Northeast 2010 Engine Emissions

Jim Balkonis MaxxForce Marketing Manager Jim.balkonis@navistar.com 630-995-6567

Agenda
1. 2. 3. 4. EPA / EUR Emission Requirements & OEM Technical Solutions Why MaxxForce Engines are using Advanced EGR 2010 Advanced EGR Technology Enablers 2010 Big Bore Overview

EPA Emission Requirements & Technical Solutions

Diesel Engine An internal-combustion engine that uses the heat of highly compressed air to ignite a spray of fuel introduced after the start of the compression stroke. Diesel Engine Operation A.) Intake stroke B.) Compression stroke C.) Power stroke (Byproduct is exhaust = NOx & PM) D.) Exhaust stroke

EPA Emission Requirements & Technical Solutions

1. Fuel Nitrogen Oxides, (NOx) Ground level smog

2. Diesel Particulate Matter, (PM) Soot

EPA Emission Requirements & Technical Solutions

EPA Emission Requirements

1994
5.0
(g/hp-hr) (g/hp

500 PPM
(6/93)

4.0

1998
SULFUR

2.5

2002 2007
ULSD 15 PPM
(6/06)

NOx

1.2

0.2 2010 0.0 0.0 0.01

PM

(g/hp(g/hp-hr)

0.10

EPA Emission Requirements & Technical Solutions

EPA phase in process for 2010 allowing flexibility.

Current
1.4 1.2 1.0 0.8 0.6 0.4 0.2 0.0 EPA07 Standard 1.2

January 2010

2012

0.5 0.2 0.2

EPA2010 Standard

Navistar 2010 Navistar 2012

EUR Emission Requirements & Technical Solutions

5.00 5.22
4.00 3.73 2.50 2.61 1.20 1.49 0.20 0.37

NOx (g/bhp-hr) NOx (g/bhp-hr) Nitrogen Oxides Nitrogen Oxides

EPA94

EuroII

EPA98

EuroIII

EPA04

EuroIV

EPA07

EuroV

EPA10

EuroVI

1994

1996
0.186

1998

1999

2004

2005

2007

2008

2010

2013

0.100

0.100 0.075

0.100

PM (g/bhp-hr) PM (g/bhp-hr) Particulate Matter

Particulate Matter
0.015
EPA94
7

0.010
EPA07

0.015
EuroV

0.010
EPA10

0.007
EuroVI

EuroII

EPA98

EuroIII

EPA04

EuroIV

EPA Emission Requirements & Technical Solutions

Consumers have 2 choices of Emission technologys:

1. Advanced Exhaust Gas Recirculation (EGR): MaxxForce will use Advanced EGR for current and to meet 2012. In cylinder reduction of NOX 2. Exhaust Gas Recirculation (EGR) & Selective Catalytic Reduction (SCR): Others will use EGR & SCR. Exhaust treatment system which requires additional fluid to reduce NOX

EPA Emission Requirements & Technical Solutions

Advanced EGRMaxxForces solution for 2010

EGR + SCROthers solution for 2010

http://www.maxxforce.com/2010

EPA Emission Requirements & Technical Solutions

What is Urea?

EPA Emission Requirements & Technical Solutions

EGR & SCR Packaging Impacts

2010 SCR System

2007 System

EPA Emission Requirements & Technical Solutions

EGR & SCR Packaging Impacts

2010 Horizontal Urea Tank

EPA Emission Requirements & Technical Solutions

EGR & SCR Packaging Impacts

EPA Emission Requirements & Technical Solutions

EGR & SCR Packaging Impacts

EPA Emission Requirements & Technical Solutions

EGR & SCR Packaging Impacts

SCR Control System

Agenda
1. EPA Emission Requirements & OEM Technical Solutions 2. Why MaxxForce Engines are using Advanced EGR 3. Advanced EGR Technology Enablers

24

Why MaxxForce Engines utilize Advanced EGR?

1. EGRs Burden of Compliance rests on the manufacturer. 2. SCRs Burden of Compliance rests on the operator!!
EPA Requires: Tamper-proof systems System must be maintained by owner or operator No Urea Progressive warning Audible and visual indicators Engine de-rate No start

Without urea, the vehicle WILL NOT RUN

Why MaxxForce Engines utilize Advanced EGR?

1. EGR has lower operating cost. 2. SCR requires urea dosing which cost money.
Additional Fluid Required (urea) Urea price?
$2.40-$3.70 per gallon, similar to diesel

The DEF to diesel fuel consumption ratio is approximately 2-5%, dependent on the vehicle. The recommended vehicle tank size is 11 gallons. For example, If you use a mid-range estimate, for every 100 gallons of diesel fuel, a truck will use 2.5 gallons of DEF. Now assume your truck gets about 7 mpg and travels about 12,000 miles per year. Your truck will use about 1,700 gallons of diesel fuel and 43 gallons of DEF. With an 11 gallon DEF tank, you will only need to refill your DEF tank 4 times per year!

26

Why MaxxForce Engines utilize Advanced EGR?

1. EGRs driver interface is unchanged, same as today. 2. SCRs driver interface will have additional audible & visual indicators.

DEF

Urea Solution lamp added to already complex EPA07 DPFlamp package

Additional audible warnings, lamps, vehicle de-rating, refill requirements

Why MaxxForce Engines utilize Advanced EGR?

Urea Storage Requirements

122 F (50C) Ammonia Gas Forms 85-100 F (30C) Urea Breaks Down

$17.74 per HALFgallon 10-24-08

12 F (-11C) Urea Freezes Urea is corrosive to aluminum and must be stored in Stainless Steel or heavy-grade plastic tanks.

Why MaxxForce Engines utilize Advanced EGR?

1. EGR has lower total carbon footprint 2. SCR requires urea which has to be produced and distributed which increase carbon total carbon footprint.

Why MaxxForce Engines utilize Advanced EGR?

1. EGR has better Vehicle Packaging & Payload superiority 2. SCR requires Additional Tanks, Exhaust Components and Electronic Control Systems.

Medium-duty: ~300 lbs

Why MaxxForce Engines utilize Advanced EGR?

1. EGRs diagnostic requirements are unchanged 2. SCRs Electronic Control Systems will require additional technician training. Training = Time
Control System and Wiring

$
DPF

HEST

Urea Solution Urea Solution lamp added to already complex EPA07 lamp package

Why MaxxForce Engines utilize Advanced EGR?

Extra Exhaust Hardware

Extra Fluid

Additional Driver Training

Additional Maintenance

Why MaxxForce Engines utilize Advanced EGR?

Value
Fuel economy Price

EGR/SCR NEUTRAL NEUTRAL

EGR

Maintenance
Driver Training Weight (payload)

Packaging (configuration)
Trade value The choice:

Why MaxxForce Engines utilize Advanced EGR?

SCR Cummins Freightliner Detroit Diesel Mercedes Volvo/Mack

EGR Navistar Scania and MAN recently announced they are transitioning to EGR technology to meet EuroV standards going forward.

Peterbilt/KW
Caterpillar exiting the industry

Agenda
1. EPA Emission Requirements & OEM Technical Solutions 2. Why MaxxForce Engines are using Advanced EGR 3. 2010 Advanced EGR Technology Enablers

2010 Advanced EGRs Technology Enablers

Step 1: Advanced Fuel Injection Technology

Multiple injections per cycle Higher injection pressures Piezo Injector

2010 Advanced EGRs Technology Enablers

Step 1: Advanced Fuel Injection Technology

Piezo Actuator controls injection timing with extreme precision Ability to actuate 5 times per combustion event

2010 Advanced EGRs Technology Enablers

Step 2: Proprietary Combustion Bowl Design

Spray aims at edge of step to create upward turbulence for in cylinder mixing Sharp edge deflector to create additional mixing for late burn soot oxidation

2010 Advanced EGRs Technology Enablers

Step 3: Advanced Air Management

Dual turbochargers Interstage cooling Lower combustion temp

MF13

DT > 245 HP

DT < 245 HP

2010 Advanced EGRs Technology Enablers

Step 3: Advanced Air Management

Enhance EGR Systems

2010 MF DT EGR Cooler

2010 MF DT EGR Valve

2010 Advanced EGRs Technology Enablers

Step 4: Electronic Calibration Strategies

Increased computing power Continuous calculation Maximum power and efficiency New 32 bit single box ECM

2010 Advanced EGRs Technology Enablers

Model MaxxForce 5 MaxxForce 7 Adv. HP 210 220 240 260 215 230 230 245 260 270 285 300 300 315 330 310 330 350 330 370 390 410 430 475 Rated Spd. 2200 2600 2600 2600 2300 2300 2300 2300 2300 2300 2300 2300 2000 2000 2000 2000 2000 2000 1700 1700 1700 1700 1700 1700 Torq. 627 560 620 660 560 620 660 660 660 860 860 860 860 950 950 1050 1150 1150 1250 1350 1450 1450 1550 1700 Gov'd. RPM 2300 2800 2800 2800 2400 2400 2400 2400 2400 2400 2400 2400 2200 2200 2200 2200 2200 2200 1900 1900 1900 1900 1900 1900

V8

I4

MaxxForce DT

I6

MaxxForce 9

MaxxForce 10

MaxxForce 11

MaxxForce 13

QUESTIONS?