DEUTZ Variable Emission Reduction Technology

DEUTZ Variable Emission Reduction Technology
Tier 4 – our driving force, your advantage.
Since the industrialisation of the internal combustion engine
The subject of emission reduction is an extremely complex
at the end of the 19th century, the increasing need for more
one. Therefore, in addition to radical optimisation in the
compact engines with a higher power density and lower fuel
design of the basic engine and the implementation of emis-
consumption has led to the continuous further development
sion reduction measures within the engine, exhaust gas af-
of the Diesel engine. One other important driving force since
tertreatment (EAT) methods are now also being implemented
1996 has been the need to fulfil increasingly demanding
in order to comply with the extremely low limits of current
exhaust emission legislation passed at short time intervals.
emission legislation.
We are currently focussing on the fulfilment of EU Stage IV
or US EPA Tier 4, so far the strictest emission standard for
so-called non-road applications. These will be phased in
gradually between 2014 and 2015, differentiated according
to power category.
Here we remain true to our philosophy: technical changes
will only be introduced where they serve to implement legal
requirements or result in an improvement in customer
benefits.
Above all, the economy and reliability of DEUTZ engines
always remain the priority.
The development of the emission legislation
100%
Ever since the emission legislation was introduced for mobile
9.2
g/kWh
machinery, emissions of nitric oxide (NOX) and diesel soot
(PM) have both been considerably reduced. The chart to the
0.7
g/kWh
90%
right illustrates this.
With DVERT®, we have developed a modular system kit that
80%
meets all these requirements. A thorough knowledge and
considerable investment in R&D were both necessary to put
this technological concept into practice.
70%
With the introduction of the current emission standards
Stage III B in Europe and Tier 4 Interim in the USA, limits for
nitrogen oxides (NOX), hydrocarbons (HC) and particles (PM)
= NOX (+ HC) [g/kWh]
= Particulates [g/kWh]
60%
have been considerably reduced once again.
Thanks to DVERT®, our engines are also capable of fulfilling
50%
all further legal requirements without any difficulty and even
providing a better performance at the same time in most
cases.
40%
30%
20%
0.4
g/kWh
10%
0.025
g/kWh
0%
EU Stage I
US EPA Tier 1
75 –130 kW
EU Stage II
US EPA Tier 2
75 –130 kW
EU Stage IIIA
US EPA Tier 3
75 –130 kW
EU Stage IIIB
US EPA Tier 4i
56 –130 kW
EU Stage IV
US EPA Tier 4
56 – 130 kW
EU STAGE III A
US EPA TIER 3
FUEL INJECTION
COMBUSTION MANAGEMENT
Mechanical pump-line-nozzle
•���������������������������
Mechanical distributor injection pump
•�������������������������������������
DEUTZ Common Rail (DCR®)
•����������������������
Magnetic valve system (MVS®)
•��������������������������
Direct and indirect injection systems
•�������������������������������������
Natural aspirated engines
•�������������������������
•Wastegate exhaust turbochargers
Charge air cooling
•������������������
2-valve and 4-valve systems
•���������������������������
EU STAGE III B
US EPA TIER 4 INTERIM
EU STAGE IV
US EPA Tier 4
EXHAUST AFTERTREATMENT
– LOWER PARTICULATES
EXHAUST AFTERTREATMENT – REDUCING NOX
With improved engine combustion &
fuel injection systems and using the following aftertreatment methods:
Using a combination of the following
aftertreatment technologies introduced
in Tier 4 interim:
•Reduction of soluble particulate
•Reduction of soluble particulate
•Reduction of diesel soot by means of
•Reduction of diesel soot by means of
•NOX reduction by means of the selec-
•NOX reduction by selective catalytic
matter by means of diesel oxidation
catalyst (DOC)
ENGINE CONTROL TECHNOLOGY
NOX REDUCTION TECHNOLOGY
Mechanical fuel injection and control
•�������������������������������������
Mechanical fuel injection with electronic speed
•������������������������������������������������
Simple, uncontrolled internal exhaust gas recircu•��������������������������������������������������
control and engine data recording (EMR®2)
Fully electronic engine control (EMR®3)
•������������������������������������
lation (EGR)
Controlled exhaust gas recirculation with valve
•������������������������������������������������
diesel particulate filters (DPF)
tive catalytic reduction (SCR)
matter by means of diesel oxidation
catalyst (DOC)
diesel particulate filters (DPF).
reduction (SCR)
stroke management (VLM®)
Controlled and cooled exhaust gas recirculation
•�����������������������������������������������
DVERT® is our answer to the problem of harmonising future
Almost all the elements of the DVERT® system kit can be
The following EAT variants will show you how we have
emission regulations with our customers’ requirements.
combined with each other to ensure the desired result with
solved this issue for the entire power range – because we
DVERT® stands for a modularly structured system which is
regard to engine performance, observance of emission limits
are in the business of creating facts.
incorporated into different configurations of our engines.
and competitiveness. With our flexible modular system we
The basic principle is:
can ensure that “overengineering” is avoided and only as
“As much technology as necessary
and not as much as possible.”
much technology as is necessary and useful is used.
VISION
ZERO EMISSION
DIESEL ENGINES
1
•
•
•
With engines of < 4 L, 15% more power
than comparable Tier 3 engines�
Up to 10% lower average fuel consumption through d���������
ownsizing
Maintenance free and compact EAT system which can be optionally mounted onto the engine
•
Tier 4���������������������
��������������������
in combination with SCR system
���� �������
(> 56 kW)
Tier 4 interim/Tier 4:
TCD 2.9 L4 Tier 4 interim:
TCD 3.6 L4
2
•
With engines of 4 - 8 L, up to 25%
more power than comparable Tier 3 engines
•
•
•
•
Fuel consumption up to 5% lower
Compact EAT system & variants designed for easy installation�
Suitable for low-emission zones
Burner regeneration w/o operation interference under every operating condition (>130 kW)
Tier 4 interim:
TCD 4.1 L4
TCD 6.1 L6
TCD 7.8 L6
3
•
•
•
Highly efficient EAT system with UREA
injection
Engine performance improved by up to 8%*
Average fuel consumption up to 5 %
lower
Tier 4 interim:
TCD 4.1 L4*
* Agricultural engines only
TCD 6.1 L6*
TCD 7.8 L6*
TCD 12.0 V6
TCD 16.0 V8
4
•
•
•
•
Up to additional 10% increase in power
and more torque
Lower noise and fuel consumption
Proven and robust SCR techno­logy�
Durable design for all applications and
markets�
Tier 4 :
TCD 3.6 L4
5
•
•
Highly efficient EAT system with particle
filtration and UREA injection
Reduced exhaust noise 25 db������
(A),
eliminates the need for an additional silencer
•
•
Lower fuel consumption�
Proven and robust SCR techno­logy�
Tier 4 :
TCD 4.1 L4
TCD 6.1 L6 TTCD 6.1 L6*
* Agricultural engines only
TCD 7.8 L6
TTCD 7.8 L6*
Overview of DEUTZ product line-up – Tier 4 interim
Technology: Electronically controlled high pressure common rail (HPCR) injection
Model
ceEGR
Diesel Oxidation
Wall-Flow
Catalyst (DOC) System (DPF)
Overview of DEUTZ product line-up – Tier 4
Technology: Electronically controlled high pressure common rail (HPCR) injection
Selective
DEUTZ
Catalytic
Burner
Reduction (SCR)
Heat Management
System*
Model
ceEGR
Diesel Oxidation
Wall-Flow
Catalyst (DOC) System (DPF)
19 – 55.4 kW
D 2.9 L4
n
TD 2.9 L4
n
TCD 2.9 L4
TD 3.6 L4
Selective
Catalytic
Reduction (SCR)
Heat Management
System*
19 – 55.4 kW
D 2.9 L4
n
n
TD 2.9 L4
n
n
n
TCD 2.9 L4
n
n
s
s
n
TD 3.6 L4
n
n
s
s
56 – 520 kW
56 – 520 kW
TCD 3.6 L4 n
n
s
s
TCD 3.6 L4
n
n
s
n
n
TCD 4.1 L4
n
n
n
l
s
n
TCD 4.1 L4
n
n
n
n
n
TCD 6.1 L6
n
n
n
l
s n **
n
TCD 6.1 L6***
n
n
n
n
n
TCD 7.8 L6
n
n
n
l
n
TCD 7.8 L6***
n
n
n
n
n
TCD 12.0 V6
n
TCD 12.0 V6
n
n
n
TCD 16.0 V8
n
TCD 16.0 V8
n
n
n
n = Standard; s = Option; l = Agricultural engines, with SCR only
n = Standard; s = Option
* Regeneration support by engine internal measures; ** TCD 6.1 L6 > 130 kW Burner standard
*** Agri high performance version with dual stage TC
As an engine system supplier, we take pride in being specialists in solving complex drive requirements. Our job is to meet
and exceed current and future exhaust regulations safely
and effectively. By developing customised solutions for our
customers, DEUTZ has set a high standard with DVERT®,
and by using modular solutions, all engines meet the latest
emission regulations efficiently and economically.
TTCD 6.1/7.8
When making the decision to fit a T4 engine, the following
Operating costs
Exhaust gas aftertreatment systems (EAT systems)
SCR (Selective Catalytic Reduction)
questions are frequently asked, to which we would like to
DEUTZ engines traditionally stand out on account of their
The current EU Stage IIIB / US EPA Tier 4 interim standards
Alternatively, the NOX emissions can be reduced by means
briefly respond:
low fuel consumption. With our new Tier 4 engines, we set
require the use of measures within the engine in combination
of SCR technology to such a low level that the strict particle
new standards in fuel efficiency. We optimise power and
with an EAT system; either to reduce the NOX values or to
limits are also to be achieved through optimisation within the
torque through the use of the most modern engine and
reduce the particle values, whereby the other limit can then
engine.
combustion management systems, while at the same time
be achieved in each case engine internally.
Engine installation
Strict emission standards make it necessary to use additional components for exhaust gas aftertreatment (EAT).
Unfortunately, the installation space available in the equipment cannot be increased at will, which can result in huge
challenges and changes for the equipment manufacturer.
Here, DEUTZ is able to show individual solutions for making
the best possible use of the installation space. Already at
the planning stage of new equipment, we offer the possibility
of configuring the engine and the EAT system, together
with our customers, from an extensive range of installation
options from our modular “Technology Construction Kit”
DVERT .
®
reducing consumption. The saving in fuel compared with
comparable Tier 3 engines is up to 10%, depending on the
equipment application and the usage profile.
Service
In general, engines with EAT require no more effort for
servicing than comparable predecessor models. All relevant
ated:
eration, i.e, either DOC or SCR, or a combination of these.
ing on engine workload, these must be cleaned at the
advanced emission control. Therefore, the “downsizing”
clean is due.
additional room needed for cooling and emission control.
The following EAT system categories have to be differenti-
Owing to the accumulation of ash in the filters, and depend-
signal indicates to the operator in good time that a filter
additional installation space often compensates for the
in harmful emissions within the catalyst. The more complex
without particle accumulation, which do not require regen-
a considerably higher power density than engines without
cubic capacity, but a higher power density. The resulting
requires the use of a second EAT system installed in series.
exception to this is the closed Diesel particle filter (DPF).
and at the earliest after 4500 hours above 130 kW. A warning
considerably more compact Tier 4 engine having a smaller
upstream of the SCR catalyst in order to achieve a reduction
What we understand by these systems are all EAT systems
DEUTZ engines with modern EAT technology generally have
ers, this means replacing an existing Tier 3 engine with a
US EPA Tier 4 standards for the range 56 – 560 kW ultimately
service life as the engine itself. The only technology-related
earliest after 3000 hours in the power class below 130 kW
applied in numerous DEUTZ applications. For our custom-
“AdBlue”) is needed, which is sprayed into the exhaust gas
a. Open EAT systems
Power density
concept known by the automobile industry is now also being
A further reduction of emission limits by the EU Stage IV /
components of the DVERT System Kit have the same
®
DOC
Here an optimised combustion with very low NOX and PM is
targeted using a maintenance-free DVERT Oxidation Catalyst
(DOC). With slight limitations with regard to the power density, this results in a maintenance-free system which requires
To provide our customers with a trouble-free and rapid DPF
no regeneration and offers the advantage of a compact and
service, the well-established DEUTZ Xchange® program has
efficient solution for all operating conditions.
been extended to include the Diesel Particle Filter
product range.
For SCR, an additional operating fluid (called “urea” or
installation (dosing unit, pump unit, urea tank, etc.) contrasts
with the advantages of a very high power density together
with a very low fuel consumption, and low heat transfer into
the cooling system.
In the case of Stage IV / Tier 4, all DEUTZ engines > 56 kW
are equipped with SCR systems, either in combination with a
DOC, or with a DPF, or with a second SCR catalyst, depending on the power range and the engine series.
b. Closed EAT systems
When a closed DVERT Particle Filter (DPF) is used, carbon
particles are filtered out almost entirely (> 99 %) and oxidised, or “burnt off”, continually or in phases. This process
is called regeneration which, when certain framework
conditions are met, occurs either automatically, or it can be
actively initiated. We therefore differentiate between passive
and active systems.
Systems with passive or active regeneration are used by
The advantages of this solution are:
DEUTZ, depending on the power class and application.
The regeneration takes place automatically during opera-
Passive regeneration
Passive systems are characterised by regeneration of the
filter without an active initiation of the oxidation process.
The system applied by DEUTZ of a DVERT Particle Filter
optimised for continuous regeneration (CRT®) consists of a
DPF with an upstream DOC. The NO contained in the ex-
tion without impact on the performance of the equipment.
Overloading of the particle filter and an increase of exhaust
gas backpressure are reliably avoided, particularly during
operation under low load conditions. This solution facilitates
regeneration of the particle filter at any time, even under very
low-load operation conditions.
haust gas is oxidised to NO2 in the DOC, which then reacts
Summary
with the carbon particles in the DPF at temperatures above
With the DVERT® Kit, DEUTZ offers the possibility of con­
250° C. If the minimum temperature required for continuous
figuring EAT systems with only minor design modifications
regeneration of the particle filter is not achieved, then active
for cost-efficient installation, and to configure them for a
intervention is possible even with this system. A clever heat
wide range of requirements and usage profiles in construc-
management system then increases the exhaust gas tem-
tion equipment.
perature through targeted measures within the engine. This
simple and robust solution is implemented in Stage IIIB / Tier
4 interim for engines of < 130 kW. Only in rare, exceptional
cases and under certain conditions a stand-still regeneration
can be required for low-load profiles that have an extremely
low exhaust gas temperature.
In the case of Stage IV / Tier 4, the addition of an SCR
system leads to a significant optimisation of the boundary
conditions for regeneration, such that the passive system
can be used for all engines with DPF.
Active regeneration
With the Stage III B / Tier 4 interim emission standards, the
use of a passive regeneration system alone is not possible
with powers > 130 kW because of the low NOX limit. In the
case of engines in this power range which use a DPF, DEUTZ
offers solutions with active regeneration. Regene­ration of
the filter in this case takes place by means of a burner in
combination with a catalytic reaction in the DOC. The burner
generates a primary flame, by means of which additional fuel
injected into the exhaust gas is vaporised. This mixture leads
to a thermal reaction in the downstream DOC, through which
the exhaust gas temperature is raised to the level needed for
regeneration of the DPF (> 600° C | > 1112° F).
worldwide:
DEUTZ Corporation
3883 Steve Reynolds Blvd.
Norcross, GA 30093, USA
Phone: +1 770 564 7100
Telefax:+1 770 564 7222
E-Mail: [email protected]
www.deutzusa.com
DEUTZ AG (Beijing) Engine Co., Ltd.
1102 CITIC Building
19, Jian Wai Dajie,
100004 Beijing, P.R. China
Phone: +86 10 65 25 41 86
Telefax:+86 10 65 12 00 42
E-Mail: [email protected]
www.deutz.com
DEUTZ Asia-Pacific (Pte) Ltd.
10 Gul Crescent
Singapore 629523
Phone: +65 6672 7800
Telefax:+65 6264 1779/6265 3007
E-Mail: [email protected]
www.deutz.com
DEUTZ Australia PTY. LTD
Unit 4, 13 - 15 Brough Street
SPRINGVALE VIC 3171
Phone: +61 3-9549 8400
Telefax:+61 3-9549 8445
E-Mail: [email protected]
www.deutz.com
Order-No. 0031 2104 / 02 / 2013 / VC-CM
DEUTZ AG
Ottostr. 1
51149 Cologne, Germany
Phone: +49 (0) 221 822-0
Telefax:+49 (0) 221 822-3525
E-Mail: [email protected]
www.deutz.com