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Heavy-Duty Waste Hauler with Chemically Correct Natural Gas DE-AC36-99-GO10337 Engine Diluted with EGR and Using a Three-Way Catalyst: Final 5B

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Heavy-Duty Waste Hauler with Chemically Correct Natural Gas DE-AC36-99-GO10337 Engine Diluted with EGR and Using a Three-Way Catalyst: Final 5B A national laboratory of the U.S. Department of Energy Office of Energy Efficiency & Renewable Energy National Renewable Energy Laboratory Innovation for Our Energy Future Heavy-Duty Waste Hauler with Subcontract Report NREL/SR-540-38222 Chemically Correct Natural Gas September 2005 Engine Diluted with EGR and Using a Three-Way Catalyst Final Report February 24, 2004 – February 23, 2006 T. Reppert Mack Trucks, Inc. Allentown, Pennsylvania J. Chiu Southwest Research Institute San Antonio, Texas NREL is operated by Midwest Research Institute ● Battelle Contract No. DE-AC36-99-GO10337 Heavy-Duty Waste Hauler with Subcontract Report NREL/SR-540-38222 Chemically Correct Natural Gas September 2005 Engine Diluted with EGR and Using a Three-Way Catalyst Final Report February 24, 2004 – February 23, 2006 T. Reppert Mack Trucks, Inc. Allentown, Pennsylvania J. Chiu Southwest Research Institute San Antonio, Texas NREL Technical Monitor: R. Parish Prepared under Subcontract No. ZCI-4-32049-01 National Renewable Energy Laboratory 1617 Cole Boulevard, Golden, Colorado 80401-3393 303-275-3000 • www.nrel.gov Operated for the U.S. Department of Energy Office of Energy Efficiency and Renewable Energy by Midwest Research Institute • Battelle Contract No. DE-AC36-99-GO10337 NOTICE This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof. Available electronically at http://www.osti.gov/bridge Available for a processing fee to U.S. Department of Energy and its contractors, in paper, from: U.S. Department of Energy Office of Scientific and Technical Information P.O. Box 62 Oak Ridge, TN 37831-0062 phone: 865.576.8401 fax: 865.576.5728 email: mailto:[email protected] Available for sale to the public, in paper, from: U.S. Department of Commerce National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 phone: 800.553.6847 fax: 703.605.6900 email: [email protected] online ordering: http://www.ntis.gov/ordering.htm This publication received minimal editorial review at NREL Printed on paper containing at least 50% wastepaper, including 20% postconsumer waste TABLE OF CONTENTS Page EXECUTIVE SUMMARY ............................................................................................................ 1 1.0 INTRODUCTION .............................................................................................................. 2 1.1 Project Objective............................................................................................................. 3 2.0 TECHNICAL DISCUSSION/RESULTS........................................................................... 4 2.1 Engine Modifications...................................................................................................... 5 2.1.1 EGR System............................................................................................................ 5 2.1.2 Engine Control System ........................................................................................... 8 2.2 Engine Development..................................................................................................... 10 2.2.1 Test Cell Description ............................................................................................ 10 2.2.2 Engine Calibrations............................................................................................... 12 2.3 Emissions Testing ......................................................................................................... 25 2.3.1 Specifications – Formulations Used ..................................................................... 26 2.3.2 Emissions Testing with Catalyst Formulation A .................................................. 27 2.3.3 Emissions Testing with Catalyst Formulation B .................................................. 29 3. PROTOTYPE ENGINES ..................................................................................................... 32 3.1 Introduction................................................................................................................... 32 3.1.1 Demonstration Engine Design .............................................................................. 32 3.2 Component Modifications ............................................................................................ 33 3.2.1 Intake Manifold..................................................................................................... 33 3.2.2 Cooled EGR System ............................................................................................. 34 3.2.3 EGR Valve............................................................................................................ 35 4.0 HEAT REJECTION.......................................................................................................... 36 5.0 RESULTS AND CONCLUSIONS .................................................................................. 36 6.0 REFERENCE.................................................................................................................... 36 iii LIST OF TABLES Table 1: Differences between the Woodard OH2.0 and OH1.2 .................................................... 9 Table 2: EGR Control System ..................................................................................................... 10 Table 3: Average Gas Composition and Standard Deviation for Development Work................ 11 Table 4: Data Recorded ............................................................................................................... 12 Table 5: Steady-State Test Points ................................................................................................ 14 Table 6: Three-Way Calalyst Specifications ............................................................................... 26 Table 7: Transient Emissions Results with Catalyst.................................................................... 27 Table 8: Transient Emissions Results without Catalyst............................................................... 28 Table 9: 13-Mode Emissions Results (g/bhp-hr)......................................................................... 28 Table 10: FTP Emissions Results (g/bhp-hr)............................................................................... 29 Table 11: Transient Emissions Results without Catalyst............................................................. 30 Table 12: 13-Mode Emissions Results (g/bhp-hr)....................................................................... 31 Table 13: Fuel Composition for Emissions Testing .................................................................... 31 iv LIST OF FIGURES Figure 1. High Pressure EGR Loop ...............................................................................................6 Figure 2. Low Pressure EGR Loop................................................................................................7 Figure 3. High-Low Pressure EGR Loop ...................................................................................... 8 Figure 4. Steady-State Test Points............................................................................................... 14 Figure 5. Ignition Timing and EGR Sweeps for Mode 2, 800 rpm, 15% Load........................... 15 Figure 6. Ignition Timing and EGR Sweeps for Mode 3, 800 rpm, 50% Load........................... 15 Figure 7. Ignition Timing and EGR Sweeps for Mode 4, 800 rpm, 100% Load......................... 16 Figure 8. Ignition Timing and EGR Sweeps for Mode 5, 1000 rpm, 15% Load......................... 16 Figure 9. Ignition Timing and EGR Sweeps for Mode 6, 1000 rpm, 50% Load......................... 17 Figure 10. Ignition Timing and EGR Sweeps for Mode 7, 1000 rpm, 100% Load..................... 17 Figure 11. Ignition Timing and EGR Sweeps for Mode 8, 1250 rpm, 15% Load....................... 18 Figure 12. Ignition Timing and EGR Sweeps for Mode 9, 1250 rpm, 25% Load....................... 18 Figure 13. Ignition Timing and EGR Sweeps for Mode 10, 1250 rpm, 50% Load..................... 19 Figure 14. Ignition Timing and EGR Sweeps for Mode 11, 1250 rpm, 75% Load..................... 19 Figure 15. Ignition Timing and EGR Sweeps for Mode 12, 1250 rpm, 100% Load................... 20 Figure 16. Ignition Timing and EGR Sweeps for Mode 13, 1600 rpm, 15% Load..................... 20 Figure 17. Ignition Timing and EGR Sweeps for Mode 14, 1600 rpm, 25% Load..................... 21 Figure 18. Ignition Timing and EGR Sweeps for Mode 15, 1600 rpm, 50% Load..................... 21 Figure 19. Ignition Timing and EGR Sweeps for Mode 16, 1600 rpm, 75% Load..................... 22 Figure 20. Ignition Timing and EGR Sweeps for Mode 17, 1600 rpm, 100%
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