# Development and Demonstration

of a Fuel

- Efficient HD Engine

(Dept of Energy Supertruck Program)

Acknowledgements: DOE Contract: DE

- EE0003303

Industrial Partners: Bosch, ARGONNE, Federal Mogul, WERC William de Ojeda



### Navistar

Technical Session: High

- Efficiency Engine Technologies Part 1



### DOE DEER CONFERENCE

Monday 3 October 2011

Detroit, Michigan

1

# Outline

• Program Overview

– Project Goals: Approach for Fuel Economy

– Engine Baseline and Targets

– Development Facilities

– Supertruck Plan: Technology Introduction



# • Efficiency Roadmap

– Milestone 1: Engine Thermal Efficiency

– Milestone 2: Turbocompounding

– Milestone 3: Base Engine Technologies

– Milestone 4: Rankine Cycle Selection



# • Advanced Engine Concept

– Impact of Fuel Reactivity

– Challenges and Opportunities



# • Summary

• Acknowledgements

2

# Project Goals:

Approach for Fuel Economy

3 

### Supertruck Concept 

# Engine

Combustion

- Emissions

Base Engine

Heat recovery 

# 20%

improvement in freight 

# 50%

efficiency



### Aero

Gap reduction

Aero Drop

Camera Mirrors 

### Light Weight

SMART tandem axles

Composite cab, trailer

Wide base single tires 

### Driveline

SMART tandem axles

Composite cab, trailer

Wide base single tires 

### Hybrid

Dual

- Mode Drive

Electrified Accessories 

# Vehicle **Baseline**

**2010 ProStar**  **with**

**MAXXFORCE 13L**



# 30%

# Engine Baseline and Targets

4 

### Rated Power 475hp

Best BTE 42%

Engine out NOx 0.35g/bhp

- hr MY 2010

MAXXFORCE 13



### Rated Power 475hp

Best BTE 50%

Emissions HD

EPA 2010 Supertruck Targets

42% 50%

2

- Stage turbocharger 2200 bar Common Rail

2

- stage EGR cooling

DPF

Bottoming Cycles

Electric Turbo

- compound

Rankine Cycle, Thermo

- electrics Variable Valve Actuation

High Efficiency Turbochargers 

## Pushing the technology frontier

Aftertreatment

solutions 3000bar capability



### Advanced EGR cooling Combustion

feedback 

### Advanced Combustion Concepts

Advanced

Simulation

Combustion

feedback

Fuel Reactivity



### Base Engine

Friction reduction, PCP

Electrification of accessories

# Development Facilities

5 

### Federal Mogul Friction Benchmark 

### BOSCH BOSCH High

- injection pressure capability

CFD

- Engine correlations



### ANL Argonne

National Labs

Cylinder head redesign with

PFI system installation Fuel Reactivity 

### NAVISTAR Navistar Combustion Development, Emissions

Performance Benchmark

Heat Recovery Technology**Efficiency at road**

**load condition**

2010 2011 2012 2013 2014 

# Supertruck Development Plan

Technology Introduction

6 Advanced Concepts Fuel Reactivity **55% BTE dyno**

**demonstration** Heat Recovery

Base engine improvements Combustion / Aftertreatment

**50% BTE and**

**Vehicle**

**Demonstration**

**MAXXFORCE 13** 2010 2011 2012 2013 2014 **Efficiency at road**

**load condition** Dyno demonstration

Currently 46.5%

# Efficiency R oadmap

7 

## Target a combined 50%

At road load condition

block CO,HC



### Brake CAC+ISC

EGR

Exhaust

Pumping friction



### Supertruck Supertruck Brake CAC+ISC

EGR

Exhaust

Pumping friction

block CO,HC



### Supertruck Current Supertruck BTE ~45%

with TuCo ~46.5 Brake CAC+ISC

EGR

Exhaust

Pumping friction 

### Rankine

Pumping Base Engine



### Brake TuCo

Supertruck Technologies

towards 50% BTE Supertruck

### CR effect

Injection

pressure

Constant NOx

Constant inj timing



### 1% Constant NOx

Constant inj timing 

### CR effect

Injection

pressure

1% 

## Milestone 1: Engine Thermal Efficiency

8 

### BTE (CR) BTE (Inj Press)

A75 

## +1.3% +0.5% 

# Road Map

**Currently**

**demonstrated**
**+3% BTE gain (to 45%)**

B50 

## +1.3% +1.0%

C100 

## +1.2% +1.2% CR effect

Injection pressure

Constant NOx

Constant inj timing



### 1%  Minimize engine out

NOx

– Soot

 **Maximize BTE**

 Optimize :

Injection timing

Fuel pressure

Injection events

 Optimize Hardware:

Compression ratio

Cooling system

## Milestone 2: Turbocompounding

9 

### Demonstrated at road load condition:

**+1.4% BTE gain**

**(46.4% BTE)** 

## Recover exhaust energy

Criteria

- highest efficiency opportunity

- best opportunity for system optimization

- synergistic with **Supertruck** hybridization



### turbo

**- generator** 

ECU Support Systems 1

Lube oil 1

Power electronics 1

Brake resistor

Hybrid Bus 700 VDC BUS 1

PTC 1

High efficiency

turbochargers 2 Aftertreatment

location 2 System integration 2

Controls 2

### Current test results

 Broader range of improvement

from mechanical turbocompounding

**~7% BSFC**

improvement with mechanical TuCo range of **E**

**- TuCo**  

## Milestone 2: Turbocompounding (TuCo)

10 

### Optimizing work

- Load distribution across turbine wheels

- Couple hardware with flow targets (emissions)

- Leverage simulation tools

NOx range Hardware

options

lo mid high **Target region**

1215 rpm

75% load 1850rpm

50% load 

### Challenges of optimization

1215 rpm

75% load 1850rpm

50% load Two hardware

configurations

at same

emission level **NOx 0.2gNOx** 

**NOx** Varying

emissions at

fixed

hardware

configuration **Hardware shift**

## Milestone 3: Base Engine

11 

###  Up to 2% BTE gain possible across base engine improvements

 Target is 1.5% BTE gain.

Piston and liners

Bushings

Lube oil system Cooling system

Low friction camshaft

Light weight crank

## Milestone 4: Rankine Cycle

12 

## Cycle Criteria:

Achieve **target intake manifold temperature** ; **Package** in the vehicle;

Produce **fuel economy** benefit;

**Safety** and crashworthiness;

Cost and cost/performance ratio;

Reliability, durability, and product life;

Serviceability and service intervals;

Minimal weight increase.

BSFC Improvement * HTR Cooled Condenser

Road Cycle [1]

Road Cycle [2]

USSET 3.1 %

3.9%

4.9%



### Alternative Concepts *Estimates



### Evaluation of Fluids

Critical temperature, pressure

Triple point temp, Psat at

- 40 ̊C, 25 ̊C

Flammability (in air)
Decomposition temp ( ̊C), products

GWP, ODP

Cost/L (Approx)
Specific gravity at 25 ̊C

# Advanced BTE Concept

Impact of Fuel Reactivity

13 

## The High Efficiency Diesel MAXXFORCE13:

 Engine operates at gross thermal efficiencies of **51**

**- 55%** 

Dual Fuel Controller and strategy Dual Fuel Cylinder Head MAXXFORCE13 Dual Fuel

at ARGONNE 

### MAXXFORCE13 has been reworked to

**operated in Dual Fuel mode**

[1] Path to High Efficiency Gasoline Engines, Bengt Johansson, DEER 2010

[2] High Efficiency Fuel Reactivity Controlled Compression Ignition (RCCI) Combustion, Rolf D. Reitz, DEER 2010 

## Single Cylinder Research engines with advanced or two fuels:

 Engines have shown similar efficiencies (e.g. PPC [1], RCCI [2])

 Fuel reactivity shows significantly improved engine out emissions

 Challenges exist to make this “feasible”

# Fuel Reactivity

Challenges and Opportunities

14 

### Emissions Efficiency Engine Technologies



## Diesel Fuel Challenging in

- cylinder

Costly aftertreatment Retains high

efficiency In production



### Fuel Reactivity R educe engine out emissions to

2010 levels High Efficiency Challenging conditions to attain in

production



### Enablers with

the MAXXFORCE13 Dual Fuel

and Advanced EGR 

### VVA

Combustion Feedback

Variable Geometry Turbos 

### EPA regulations EGR

driving

capability cooling

# Summary

Project is focused on assessing and developing engine and vehicle technologies to improve
freight efficiency for class 8 truck and trailer.

The MAXXFORCE 13L engine is well posed to deliver 50% BTE

The work to date includes :

 Milestone 1: Combustion optimization demonstrated efficiency improvement of 3% BTE

 Milestone 2: Demonstrated turbocompounding improvement of 1.4% BTE

 Milestone 3: Base Engine Technologies selection targeting 1.5% BTE gain

 Milestone 4: Rankine Cycle Selection (including hardware, refrigerant)

targeting 1.5% BTE gain

In addition :

 Engine has been prepared to examine the impact of Fuel Reactivity

15

# Acknowledgements

Engine Project Partners

TM

CFD Fuels Enabling

Technologies

16 WERC BOSCH ARGONNE

NATIONAL

LABS FEDERAL

MOGUL

Willy de Ojeda

Navistar, Inc.

2601 Navistar Drive

Lisle, IL 60532

willy.deojeda@navistar.com 

# Thank You