / 360 294 / 400 324 / 440 353 / 480 371 / 505
2-stage 2-stage 2-stage 2-stage 2-stage 2-stage 2-stage 2-stage 2-stage 2-stage 2-stage 2-stage 2-stage 2-stage 2-stage 2-stage 2-stage 2-stage
H. Gossner, M. Bayer
Intermediate Exhaust Cooling Norm
Exhaust Cooling Treatment Concept
without without with with with with with with with with with with with with with with with with
Oxi-Cat PM-Cat Oxi-Cat Oxi-Cat CRT-Filter CRT-Filter PM-Cat PM-Cat PM-Cat CRT-Filter CRT-Filter CRT-Filter PM-Cat PM-Cat PM-Cat PM-Cat PM-Cat PM-Cat
Euro 5 EEV Euro 5 Euro 5 EEV EEV EEV EEV EEV EEV EEV EEV Euro 5 Euro 5 Euro 5 EEV EEV EEV
Euro4/Euro5/EEV
12. Dez 2008
conventional conventional conventional conventional conventional conventional NT-Cooling NT-Cooling NT-Cooling conventional conventional conventional conventional conventional conventional conventional conventional conventional
41
Strategy for future technoligy US2010 / Euro6
EPA 2007 EGR-Technology + 2-stage turbo charge with Carge air intercooling + Filter (PM-KAT®/CRTec®)
EPA 2010
+
MAN AdBlue®
Euro 6
Euro 5
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
Strategy for future technology US2010 / Euro6
2 stage turbo charging with intercooling
serial n i y d Allrea uction prod
AGR+PM-KAT®/CRTec®
serial n i y d Allrea uction prod
MAN AdBlue®
serial n i y d Allrea uction prod
MAN has allready developed the principal key technology in compliance with the requirements for EPA 2010 and Euro 6!
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
New emission standard Euro5 / EEV
Thank you for your attention !
MAN Nutzfahrzeuge Business Unit Engines Vogelweiher Str. 33 90441 Nürnberg Hubert Gossner Manager Application Engineering (MVLF) Phone: +49 911 420 6387 eMail:
[email protected] MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Michael Bayer Technical Support Phone: +86 10 8048 0505 ext. 7302 eMail:
[email protected] Euro4/Euro5/EEV
12. Dec 2008
44
Outlook into the future: Euro 5 engines from 2009 onwards
Power [kW]
EGR + MAN PM-CAT®
110 kW (150 PS)
570
132 kW (180 PS)
700
162 kW (220 PS)
830
184 kW (250 PS)
925
250 kW (340 PS)
213 kW (290 PS)
1100
1250
235 kW (320 PS)
265 kW (360 PS)
1600
1800
294 kW (400 PS)
1900
324 kW (440 PS)
2100
353 kW (480 PS)
2300
max. Torque [Nm] MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
MAN’s engine technology: Engine lines and power output
600
540
500 480
Rated Power in HP
460 430
400 390 350 300
440
400
360
320 280 240
200 206 180 100
0 D0834 CR EURO4
D0834 CR D0836 CR D0836 CR EURO4 EURO3/4 EURO3/4
MAN Nutzfahrzeuge AG
D2066 CR D2066 CR D2066 CR D2066 CR D2066 CR D2066 CR D2066 CR EURO4 EURO3 EURO4 EURO3 EURO4 EURO3 EURO4
H. Gossner, M. Bayer
Euro4/Euro5/EEV
D2676 CR D2676 CR D2676 CR EURO3 EURO4 EURO4
12. Dez 2008
46
How to comply with the Euro4 : MAN-Exhaustfilter obtains Environmental Award Clean, cleaner, MAN PM-KAT®! The innovative dieselfilter for particulate matter for commercial vehicles was awarded the renowned “BDI-Umweltpreis für die Industrie 2005/2006” (Federal Association of German Industry – Environmental Award for the Industry 2005/2006) A high ranking jury consisting of leading characters from industry, science, politics and environmental associations was convinced: Within the category “Environment-friendly products” the MAN PM-KAT® is outstanding. Thereby this filter – that is used by MAN serially for trucks and busses since the end of 2004 – is nominated as German contribution for the European Environmental Competition. The patended filtering concept – that was developed together with the catalyzer experts from EMITEC – retains up to 90% of the particulate matter which is deemed especially hazardous. In contrast to conventional diesel filters, the MAN PM-KAT® is absolutely maintenance free. It cannot clog and runs without any additives. A distinct advantage over competitor’s products!
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
47
How to comply with Euro4: Comparison fuel consumption D2066 E3 (without catalyzer) and E4 (with catalyzer)
+ 5 % cost for Urea
110%
- 1 % to 2 % D0836
+ 2 % to 3 % D0836
Euro 4 with PMKAT
- 3 % to 5 %
±0% D2066
D0836
D2866
70%
50%
Euro 3
- 3 % to 5 %
80%
60%
D2066
90%
D2066
100%
40% Euro 3
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
Euro 4 with GDKAT
12. Dez 2008
48
MAN’s New Engine Technology: D08 CR – Technical information an customer‘s benefits Engine line D0834/36 Diesel engine with direct injection with 4,6 respectively 6,9 l swept volume Common-Rail-Injection with EDC7 engine management system Several models with cooled external EGR The 206 HP 4 Cylinder engine comes with twin turbo chargers Customers benefit‘s: Engines with high output in power and torque Long intervals between oil-changes of up to 80.000 km (long distance transport) Favourable torque curve and start trait Quiet engine (esp. at partial load) Low fuel consumption – highly environmental friendly
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Euro4/Euro5/EEV
12. Dez 2008
49
MAN’s New Engine Technology: D20 CR – Technical information an customer‘s benefits Engine line D2066 CR Economical 10,5-l-engines with state-of-the-art technology – Especially the Common-Rail-Injection guarantees low consumption combined with high performance The D2066 CR offers fuel economy of up to 5 % compared to the older D28 Lowest engine mass in the 430 HP category (967 kg dry weight) – hence biggest payload advantage Long intervals between oil-changes of up to 120.000 km (long distance transport) Use of cooled external EGR in all D20 models Approx. 1,5 Mio km until major engine overhaul is necessary
Customers benefit‘s:
First time ever in a commercial vehicle: Oil
Cylinderhead in one piece
pump as a Trochoid-Pump
MAN Nutzfahrzeuge AG
H. Gossner, M. Bayer
Low fuel consumption Big payload advantage due to low engine weight Very little downtime due to long maintenance intervals
Euro4/Euro5/EEV
12. Dez 2008
50
