CuproBraze® 58

ExecutRivepoert Diesel Makers Strive to Meet EPA, EU and Japanese Emissions Standards for Highway, Off-road and Applications, Part I

New Low-Emission Engine Technologies Adopt CuproBraze Heat-Exchangers

Part I – Overview of Legislation and Review of On-Highway Emissions Standards

[Editor’s Note: See CuproBraze Executive Report Number 59 for Part II, which will describe the new emissions standards for off-road equipment, and stationary power generators.]

iesel engine manufacturers are fac- Growing concerns about global warm- ing a situation of historic, global ing are also bringing about increased proportions. Independently and col- regulation of fuel efficiencies. In 2007, lectively, nations around the world the U.S. Supreme Court ruled that the have passed legislation that requires Environmental Protection Agency (EPA) OEMs to develop environmentally can lawfully regulate carbon dioxide emis- D“clean” and related equipment. sions. Although the consequences are still Manufacturers that fail to meet increasingly to be determined, this decision eventually tougher new standards eventually will be will spur the development of clean, fuel- prevented from selling their products in any efficient diesel engines in the U.S. and market. globally. The impetus behind this movement is For at least a decade, various government the fact that diesel engines are a significant agencies around the world have placed source of emissions that cause health prob- ever-stricter regulations on emissions from lems. A recent report titled “No Escape large diesel engines. These regulations have from Diesel Exhaust: How to Reduce required engine makers to develop new Commuter Exposure” published by the engine technologies and dramatically reduce Clean Air Task Force (www.catf.us) impli- emissions of particulate matter (PM) and cates diesel exhaust as a major source of nitrogen oxides (NOx) from their products. noxious air pollutants. According to CATF, In the U.S., the EPA acknowledged the emissions from an estimated 13 million die- impact of diesel emissions on health many sel engines in the U.S. alone are associated years ago and passed several tiers of rules with respiratory illness, cancer, heart attacks gradually tightening emissions standards for and premature death. Its web site provides various classes of diesel engines as detailed national, state, metropolitan area and local later in this article. (county) estimates of the health impacts of The European Union currently has six diesel particulate matter. tiers of emissions standards for heavy duty (a) well as off-road vehicles. These standards are 1.5 described in reports available in English on the Ministry of the Environment (Government of 1.2 Japan) web site (www.env.go.jp). For example, -hr) the Eighth Report on “Future Policy for Motor Vehicle Emission Reduction” is avail- 0.9 able online in English at www.env.go.jp/en/ air/aq/mv/vehicle-8th.pdf. 0.6 China has been adopting emission stan- dards since the 1990s through its State

drocarbons (gm/bhp Environmental Protection Administration

Hy 0.3 .14 (SEPA), typically basing its standards on European regulations with built-in implemen- 0.0 tation delays. Russia also has adopted the EU 1988 1998 2007 emissions standards (Tier I-V and Stage I), according to specific implementation dates. EPA’s “HD2007” (b) 12 emissions standards 10 Advantage CuproBraze

apply to on-highway -hr) heavy-duty . These changes affect all types of diesel Compared to previous 8 engines. Because commercial vehicles and emissions standards, equipment tend to have large diesel engines, the HD2007 standards 6 the new standards are especially applicable call for a dramatic xides (gm/bhp to heavy duty trucks, buses, mobile off-road reduction in a) non- 4 equipment (for agriculture, construction and methane hydro- industry), locomotives and marine applications

carbons, b) oxides Nitrogen O 2 as well as stationary diesel engines for power of nitrogen and c) .20 generators and industrial compressors. particulate matter. The 0 These stringent emissions regulations have European Union and 1988 1998 2007 impacted the industry beyond engine manu- Japan have passed 0.6 facturing and have prompted engine makers similarly stringent (c) to re-examine basic premises about ancillary regulations. equipment such heat-exchangers. 0.5 -hr) As a new materials technology for heat exchangers, CuproBraze is extremely attractive 0.4 in heavy duty on-highway and off-road applica- tions because it offers distinct advantages over 0.3 aluminum. While aluminum is less dense than , copper is stronger per unit volume and 0.2 has a higher . Copper’s

ticulate Matter (gm/bhp thermal conductivity is 360 W/m-K compared 0.1

r Pa to 260 W/m-K for aluminum. The result is .01 that, for the same volume of heat exchanger, 0.0 1988 1998 2007 aluminum fins and copper fins provide about the same heat dissipation but the copper-fin heat exchanger provides a lower airside pres- sure drop with its associated benefits. trucks and buses, beginning with Tier I in In other words, CuproBraze provides greater 1992 and culminating in 2013 with Tier VI cooling efficiency than aluminum. Such dif- standards. For off-road engines, the EU has ferences add up in the large-volume heat four levels of emissions standards, beginning exchangers used to cool air charges as well as in 1997 for Stage I and culminating in 2014 blocks and engine oil in heavy with Stage IV. European emission standards duty on-highway and off-road applications. can be found online at http://ec.europa.eu/ For mobile and stationary diesel applications, environment/air/transport/index.htm. the advantages of cooling efficiency, heat Japan’s Ministry of Environment (MoE) also exchanger size and durability are keys. The has established strict emissions regulations, result is that more space is available for other including regulations for heavy duty trucks as uses. Coupling that advantage with increased durability and high resistance, it is restricts NOx to 0.4 (a) Aluminum easy to see why manufacturers are increasingly g/kWh (~ 0.3 g/bhp- CAC Pre-cooler gravitating toward the CuproBraze alternative. hr) and PM to 0.01 g/ Turbocharger Young Touchstone, a Wabtec Company kWh (~ 0.008 g/bhp-

(Jackson, Tennessee), is a leader in the devel- hr) [2, 3]. Ambient Air Exhaust Gas opment of CuproBraze heat exchangers. Mike The 2009 Japanese Sprenger, director of Sales & Marketing, says, JE05 standards will “Diesel engines designed to meet the increas- bring NOx down to ingly stringent emissions levels worldwide 0.7 g/kWh (~ 0.52 g/ require more and more from cooling systems. bhp-hr) and PM to Compressed, Cooled Air These new diesel engine cooling systems reject 0.01 g/kWh (~ 0.008 Entering Engine more heat, operate at higher pressures and g/bhp-hr). A concise , have higher power , and summary of emis- operate in a variety of demanding applications. sions standards for Fig. 1a – Aluminum CAC System Schematic Young Touchstone’s cooling systems with heavy duty trucks and (b) FLAT-ROUND® CuproBraze technology can buses is provided by fulfill these needs for our global OEM cus- DieselNet at www.die- tomers with a low total-cost solution.” selnet.com/standards/ us/hd.php. HD Emissions The U.S. “HD2007” standards are poten- Emissions standards for heavy duty (HD) tially the most restric- trucks and buses were established and gradu- tive, but makers ally tightened by the U.S. EPA for model have at least another years 1988 through 1998. Beginning in 2007, year to fully imple- these limits were lowered further to historic ment them. Although levels. Known as the HD2007 standards, they the PM emission stan- included: dard took full effect In the near future, • Particulate matter (PM) is restricted to 0.01 in the 2007 heavy-duty engine model year, the higher charge air g/bhp-hr [1] NOx and NMHC standards will be phased temperatures will in for diesel engines between 2007 and 2010. mandate the use of • Nitrogen oxides (NOx) are restricted to 0.20 (a) a pre-cooler to g/bhp-hr According to DieselNet, very few engines will meet the 0.20 g/bhp-hr NOx requirement cool the charge air • Non-methane hydrocarbons (NMHC) are before 2010 because most manufacturers will before it reaches restricted to 0.14 g/bhp-hr opt instead for a Family Emission Limit (FEL) the temperature- To put these new numbers in perspective, for most of their engines [4]. challenged aluminum by comparison the 1988 limits were 60 times CAC; or (b) the con- higher for PM (at 6.0 g/bhp-hr) and more than ventional approach 50 times higher for NOx (at 10.7 g/bhp-hr). CuproBraze and HD (no pre-cooler) with Effective in 2008, the Euro Tier V standard Because CuproBraze and charge air a copper- CAC. restricts NOx to 2.0 g/kWh (~ 1.5 g/bhp-hr) coolers provide greater cooling capacity than and restricts PM to 0.02 g/kWh (~ 0.015 g/ their aluminum counterparts, heavy-duty truck bhp-hr). In 2013, the Euro Tier VI standard makers benefit from more available space under the hood. In some cases, aluminum- based systems require a stainless- steel pre-cooler to meet the more stringent emissions standards, which takes up additional space and adds cost to the cooling systems. The use of a pre-cooler also may be avoided because CuproBraze CACs can operate at higher temperatures than alumi- num CACs [5].

This huge CuproBraze CAC is for a locomotive application. (Photograph courtesy of Young Touchstone.) The International Copper The higher tem- Association, Ltd. (ICA) perature operation of clean diesel engines The International Copper Association, Ltd. (ICA) is the also shortens the use- leading organization for promoting the use of copper worldwide. The Association’s 38 member companies ful life of aluminum represent about 80 percent of the world’s refined copper CACs. Buses typi- output. ICA’s mission is to promote the use of copper cally have a longer by communicating the unique attributes that make this life cycle than HD sustainable element an essential contributor to the trucks, so durability is formation of life, to advances in science and technology, especially important and to a higher standard of living worldwide. for these vehicles. Emissions reduction For information about the CuproBraze process or ICA’s CuproBraze consulting services, please contact the is equally vital for International Copper Association at: buses, which trans- [email protected]. port people, including For European inquiries contact: [email protected]. schoolchildren, and frequently operate Close-up of a CuproBraze CAC built for a locomotive application. Note in population-dense that the copper fins and brass tubes have been painted. New emissions Footnotes and References urban settings. standards for locomotives will be discussed in Part II. (Photograph is CuproBraze is an courtesy of Young Touchstone.) 1. European emission regulations for new heavy- extremely attractive duty diesel engines are commonly referred to option for clean die- as Euro I ... VI but sometimes Arabic numerals sel engines in buses. Buses also stand to A Turning Point are also used (Euro 1 ... 6). Following the benefit from the space-savings advantage At this critical juncture, OEMs are work- example of DieselNet, we will use Roman ing hard to create new generations of die- numerals when referencing standards for of compact CuproBraze heat exchangers, heavy-duty engines. which leave more space available for pas- sel engines to meet these stringent diesel emission standards, which will be imple- 2. Since emission standards for both gasoline sengers. and diesel heavy-duty engines are expressed in The elevated pressures and tempera- mented globally within the next decade. terms of grams per brake-horsepower-hour tures associated with new clean diesel Existing diesel emissions standards (g/bhp-hr), conversion factors in terms of engine technologies favor a transition were covered in previous editions of brake-horsepower-hour per mile (bhp-hr/mi) from aluminum to copper and brass in CuproBraze Executive Report (Numbers 21 must be used to convert the emission data heavy-duty truck and bus applications. and 29), which are available online at from engine certification testing to in-use gram www.cuprobraze.com/lit_er.asp. Since per mile emission factors. Unfortunately, the adoption of brazed copper and brass in this marketplace has then, new standards have been intro- 3. To compare Euro standards with U.S. EPA duced for locomotives and stationary standards, it is necessary to convert brake been slowed because OEMs and end- horsepower to kilowatts; the values in paren- users are still accustomed to specifying power generators. Current standards are theses are based on conversion factor of 1 bhp aluminum radiators and charge air coolers also summarized by DieselNet at www. = 0.7457 kW. in these applications. dieselnet.com/standards along with refer- 4. Family emission limit (FEL) means an emis- CuproBraze radiators and CACs are ences to the original rules. ■ sion level declared by the manufacturer which expected to capture a steadily increasing serves in lieu of an emission standard for market share as OEMs and end-users real- Editor’s Note: Part II will be presented in the certification purposes in any of the averaging, ize that CuproBraze heat exchangers offer next CuproBraze Executive Report (i.e., issue trading, or banking programs. superior cooling efficiency, durability and number 59). Part II will review timetables for 5. For more about possible cost savings in this high temperature performance compared the implementation of diesel emissions standards application, see CuproBraze Executive Report worldwide for off-road equipment as well as loco- Number 50, “Brazed Copper-Brass Simplifies to the aluminum alternatives. Currently, Charge Air Cooling System for Clean Diesel,” SHAAZ in Russia is pioneering the use motives and stationary power generators. In par- available online at www.cuprobraze.com/ of CuproBraze radiators and CACs in on- allel with this overview, updates will be provided lit_er.asp. highway applications. In North America, on the development of CuproBraze heat exchang- Climex World (Monterrey, Mexico) is ers for these applications. gearing up to provide CuproBraze CACs and radiators as replacement parts for popular OEM heavy duty trucks.

International Copper Association, Ltd. 260 Madison Avenue, 16th Floor, New York, NY 10016-2401 Tel: 212.251.7240, Fax: 212.251.7245