CAFEE Center for Alternative Fuels, Engines & Emissions West Virginia University Heavy-Duty Vehicle Diesel Engine Efficiency Evaluation and Energy Audit October 2014 Final Report Arvind Thiruvengadam, Ph.D. – Principal Investigator Saroj Pradhan Pragalath Thiruvengadam Marc Besch Daniel Carder Mechanical and Aerospace Department West Virginia University, Morgantown, WV Oscar Delgado, Ph.D. The International Council on Clean Transportation Washington, DC Table of Contents EXECUTIVE SUMMARY .......................................................................................................................................... 1 1 INTRODUCTION ................................................................................................................................................... 4 1.1 BACKGROUND ................................................................................................................................................... 5 1.1.1 Simulation Modeling of Fuel Consumption ..................................................................................... 5 1.1.2 Engine Transient Phenomena .......................................................................................................... 5 1.1.3 Engine Efficiency and Loss Mechanisms ......................................................................................... 6 1.1.4 Engine Model ................................................................................................................................... 7 2 TEST ENGINE SPECIFICATION ........................................................................................................................ 9 2.1 US EPA 2010-COMPLIANT HEAVY-DUTY DIESEL ENGINE ............................................................................... 9 2.2 LEGACY US EPA 2004 COMPLIANT HEAVY-DUTY DIESEL ENGINE ............................................................... 10 2.3 US EPA 2010 COMPLIANT MEDIUM-DUTY DIESEL ENGINE ........................................................................... 11 3 EXPERIMENTAL SETUP ................................................................................................................................... 13 3.1 TEST CELL INTEGRATION ................................................................................................................................ 13 4 TEST PROCEDURE ............................................................................................................................................. 14 4.1 ENGINE INSTRUMENTATION ............................................................................................................................ 14 4.2 ENGINE LUG CURVE ........................................................................................................................................ 15 4.3 MOTORING PROCEDURE .................................................................................................................................. 15 4.4 FUEL MAP DEVELOPMENT .............................................................................................................................. 15 4.5 ENERGY AUDIT METHODOLOGY ..................................................................................................................... 18 4.6 WASTE HEAT RECOVERY SIMULATION ........................................................................................................... 20 5 RESULTS ............................................................................................................................................................... 23 5.1 FUEL MAP CHARACTERIZATION ..................................................................................................................... 23 5.1.1 MY 2005 Mercedes OM460 ........................................................................................................... 23 5.1.2 MY 2011 Mack MP8 505C ............................................................................................................. 24 5.1.3 Difference between steady-state and transient maps ..................................................................... 26 5.1.3.1 Transient Correction Factor ............................................................................................................................ 29 5.1.4 MY2011 Cummins ISB6.7 .............................................................................................................. 30 5.2 AUTONOMIE FUEL MAP .................................................................................................................................. 31 5.3 ENERGY AUDIT ............................................................................................................................................... 32 5.3.1 USEPA 2010 Heavy-Duty Engine Energy Audit ........................................................................... 33 5.3.2 USEPA 2010 Medium-Duty Engine Energy Audit ........................................................................ 34 5.4 FUTURE ENGINE PREDICTION .......................................................................................................................... 35 5.4.1 Oil Pump ........................................................................................................................................ 36 5.4.2 Water Pump ................................................................................................................................... 36 5.4.3 Air Compressor .............................................................................................................................. 37 5.4.4 Exhaust Backpressure .................................................................................................................... 37 5.4.5 Engine Friction .............................................................................................................................. 38 5.4.6 Prediction Methodology ................................................................................................................ 38 5.4.6.1 Pumping Loss Improvements ......................................................................................................................... 38 5.4.6.2 Engine Accessories ......................................................................................................................................... 39 5.4.6.3 Engine Friction ............................................................................................................................................... 39 5.4.6.4 Exhaust Energy ............................................................................................................................................... 39 5.4.6.5 Coolant Energy ............................................................................................................................................... 41 5.4.7 2017 Engine Map Analysis ............................................................................................................ 42 5.4.8 2020+ Engine Map Analysis .......................................................................................................... 46 5.5 REGULATORY CYCLE PREDICTIONS ................................................................................................................ 49 5.5.1 Heavy-duty SET Prediction ........................................................................................................... 50 5.5.2 Medium-duty FTP Prediction ........................................................................................................ 51 ii 5.6 WASTE HEAT RECOVERY ................................................................................................................................ 52 5.6.1 USEPA 2010 Heavy-Duty Diesel Engine WHR Model ................................................................. 53 5.6.2 USEPA 2010 Medium Duty Diesel Engine WHR Model ............................................................... 55 6 CONCLUSIONS .................................................................................................................................................... 57 7 REFERENCES ....................................................................................................................................................... 59 8 APPENDIX ............................................................................................................................................................. 61 iii ACKNOWLEDGEMENTS The West Virginia University Center for Alternative Fuels, Engines and Emissions would like to thank the International Council for Clean Transportation (ICCT) for funding this study. We thank Volvo Technology North America for supporting test cell integration of their engine, and thank Cummins Inc. for donating a medium-duty diesel engine for research purposes. In addition, we thank the Cummins and Volvo teams, Dr. Rachel Muncrief, and Fanta Kamakaté, for their reviews and input on an earlier version of the report. We also thank Dr. Oscar Delgado for being the technical lead from the ICCT and Dr. Nic Lutsey for providing valuable inputs during the course of the study. iv EXECUTIVE SUMMARY The modern diesel engine, the primary propulsion source for most heavy-duty vehicle freight movement, is subject to many design constraints, including durability, efficiency, and low emissions. The most stringent emission regulations, for example those in the United States and