### Advanced Technologies

1 Low Temperature Combustion Demonstrator for High
Efficiency Clean Combustion

DE

- FC26

- 05NT42413 This presentation does not contain any proprietary, confidential, or otherwise restricted information 

## SuperTruck

– Development and Demonstration of a

Fuel

- Efficient Class 8 Tractor & Trailer

Engine Systems

DOE Contract: DE

- EE0003303

NETL Project Manager: Ralph Nine

William de Ojeda, PhD, PE

Navistar

DOE MERIT REVIEW

WASHINGTON, D.C.

16 May, 2013 National Energy Technology Laboratory

Department of Energy

Project ID: ACE059

### !"#$%&'"(()'&*%+,+-.'/



## 56+7'&3(8#'6#.'9(

**2 SuperTruck – Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer** 

**DE-EE0003303** 

### X$+=0"+2G"P/Z';1M'0"

**!** **<*8(/>,'.,*%CBE%684'(=*8*/,%6/%F'*605,%*G+6*/+H%** **!** **<*8(/>,'.,*%CBE%*/06/*%I#"%** **!** **<*8(/>,'.,*%4.,5%,(J.'9>%CCE%*/06/*%I#"%**
**!** **&'(=69*%.%'*.36>K+%,*+5/(3(0H%9*8(/>,'.,('%,(%'*9L+*%4*,'(3*L8%+(/>L84K(/%6/%,5*%,'L+M%8.'M*,N%%**



### &6('=62'"

**&'()*+,%O,.',1% %P*Q% %RBSB%** **%&'()*+,%"/91% %@4'63%%RBSC%TCBE%+(843*,*U%**



### 92762'"[+**6'*0"

**@+56*=6/0%CBE%F'*605,%*G+6*/+H%J563*%Q.3./+6/0%VW(6+*%(F%AL>,(8*'X%/**9>%%** **%&.+M.06/0;%>4*+6Y+.33H%(F%>H>,*8>%>L+5%.>%7.>,*%Z*.,%2*+(=*'H%** **%-.6/,.6/6/0%%,'.+,('%J*605,%J563*%.996/0%/*J%>H>,*8>%**



### [-G7',""

**%#(,.3%&'()*+,%PL/96/01 %<:"%** **% %[\];\R^;D\\%**
**%&'68*%A(/,'.+,(' % %[CS;^BS;S_`%**

**%#(,.3%&'()*+,%A(>,%,(%9.,* %<:"%PL/96/0%2*+*6=*9 %[%RB;BBB;BBB%**

**%&'68*%+(/,'.+,(' %[%RS;BBB;BBB%**



### \+*,2'*0"
**I:OAZ;%P*9*'.3%-(0L3;%@'0(//*%!.K(/.3%$.Q>;%I"Z2;%76>+(/>6/%"/06/*%2*>*.'+5%A*/,*'%** 

# 56+-6$4(8#'6#.'9(

### Advanced Technologies



## Project Overview

3 SuperTruck

– Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE

- EE0003303 

### Goals and Objectives

1. Demonstrate 50% improvement in freight efficiency
20% through Engine technologies
30% through Vehicle technologies

2. Demonstrate 50 % BTE on Engine Dynamometer

3. Demonstrate path towards 55% BTE



### Relevance

 Provide a realistic technology demonstrator to reduce petroleum consumption in the truck market:

 Engine technologies closely worked with the “Voice of Customer”

 Attain a payback of less than 1 year for technology introduction

 Focus on p ackaging and customer interface (key in the case of Waste Heat Recovery)

 Work with Partners to develop robust products for commercial integration :  High pressure common rail system ( BOSCH)

 Advanced base engine technologies for friction reduction ( Federal Mogul)

 Electrified systems such as cooling pump for advanced cooling system (BEHR).

 Provide innovative solutions for alternative fuels and clean combustion systems

 Worked with Argonne National Labs and Wisconsin Engine Research Center

 Provide engine demonstrator to improve engine efficiency with simplified aftertreatment system 

# Objectives and Relevance

### Advanced Technologies



### Navistar completed actions by Oct 2012

- Emissions and combustion development

- Turbocompounding

- Base engine

- VVA



### Navistar entered PAUSE MODE to focus on production launches (resume in 2014) 

### Argonne will CONTINUE working on the 55% BTE demonstration 

# Project Development update

SuperTruck

– Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE

- EE0003303 4 

### ANL

WISCONSIN

REASEACH

CONSULTANTS **Completed 45.1% (combustion only)**  **Simplified aftertreatment Continuation**  

### 55% **BTE**

**Demo**



### AMR 2012 AMR 2013 AMR 2011 

### Navistar

BEHR

Federal Mogul

BOSCH **Completed**

**48.2%**

**PAUSE** 

### 50% **BTE**

**Demo**

**Resume** Oct

- 13 Oct

- 12 Oct

- 11

### Advanced Technologies

Phase II 

# Engine Partnerships and completed tasks

SuperTruck

– Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE

- EE0003303 5 Phase I Phase III

- IV



### BOSCH  **High**

**- injection pressure deployment** 

 **CFD**

**- Testing**  **benchmarks**

 **High CR testing**



### ANL

WISCONSIN

REASEACH

CONSULTANTS  **Engine Design**

 **Controls deployment**

**Adv Technologies**   **Fuel Reactivity testing VVA** 

**Fuels** 

### 55% **BTE**

**Demo**



### AMR 2012 AMR 2013 AMR 2011 

### Navistar

BEHR  **Combustion and Emissions** 

 **Turbocompounding**

 **VVA Base Engine PHASE II**  

### 50% **BTE**

**Demo**

 **Base Engine Phase I** 



### Federal Mogul  **Accessory prove out**  **Friction Benchmark**  **Friction Reduction**  **procurement** Oct

- 13 Oct

- 12 Oct

- 11

### Advanced Technologies 

# Barriers and technology roadmap

System Barriers (challenges) Technology Roadmap

Engine &

Vehicle • Cost effective

• Robust (controls, durable)

• Reduced weight Rely on analysis to select technology 

Engine • High combustion efficiency with low emissions (NOx, PM) Improve Fuel Injection/Air Systems 

Advanced Combustion Regimes 

Engine • Modest bottoming cycle efficiency

• Simplified aftertreatment Advanced designs 

Close collaboration with suppliers 
Optimum integration to engine 

Engine • Non optimum fuel formulation

• High

- efficiency combustion range Introduce reactivity control 

Introduce combustion feedback 
Understanding of chemical kinetics 

6 SuperTruck

– Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE

- EE0003303 Key:  high confidence to contain

 working on improving solution

### Advanced Technologies 

# Scope of Work

7 SuperTruck

– Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE

- EE0003303 Task Description Status

2.1

- 1 Engine and vehicle model Integrate engine model to vehicle 80%

2.1

- 2 Advanced Diesel Combustion

Fuel System to 2900bar with Comb Fbk Complete 100%

WHR

- TUCO Complete 100%

VVA Phase II: Installed and Tested 10/12

Phase III will consider system integration 100%

Aftertreatment SCR system with >80% conversion

Phase III will report on vehicle installation 100%

Friction reduction and electrification Phase II procurement complete

Electrified components complete

Remain to incorporate power cylinder tests 80%

Control System Platform is built and tested 100%

2.1

- 3 Fuel Reactivity Engine

Lab/Engine/Controls Design and Build Completed Engine and DAQ install 100%

Test ing of multi

- fuels with Hdw level 1 Combustion characterization 80% 

### Technology Development and Concept Readiness

Phase II 

### : 1 October 2011

– 30 September 2013 completed In progress

### Advanced Technologies 

# Approach

Technology Selection

Air System
Two Stage Turbocharging

Variable Valve Actuation



## Optimize

Integration

Criteria

Efficiency gain (BTE)
Weight (Ton

- mile/gallon)

Cost (payback)

8 SuperTruck

– Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE

- EE0003303 Friction

- Accessories

VOP, VWP
Power Cylinder Components

Combustion

<1gNOx, <0.02gPM
HP CR Fuel injection

Increased PCP
Two stage cooling Aftertreatment
DOC/DPF + SCR

Close coupled
Fast light

- off

Low DPCooling modules



## 1 2 3

WHR
Turbocompounding 

## 4Two StageDOC DPF

SCR

### Advanced Technologies

Current Status

AMR 2013 

# Approach

Optimum Roadmap Towards 50% BTE

Selection completed

 Testing and present projections indicate the program goals will be

attained.

Addressed Concerns

 Program will deploy only turbocompounding.

 ORC system was not pursued owing to complexity.

 Technologies selected aimed to less than 1 year payback.



### Target :

20% Efficiency gain
20% Ton

- mi/gal

9 SuperTruck

– Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE

- EE0003303 

### Final Program

Projections



### Forecast:

18% ~ 50% BTE
16% Ton

- mi/gal

### Advanced Technologies 

# Accomplishments

Engine Dyno current efficiency at 48.2% BTE

10 SuperTruck

– Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE

- EE0003303 

### AMR 2012

46.5% BTE 

### AMR 2013 (current)

48.2% BTE cooling sys TUCO (Next Generation)

lube sys power cyl Re

- optimized comb (high CR)

TUCO

Comb



### AMR 2011

45% BTE VVA



### pause

### Advanced Technologies 

# Accomplishments

Friction reduction

11 SuperTruck – Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE

- EE0003303 Phase II

 Power cyl comp BTE - Phase I Cooling + Lube

0.75 +1 %

+2%

+3% +1 %

+2% 0.45 BTE - Phase I Cooling system  Phase I accomplished the predicted friction reduction.

 Phase II work will complete work with introduction of Power Cylinder Components

### Advanced Technologies 

# Accomplishments

Air System / VVA

12 SuperTruck

– Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE

- EE0003303 0.0 0.5 1.0 1.5 2.0 2.5 3.0

480 530 580 630% BSFCimprovement

 Early IVC 1500 rpm

50% load ∆λ =0.1 simulation experiment  Successfully brought the engine
hardware from bench testing to

engine builds

 VVA system is designed to work
with the two stage boost

system

 First tests show the hardware
aligns to early system
simulations for performance

enhancements Engine tests performed at

constant combustion phasing

AFR and EGR

decrease as IVC is

advanced Bench testing of VVA VVA installation on MAXXFORCE 13

### Advanced Technologies 

# Accomplishments

55% BTE Target with Dual Fuel Engine

SuperTruck

– Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE

- EE0003303 13 Engine Setup at Argonne:

 Alcohol/gasoline extended LTC load to 19 bar BMEP

 Fuel

- bound oxygen led to soot reduction

 improved fuel efficiency : best BTE: 45.1%

Significant improvement on BTE with fuel

reactivity at better controlled engine out

emissions

35% 37% 39% 41% 43% 45% 47%

5 10 15 20 25**BTE [%]**

**BMEP (bar)** A/G+D

G+D

STK High Eff. Diesel **>7 bar load**

**extension**

0 0.2 0.4 0.6 0.8

1 1.2 1.4 1.6

5 10 15 20 25Smoke Number [FSN]

BMEP [bar] A/G+D

G+D

STK High Eff. Diesel

0 0.2 0.4 0.6 0.8

1 1.2 1.4 1.6

5 10 15 20 25BS NOx [g/hp-hr]

BMEP (bar) A/G+D

G+D

STK High Eff. Diesel

### Advanced Technologies 

# Accomplishments

Current target is 47% BTE with engine and fuels
Additional efficiency will be accounted by other technologies

SuperTruck

– Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE

- EE0003303 14 

### 55% fuel reactivity

engine Progress to Date

Diesel Alcohol/Gasoline + Diesel 45.1%

Gasoline + Diesel 43.6%



### Current Target

Reactivity + CR



### BTE > 47%

at NOx < 0.15gNOx VVA TUCO

Friction

ORC



### Technologies

from the Diesel

platform



### Diesel

Diesel Significant NOx reduction

Significant soot reduction

### Advanced Technologies 

# Remaining Activities for 2013

15 SuperTruck

– Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE

- EE0003303 

### I. No activities at Navistar owing to PAUSE mode until 2014

II. Activities will continue at ARGONNE

• Complete testing of fuel reactivity matrix

• Upgrades:

 Higher Compression Ratio

 Installation of VVA engine

• Impact of Effective Compression ratio on load extension

### Advanced Technologies 

# Project Summary

I. To date the following technologies have been incorporated:

 On engine combustion, leading to a growth in BTE from 42 to 45%:

- Extended peak cylinder pressure capability (190→220 bar)

- Higher injection pressure (2200→2900 bar)



###  On heat recovery, leading to a further increase to 46.5%:

- Electrical turbo

- compounding with advance air system

- Transferred to vehicle



###  Base components, lube and cooling, were updated raising efficiency to 47.2%

- Power cylinder components were procured. Documentation will be postponed to 2014



###  VVA engine was commissioned and early tests indicate BTE increase to 48.2%.

II. Advanced 55% BTE demonstrator is operational at ANL

 Reactivity studies performed with gasoline and alcohol fuels

- High engine efficiencies were compatible with very reduced engine emissions

- Study will continue with enabling features recently added such as VVA

16 SuperTruck

– Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE

- EE0003303