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
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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 packaging 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

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ANL

WISCONSIN 

REASEACH 

CONSULTANTS

Completed

45.1% (combustion only)

Simplified aftertreatment Continuation 

55% BTE

Demo

AMR 2011 AMR 2012 AMR 2013

 

Navistar

BEHR

Federal Mogul

BOSCH

Completed

48.2%

PAUSE

50% BTE

Demo

Resume

Oct-11 Oct-12 Oct-13
Advanced Technologies

Phase II

Engine Partnerships and completed tasks

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Phase I Phase III-IV

BOSCH  High-injection pressure deployment

 CFD-Testing benchmarks

 High CR testing

ANL

WISCONSIN 

REASEACH 

CONSULTANTS

 Engine Design  Controls deployment 

 Fuel Reactivity testing Adv Technologies 

VVA 

Fuels 

55% BTE

Demo

AMR 2011 AMR 2012 AMR 2013

 

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-11 Oct-12 Oct-13
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 

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Key:  high confidence to contain

 working on improving solution
Advanced Technologies

Scope of Work

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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%

Testing 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)

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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 DP

Cooling modules

1

2 3

WHR

Turbocompounding

4

Two Stage

DOC

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 

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Final Program 

Projections

Forecast:

18% ~ 50% BTE 

16% Ton-mi/gal
Advanced Technologies

Accomplishments

Engine Dyno current efficiency at 48.2% BTE

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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

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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

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0.0

0.5

1.0

1.5

2.0

2.5

3.0

480 530 580 630

% BSFC improvement

 Early IVC 1500rpm 

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

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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 25

Smoke 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 25

BS 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

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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

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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

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