Automotive Technologies for BS-III and BS-IV

BHARAT DOGRA AUTOMOBILE DEPARTMENT

Contents:
Emission Regulations and Auto Fuel Policy Technology progression BS III and BS IV technology requirements Challenges and issues, Next steps

BHARAT DOGRA AUTOMOBILE DEPARTMENT

History Of Emission Regulations in India (Lead Introductions)

BS-IV (SELECT CITIES)

Cabinet accepts Auto fuel policy 09, 2003

CNG Buses Delhi BS-II (NCR) Report by Committee

BS-III (ENTIRE COUNTRY)??

BS-III (11 CITIES)

CMVR 92 (DIESEL) FAS (DIESEL) CMVR 91 (PETROL)

CMVR 96 (DIESEL) EVA & CC EMI (PETROL)

BS-I (NCR)

BS-I
(ENTIRE COUNTRY)

BS-IV Review

Court Intervention

Formation of Committee

IDLE EMISSION

1989

1992

1995

1998

2001

2004

2007

2010

BHARAT DOGRA AUTOMOBILE DEPARTMENT

Auto Fuel Policy (A Recap)

Expert Committee Constituted by Government of India, headed by Dr R A Mashelkar, (Director General, CSIR) Provides guideline road-map for new vehicles, with review to be done in year 2006

Took an holistic view:

Automobile Technologies Corresponding Fuel Quality Impact on Environment Social Cost Security of Fuel supply Emissions from in-use vehicles

Guiding principles in respect of taxation of fuels:

To the extent auto fuels meet the recommended emissions norms, the choice of fuel should not be distorted by way of taxes. Maintenance of relative prices with appropriate consideration to energy content should be a desirable goal of taxation policy.

Recommendation by committee
Quote:
As elsewhere in the world, the Government should decide only the vehicular emission standards and the corresponding fuel specifications without specifying vehicle technology and the type of fuel.

:Unquote

Report was approved by the Cabinet in October 2003 BHARAT DOGRA

4 AUTOMOBILE DEPARTMENT

Change in Tailpipe Emissions

Diesel Passenger Car
Regulated Pollutants (g/km)
18 16 14 12 10 8 6 4 2 0

Petrol Passenger Car

16.3

Regulated Pollutants (g/km)

25
21.6

20 15 10 5 0
1991 1996 7.9 3.83 1999 BS-I 2000 BS-II 1.78 2005 BS-III 1.25

11.68

3.69

2.7
2.65 1.18 2015 ?

0.825 2015 ?

2010 ? BS-IV

1991

1996

1999 BS-I

2000 BS-II

2005 BS-III

2010 ? BS-IV

25.50 25.00 20.00 15.00 10.00 5.00 0.00 1991 1996 2000 2005 8.10 4.00 3.00

Regulated Pollutants (g/kWhr)

Regulated Pollutants (g/km)

30.00

2 & 3 Wheelers

Commercial Vehicles
35 30 25 20 15 10 5 0

29.0

13.96

12.25 7.86 3.98

19 96

St ag eI)

St ag eII )

(B ha ra t

(B ha ra t

(B ha ra t

20 00

20 02

20 05

Need to assess BHARAT DOGRA environment an impact on

5 AUTOMOBILE DEPARTMENT

20 10

(B ha ra t

BS-III

St ag eIV

St ag eIII

1991

1996

2000 BS-I

2001

2005

2010 ? BS-IV

The Law of Diminishing Returns

The closer we get to the goal of zero emissions of a pollutant, the more costly it becomes to eliminate each unit. Continued progress, however, requires using methods that are more and more expensive, and remove smaller and smaller amounts of pollutants. At some point, the costs outweigh the benefits.

Source: ECO-SANITY, A Common Sense Guide to Environmentalism, Joseph L Bast et al

BHARAT DOGRA AUTOMOBILE DEPARTMENT

Technology Movement - Diesel

BS-III 10001200 bar
(Electronic injection control)

BS-IV

Injection Pressure s

300 / 600 bar

(IDI / DI Engines)

800-1000 bar
Mech injection

16001800 bar (CR, UI)

>2000 bar

Cylinder head/ports

2 valve/cylinder, inclined injector location

4valves/cylinder, centralised injection

Turbo system

Natural aspiration

Turbocharge r (Optional waste-gate & Intercooler)

Turbocharge r With intercooler

Variable Geometry Turbocharger

After treatment System

Simple exhaust

With EGR &/or catalytic converter

With DPF / SCR

BHARAT DOGRA AUTOMOBILE DEPARTMENT

Typical Common Rail System with Sensors and ECU

BHARAT DOGRA AUTOMOBILE DEPARTMENT

Significance of Common Rail

Injection pressures are going up from 1000 to 1800 bar and beyond Common rail system is sensitive to fuel quality parameters such as sediments, water content, particulate matter content, lubricity, any other market abuse System Servicing needs to be done by authorised and trained staff

BHARAT DOGRA AUTOMOBILE DEPARTMENT

SCR and EGR options for NOx control

Sr. No.

Parameters

SCR
* Urea tank * Delivery Module * Dosing Module * Injection Nozzle * ECU Yes

EGR
* EGR Valve * EGR Cooler * EGR Control

Components

NOx reducing potential Particulate after treatment Fuel economy impact Infrastructure requirements for urea Development Time System Complexity

Adequate

3
4 5 6
10

Not required for Euro-IV

1- 3% benefit over EGR (urea consumption included) Yes High
BHARAT DOGRA AUTOMOBILE DEPARTMENT High

Required (POC / DPF)

-No Low Moderate

Selective Catalytic Reduction

Engine ECU
CAN link Urea-SCR ECU

Air

Urea Tank

Pump T_in NOx Urea injection T_out

SCR catalyst

CO, HC,

CO2, H2O, PM, NO/NO2

CO2, H2O,
PM, N2

Exhaust gas

PM, NOx

DOC 2NO + O2 2NO2 4HC + 3O2 2CO2 + 2H2O 2CO + O2 2CO2

DOC Urea injection

SCR
SCR 4NH3 + 4NO + O2 4N2 + 6H2O 8NH3 + 6NO2 7N2 + 12H2O

C + O2 2CO2

Relies on UREA for emissions reduction - Infra structure required BHARAT DOGRA
11 AUTOMOBILE DEPARTMENT

Significance of SCR Technology for Heavy Duty Application

Improved fuel economy Necessary for Heavy Duty trucks particularly viewed against infrastructure

development
In Europe, most of OEMs are with SCR at Euro-IV, notably being Daimler Chrysler, Iveco, Volvo, DAF etc. Inevitable for Heavy Duty Euro-V and beyond

12

BHARAT DOGRA AUTOMOBILE DEPARTMENT

Particulate Filters

Particulate burning through a secondary injection Fuel availability of less than 50 ppm sulphur content must High ash content in oil is deterrent for satisfactory operation of DPF Generally used on light duty diesel and passenger cars
BHARAT DOGRA AUTOMOBILE DEPARTMENT

13

Technology movement - Gasoline

BS-IV

Fuel system

Carburetor with open loop system

MPFI with EMS and close loop

MPFI with multi-valve 4 v/cyl, VVT

Direct injection

Exhaust system

EGR/3way catcon

Mapped EGR/Advanced EGR tolerant processes

Catalyst with early light-off technology

Close coupled catalyst

14

BHARAT DOGRA AUTOMOBILE DEPARTMENT

Gasoline Engines BS IV Compliance Challenges

Exhaust Emissions After Treatment & EMS Technology
Objective: To minimise engine warm up and catalyst light-off duration to reduce cold emissions. Close coupled catalyst with faster light- off components comprising of optimized precious metal loading, wash coat and thin wall substrate. Thermally stable & durable catalyst substrate and wash coat technology. EMS control strategy to enable rapid catalyst light- off, optimized open loop after start fuelling (trade off between CO/HC emissions, driveability and catalyst light-off duration). Faster response oxygen sensors to enable quicker closed loop AFR control.

BHARAT DOGRA AUTOMOBILE DEPARTMENT

Technology movement CNG (3 & 4 Wheelers)

BS-IV
Stochiometric combustion, Naturally aspirated, 3 way catalyst, mechanical/electronic distribution systems

Engine

Turbocharged , intercooled

Low weight gas cylinders need to be developed

16

BHARAT DOGRA AUTOMOBILE DEPARTMENT

What fuel parameters need to be addressed for BS-III and BS-IV norms?
Fuel Properties BS-III BS-IV Remarks

Cetane Number Diesel

51

51

Higher Cetane number is desired (~53) to improve cranking time, cold startability, exhaust emissions and combustion noise
Reduction in sulphur must for PM reduction and for after-treatment system. Europe is promoting 10 ppm. Adulteration adversely impacts durability of emission control system. Must for FIE durability. Adulteration adversly impacts this requirement.

Max Sulphur content, ppm - Diesel

350

50

Lubricity, max, microns

460

460

17

BHARAT DOGRA AUTOMOBILE DEPARTMENT

Challenges & Issues, Next Steps

Technology development Investment & Installation of manufacturing Plant and machinery Supply chain management Duality of norms Clean fuel at outlets Infrastructure of Urea Inspection & Maintenance Programme

- Cost

18

BHARAT DOGRA AUTOMOBILE DEPARTMENT

END OF LECTURE

19

BHARAT DOGRA AUTOMOBILE DEPARTMENT