MAN Engine

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



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


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



Euro4/Euro5/EEV

12. Dez 2008

4

Truck Division

Light/Medium Range

Heavy Range

Special-purpose Vehicles MAN Nutzfahrzeuge AG


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


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12. Dez 2008

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Bus Division

Coaches

Coaches / Inter-city Buses

City Buses

Chassis



Euro4/Euro5/EEV

12. Dez 2008

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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



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


2004

2008

2012


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



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



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

λ<1

Todays Exhaust Gas Emission

Soot-Emission: UP NOx-Emission: DOWN

Future goals in the development of the combustion process NOx-Soot-Relation Soot-Emission: DOWN NOx-Emission: UP

λ>1

NOx-Emission MAN Nutzfahrzeuge AG


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


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



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


Euro4/Euro5/EEV

12. Dez 2008

17

MAN’s engine technology: PM-Catalyzer

Catalyzer element cut open Detail: Open Cell Structure MAN Nutzfahrzeuge AG


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


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



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



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12. Dez 2008

21

Euro 5 features Exhaust-gas recirculation system

• Dual exthaust system • Water cooled EGR-module



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12. Dez 2008

22

Euro 5 features 2-stage turbo charging



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



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



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


2


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




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



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




Euro4/Euro5/EEV

12. Dez 2008

29

Concept D20 / 26 LOH Euro 4 / EEV Coolant systems Euro 4 Euro 4 Coolant circuit 1



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


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



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



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



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


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


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


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



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



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



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


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


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



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®


MAN AdBlue®


MAN has allready developed the principal key technology in compliance with the requirements for EPA 2010 and Euro 6!



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


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


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


D2066 CR D2066 CR D2066 CR D2066 CR D2066 CR D2066 CR D2066 CR EURO4 EURO3 EURO4 EURO3 EURO4 EURO3 EURO4


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!



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



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



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



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

MAN Engine

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