And Heavy-Duty Truck Fuel Efficiency Technology Study – Report #1 DISCLAIMER
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DOT HS 812 146 June 2015 (Revised October 2015) Commercial Medium- and Heavy-Duty Truck Fuel Efficiency Technology Study – Report #1 DISCLAIMER This publication is distributed by the U.S. Department of Transportation, National Highway Traffic Safety Administration, in the interest of information exchange. The opinions, findings, and conclusions expressed in this publication are those of the authors and not necessarily those of the Department of Transportation or the National Highway Traffic Safety Administration. The content is not intended to be used for determination of federal grant programs. The United States Government assumes no liability for its contents or use thereof. If trade or manufacturers’ names or products are mentioned, it is because they are considered essential to the object of the publication and should not be construed as an endorsement. The United States Government does not endorse products or manufacturers. Suggested APA Format Citation: Reinhart, T. E. (2015, June [Revised October 2015]). Commercial medium- and heavy-duty truck fuel efficiency technology study - Report #1. (Report No. DOT HS 812 146). Washington, DC: National Highway Traffic Safety Administration. TECHNICAL REPORT DOCUMENTATION PAGE 1. Report No. 2. Government Accession No. 3. Recipient's Catalog No. DOT HS 812 146 4. Title and Subtitle 5. Report Date Commercial Medium- and Heavy-Duty (MD/HD) Truck Fuel June 2015 Efficiency Technology Study – Report #1 (Revised October 2015) 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. Thomas E. Reinhart, Institute Engineer 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) Southwest Research Institute 6220 Culebra Rd. 11. Contract or Grant No. San Antonio, TX 78238 GS-23F-0006M/DTNH22- 210.522.5876 12-F-00428 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered National Highway Traffic Safety Administration Final 1200 New Jersey Avenue SE. 14. Sponsoring Agency Code Washington, DC 20590 NHTSA/NVS-132 15. Supplementary Notes Prepared for: James MacIsaac (COR) Coralie Cooper Dr. John Whitefoot (Alternate COR) U.S. Department of Transportation U.S. Department of Transportation Volpe National Transportation Systems Center National Highway Traffic Safety Administration Energy Analysis and Sustainability Division Fuel Economy Division, NVS-132 55 Broadway 1200 New Jersey Ave, SE Cambridge, MA 02142-1093 Washington, DC 20590 16. Abstract This research project is to inform NHTSA and EPA’s development of Phase 2 Greenhouse Gas Emissions and Fuel Efficiency Standards for Medium- and Heavy-Duty Engines and Vehicles (Class 2b – 8). A literature review is used to identify potential fuel saving technologies and review the state of the art. A large number of engine and vehicle technologies are selected for additional analysis, and their fuel saving performance is simulated to project the fuel savings potential of each technology over a wide range of duty cycles. Wherever possible, experimental data is used to inform and validate the simulation results. All baseline engine and vehicle models are validated against experimental data. Trade-offs between engine-out NOx levels and fuel consumption are reviewed. There is a review of fuel consumption, fuel economy, and GHG metrics, and of test and analysis procedures. The existing international truck fuel consumption and GHG regulations are compared and contrasted. Certification issues are explored, including the potential for including trailers in future regulations. Note: This report was subjected to external peer review per OMB guidelines for a Highly Influential Scientific Assessment (HISA). Materials from the peer review process are publicly available in accompanying documents. 17. Key Words 18. Distribution Statement Fuel Consumption, GHG Emissions, Medium Duty, Heavy This report is available to the public Duty, Engine Simulation, Vehicle Simulation from the National Technical Information Service www.ntis.gov 19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 22. Price Unclassified Unclassified 302 Form DOT F 1700.7 (8-72) Reproduction of completed page authorized i EXECUTIVE SUMMARY In 2011, the National Highway Traffic Safety Administration (NHTSA) and Environmental Protection Agency (EPA) jointly issued a first phase of fuel efficiency and greenhouse gas (GHG) standards that apply to medium- and heavy-duty on-highway engines and vehicles for model years (MY) 2014 to 2018 and beyond. These regulations are commonly referred to as “Phase 1” of the Heavy-Duty National Program. The standards cover all vehicles in weight classes 2b through 8, which encompasses most vehicles with gross vehicle weight ratings (GVWR) over 8,500 pounds except for a limited number of passenger vehicles covered under the light duty corporate average fuel economy (CAFE) standards, and recreational vehicles, which were included in EPA’s GHG standards but not NHTSA’s fuel efficiency standards. Phase 1 has two implementation stages. EPA’s greenhouse gas emission standards are mandatory beginning with model year 2014. NHTSA’s fuel consumption standards are voluntary in model years 2014 and 2015, becoming mandatory with model year 2016 for most regulatory categories. Commercial trailers were not regulated in Phase 1. The Phase 1 GHG and fuel consumption standards were developed using input from a number of studies that evaluated the fuel saving technologies that are available, such as the NESCCAF 2009 report [1] and the NHTSA and NAS 2010 reports [2, 3]. The research project described in this report has been completed for NHTSA to help to inform the next phase (“Phase 2”) of the regulations, which would set standards in coordination with EPA for model years beyond 2018. In order to prepare for Phase 2, NHTSA directed SwRI to update prior research on fuel saving technologies to reflect the effects of the Phase 1 regulations, as well as to include technical progress that has been made over the last few years. In particular, SwRI was tasked with assessing the current commercial fleet technology baseline at the time of contract award (MY 2011/2012) and assessing the effectiveness and cost of potential fuel efficiency/GHG improving technologies for the Phase 2 timeframe (post MY 2018). When considering potential fuel efficiency/GHG-reducing technologies, NHTSA directed SwRI to include a range of factors: design, functionality, duty cycle, use (type of work done by the vehicle), and factors that can influence the effectiveness, feasibility, and cost. Vehicle utility and performance are also to be considered. The content of report sections is summarized below. After an introduction (Section 1), Section 2 provides a literature review covering the following topics: • Fuel saving technologies for MD and HD engines and vehicles • Market segmentation of fleets • Current and planned fuel economy regulations in markets around the world Four references were found regarding vehicle segmentation. This is a challenge in the medium- and heavy-duty vehicle world, where there are hundreds of applications, and where any given vehicle type may be exposed to a wide range of different drive cycles. SwRI determined that the most promising segmentation approach has been developed by CalHEAT in California. Calheat breaks the Class 2b through Class 8 market into six segments: ii 1. Heavy duty pickups and vans 2. Long haul tractors 3. Short and regional haul tractors 4. Work site vocational trucks such as dump trucks, concrete truck, utility service trucks, etc. 5. Urban vocational trucks such as refuse haulers, busses, delivery trucks, transit bus, school bus, etc. 6. Rural vocational trucks, including motor coach, forestry, petroleum, heavy haulers, etc. Nineteen references were found regarding government regulations of truck fuel consumption and GHG emissions around the world. A review of the literature shows that the world is moving towards quite different fuel consumption / GHG regulations in different markets. The differences in national regulations reflect the unique characteristics and needs of each market, as well as variation in regulatory philosophy. Japan has the first regulation to go into effect. Its regulations use a simple vehicle simulation model where factors such as vehicle weight, aerodynamic drag, and rolling resistance are held constant. The Japanese regulation effectively targets engine brake specific fuel consumption (BSFC) and transmission match. China is implementing a regulatory approach based on a combination of chassis dynamometer testing and simulation. Vehicles are assigned a target fuel consumption based on vehicle type and Gross Vehicle Weight (GVW) rating. A modified version of the World Harmonized Vehicle Cycle (WHVC) is specified for the drive cycle, with different weightings of the urban, rural, and motorway cycles as a function of vehicle application. At the end of the literature review task in January 2013, NHTSA, EPA, and SwRI agreed on a list of vehicle and engine technologies that form the main subject of this project. Section 3 addresses the heart of the project, which is a performance analysis of technologies that could be used to comply with a future Phase 2 fuel consumption / GHG regulation, for the time frame beyond 2018. The analysis included both engine technologies and vehicle technologies, using a technology list described in Section 3.1 that was developed during the literature review. Four basic engines and four vehicles were selected for simulation.