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Euro4, Euro5 and EEV

MAN Engine Technology for Today and Tomorrow

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dec 2008 1


New emission standard Euro5 / EEV
Overview

Introduction of MAN Group


Once and Today: A Comparison
Development of exhaust gas stages
NOx or PM: How to influence the Combustion
Combustion with reduced NOx amount: The MAN way
Euro 5 Concept for D0834
Euro 5 Concept for D0836
Euro 5 Concept for D20/26
Advantages for the Customer
Strategy for future technology
Summary

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 2


MAN Group

Sales in 2007: €15.5 billion (No. 375 in Fortune 500)

69%

Commercial 10%
Vehicles
7% 14%

Industrial Services

Turbomachinery
(plus industrial cooperations and
financial services)

Diesel Engines
MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 3
MAN Nutzfahrzeuge Group

Sales in 2007: €10.4 billion

Buses and
13% Coaches
87% Trucks
Buses & Coaches

Trucks

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 4


Truck Division

Light/Medium Range Heavy Range

Special-purpose Vehicles

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 5


Truck Production in 2007

Total: 93,260 units

60,500
TGL

TGA 23,041
3,120 TGM
6,599

Special-purpose Vehicles

TGX/TGS

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 6


Bus Division

Coaches Coaches / Inter-city Buses

City Buses Chassis

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 7


Components

Axles Engines

Pressings Transfer Cases

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer MN Euro4/Euro5/EEV 12. Dez 2008 8


Product Innovations

Optimised Tractors for D20 Common-Rail NEOPLAN Starliner


Europe Euro 4 with PM-Kat®

TGL D 08 TGX/TGS MAN PriTarder

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 9


New emission standard Euro5 / EEV
Once and Today: A Comparison

Engine D0834 LFL

Displacement 20 ltr,. 15 kW (20 HP) 4,5 to Displacement 4,6 ltr,. 151 kW (206 HP) 480 kg

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 10


New emission standard Euro5 / EEV
Energy Mix of the future

100
Hydrogen
Natural gas
LPG

80

Petrol (fossil)
Market shares %

60

Renewable energy

40

Diesel (fossil)

20

GTL fuels
0 (Gas to Liquid)
2000 2004 2008 2012 2016 2020 2024 2028

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 11


Development of the Euro-Stages
Timeline

2003 2004 2005 2006 2007 2008 2009 2010 2011/12


Euro 3 ->
01.10.2005

01.10.2006
Euro 4
Type approval

Euro 4 01.10.2008
Registration
Euro 5
new homologation 01.10.2009

Euro 5
2011/12?
Registration

Euro 6
new homologation

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 12


Development of the Euro-Stages
What it means in terms of NOx and PM

0.8 16
Euro 0 Euro 1 Euro 2 Euro 3 Euro 4 Euro 5
14.1
0.7 14
0.7

0.6 12
PM Reduction
E0 to E4: 85%
E0 to E5: 97%
0.5
NOx Reduction E0 to E4: 75% 10

NOx (g/kWh)
9
PM (g/kWh)

E0 to E5: 85%
0.4 8
0.4 7

0.3 6
5

0.2 4
0.15 3.5

0.1 2
0.1 2

0.02
0 0
1988

1989

1990

1991

1992

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010
MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 13
MAN’s engine technology:
Soot – NOx - Tradeoff

Todays Exhaust Gas Emission


λ<1 Soot-Emission: UP
NOx-Emission: DOWN
Soot-Emission

Future goals in the development of the


combustion process

NOx-Soot-Relation Soot-Emission: DOWN


NOx-Emission: UP
λ>1

NOx-Emission

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 14


MAN’s engine technology:
EGR function schematic

air- MAN-engine EGR-valve


filter

Pressure
peak-valve

EGR-Cooler
Air charging
cooler

 Regulated exhaust gas recirculation


 increased EGR-ratio in comparison to Euro 3 Exhaust gas is fed into the EGR-cooler
 improved EGR- cooling unit where it is cooled and
Exhaust gas fed into the intake air again
Effect: Lower combustion temperature and thus less NOx
MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 15
MAN’s engine technology:
Catalyzer Chemistry

V P
PM = Particulate matter

V Pre-oxidation Pt,Pd,Rh cat: 2NO + O22  2NO22


Pre-oxidation

P Soot
Soot particle separator: C+2NO22 
particle separator  CO22+ 2NO
C+ O22  CO22

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 16


MAN’s engine technology:
PM-Catalyzer Type BC

Composition of the BC-Type Particleseperation during flow


through the fleece

As a result of the open structure, the PM-Kat cannot be mechanically blocked


in normal use!
MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 17
MAN’s engine technology:
PM-Catalyzer

Catalyzer element cut open


Detail: Open Cell Structure

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 18


MAN’s engine technology:
Separationrate as function of the particle size

10 100
dN/dlog Dp[ x10 Particle/cm3 ]

8 80

Separation [%]
6 60
before PM-KAT
13

after PM-KAT
Separation
4 40

2 20

0 0
5 10 50 100 300
‘electrical mobility diameter’ [nm]
MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 19
From Euro 4 to Euro 5
Overview

Common Rail System 2nd generation


Exhaust-gas recirculation system
2-stage turbo charging
Indirect inter- and main charge air cooling
PM-Kat

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 20


Euro 5 features
Common Rail System

Injector 1800bar with 8


pinhole nozzle

Welded rail
HDP fuel lubricated

Injection pipes Ø8x2,5

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 21


Euro 5 features
Exhaust-gas recirculation system

• Dual exthaust system


• Water cooled EGR-module

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 22


Euro 5 features
2-stage turbo charging

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 23


Concept D20 / 26 LOH Euro 4 / EEV
Coolant systems Euro 5 / EEV

Euro 5 EEV NT Coolant circuit

3
2

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 24


Concept D0834 LOH Euro 5 / EEV
Coolant systems

D0834 cooling circuit Euro 5

DPF
Cooling Air

1 2

Main coolant circuit


Exhaust Gas
Charged Air

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 25


Concept D0834 LOH Euro 5 / EEV
Comparison to Euro 4

D0834 LOH 52/53 Euro 4 D0834 LOH 60/61 Euro 5 / EEV

1 1

2 2

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 26


Concept D0836 LOH Euro 5 / EEV
Coolant systems

D0836 cooling circuit Euro 5

DPF
Cooling Air

1 2

LLK

Main coolant circuit


Exhaust Gas
Charged Air

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 27


Concept D0836 LOH Euro 5 / EEV
Comparison to Euro 4

D0836 LOH 55/56 (SAE 1) D0836 LOH 64/65 (SAE 1)


Euro 4 Euro 5 / EEV

3 2

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 28


Concept D20 / 26 LOH Euro 4 / EEV
Coolant systems Euro 4

Euro 4 Coolant circuit

DPF
Cooling Air

Main coolant circuit


Exhaust Gas
Charged Air

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 29


Concept D20 / 26 LOH Euro 4 / EEV
Coolant systems Euro 4

Euro 4 Coolant circuit


1

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 30


Concept D20 / 26 LOH Euro 4 / EEV
Coolant systems Euro 5 / EEV

Euro 5 EEV NT Kühlkreislauf / Euro 5 EEV NT Coolant circuit

DPF
Cooling Air

NT Circuit
HT Circuit

3 4

2
1

ND-LLK
HD-LLK

Main coolant circuit (HT-Circuit)


Exhaust Gas
Low Temperature Water Circuit (NT-Circuit)

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 31


Concept D20 / 26 LOH Euro 4 / EEV
Coolant systems Euro 5 / EEV

EEV NT Coolant circuit


3

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 32


Concept D20 / 26 LOH Euro 4 / EEV
Exthaust System Euro 4

D2066 LOH 01/02/03/04 Euro4

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 33


Concept D20 / 26 LOH Euro 4 / EEV
Exthaust System Euro 5 / EEV

D2066 LOH 26/27/28 EEV

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 34


MAN’s engine technology:
How to achieve Euro 4 limits

Combustion chamber and injection:


Compression ratio raised from 19:1 to 20,5:1
Optimization of combustion chamber
Use of improved injection nozzles (7-hole) for optimised combustion
Injection pressure was raised to 1600 bar
Useage of postinjection to reduce formation of soot

Useage of an optimized EGR-system:


EGR-rates of up to 20 %
Lower temperatures of the recirculated exhaust gas
The formation of NOx is in-line with E4 regulations

Useage of the PM-catalyzer to reduce the soot output


Maintenance free, price-winning system that keeps the PM output in-
line with E4 regulations
MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 35
MAN’s engine technology:
How to achieve Euro 5 limits

Injection:
Usage of 2nd generation CommonRail system
Use of improved injection nozzles (8-hole) for optimised combustion
Injection pressure was raised to 1800 bar (for E6 pressure of up to
2400 bar is planned)

Further optimized EGR-system:


EGR-rates of up to 30 %
Double-fold exhaust system to achieve high EGR-rates
Lower temperatures of the recirculated exhaust gas due to a better
cooling unit
The formation of NOx is in-line with E5 regulations

Turbo charger and cooling system


Double turbo charger
Elaborate cooling system with air-water-intercooling for both turbos
MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 36
MAN’s engine technology:
Comparison of old and new engine generation
1900

Torque D2066 (Nm, E4)


Torque D2066 (Nm, E5)
1800 Torque D2866 (Nm, E3)

1700
kW

1600

1500

1400

1300
800

900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000
RPM

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 37


MAN’s engine technology:
Comparison of old and new engine generation

280

270

260

250

240
kW

230

220

210
Output D2066 (kW; E4)
200
Output D2866 (kW; E3)
190 Output D2066 (kW; E5; EGR)

180
900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000
RPM

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 38


MAN’s engine technology:
Comparison of old and new engine generation

240

235 Consumption D2066 (g/kWh; E4)


230 Consumption D2066 (g/kWh; E5; EGR)
225 Consumption D2866 (g/kWh; E3)
220

215
g/kWh

210

205

200

195

190

185

180
900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000
RPM

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 39


Euro 4/5 Technology with MAN PM-KAT®
Advantages for the customer

 Lower weight and reduced installation space (compared to SCR-solution)


 No increased consumption compared to Euro3 (D28)
 Robust and maintenance-free system
 No reduction-agent necessary  no urea heating or seperate tank is needed
 No complex metering system needed

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 40


Overview
MAN Euro5 / EEV Engines

Engine Type Rated Power Charging Intermediate Exhaust Exhaust Cooling


kW / HP Cooling Norm Treatment Concept
D0834LOH60 132 / 180 2-stage without Euro 5 Oxi-Cat conventional
D0834LOH61 132 / 180 2-stage without EEV PM-Cat conventional
D0836LOH65 184 / 250 2-stage with Euro 5 Oxi-Cat conventional
D0836LOH64 213 / 290 2-stage with Euro 5 Oxi-Cat conventional
D0836LOH61 184 / 250 2-stage with EEV CRT-Filter conventional
D0836LOH60 213 / 290 2-stage with EEV CRT-Filter conventional
D2066LOH26 235 / 320 2-stage with EEV PM-Cat NT-Cooling
D2066LOH27 265 / 360 2-stage with EEV PM-Cat NT-Cooling
D2066LOH28 294 / 400 2-stage with EEV PM-Cat NT-Cooling
D2066LUH46 206 / 280 2-stage with EEV CRT-Filter conventional
D2066LUH47 235 / 320 2-stage with EEV CRT-Filter conventional
D2066LUH48 265 / 360 2-stage with EEV CRT-Filter conventional
D2066LUH32 235 / 320 2-stage with Euro 5 PM-Cat conventional
D2066LUH33 265 / 360 2-stage with Euro 5 PM-Cat conventional
D2066LUH34 294 / 400 2-stage with Euro 5 PM-Cat conventional
D2676LOH26 324 / 440 2-stage with EEV PM-Cat conventional
D2676LOH27 353 / 480 2-stage with EEV PM-Cat conventional
D2676LOH28 371 / 505 2-stage with EEV PM-Cat conventional

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 41


Strategy for future technoligy
US2010 / Euro6

EPA 2007
EGR-Technology
+ EPA 2010
2-stage turbo charge
with
Carge air intercooling
+
+ MAN AdBlue®

Filter (PM-KAT®/CRTec®)
Euro 6
Euro 5

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008


Strategy for future technology
US2010 / Euro6

2 stage turbo charging


with intercooling AGR+PM-KAT®/CRTec® MAN AdBlue®

y in serial y in serial y in serial


d d d
Allrea uction Allrea uction Allrea uction
prod prod prod

MAN has allready developed the principal key technology


in compliance with the requirements for EPA 2010 and Euro 6!

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008


New emission standard Euro5 / EEV

Thank you for your


attention !

MAN Nutzfahrzeuge
Business Unit Engines
Vogelweiher Str. 33
90441 Nürnberg

Hubert Gossner Michael Bayer


Manager Application Engineering (MVLF) Technical Support
Phone: +49 911 420 6387 Phone: +86 10 8048 0505 ext. 7302
eMail: hubert.gossner@man.eu eMail: michael.bayer@man-china.com

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dec 2008 44


Outlook into the future:
Euro 5 engines from 2009 onwards

EGR + MAN PM-CAT®

353 kW
324 kW (480 PS)
294 kW (440 PS)
265 kW (400 PS)
Power [kW]

250 kW
235 kW (360 PS)
(340 PS)
213 kW (320 PS)
184 kW (290 PS)
162 kW (250 PS)
132 kW (220 PS)
110 kW (180 PS)
(150 PS)

570 700 830 925 1100 1250 1600 1800 1900 2100 2300
max. Torque [Nm]

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008


MAN’s engine technology:
Engine lines and power output

600

540
500

480
460
440
430
Rated Power in HP

400
400
390
360
350
300 320
280

240
200
206
180

100

0
D0834 CR D0834 CR D0836 CR D0836 CR D2066 CR D2066 CR D2066 CR D2066 CR D2066 CR D2066 CR D2066 CR D2676 CR D2676 CR D2676 CR
EURO4 EURO4 EURO3/4 EURO3/4 EURO4 EURO3 EURO4 EURO3 EURO4 EURO3 EURO4 EURO3 EURO4 EURO4

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 46


How to comply with the Euro4 :
MAN-Exhaustfilter obtains Environmental Award
Clean, cleaner, MAN PM-KAT®! The innovative dieselfilter for particulate matter for
commercial vehicles was awarded the renowned “BDI-Umweltpreis für die Industrie
2005/2006” (Federal Association of German Industry – Environmental Award for the
Industry 2005/2006)
A high ranking jury consisting of leading characters from
industry, science, politics and environmental associations
was convinced: Within the category “Environment-friendly
products” the MAN PM-KAT® is outstanding.
Thereby this filter – that is used by MAN serially for trucks
and busses since the end of 2004 – is nominated as German
contribution for the European Environmental Competition.
The patended filtering concept – that was developed together
with the catalyzer experts from EMITEC – retains up to 90%
of the particulate matter which is deemed especially
hazardous.
In contrast to conventional diesel filters, the MAN PM-KAT®
is absolutely maintenance free. It cannot clog and runs
without any additives. A distinct advantage over competitor’s
products!

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 47


How to comply with Euro4:
Comparison fuel consumption D2066

E3 (without catalyzer) and E4 (with catalyzer) + 5 % cost for Urea

110%

100%

90%

+ 2 % to 3 %

- 1 % to 2 %
- 3 % to 5 %

- 3 % to 5 %
80%

±0%
70%

60%
D2866

D2066
D0836

D2066
D0836

D2066
D0836
50%

40%
Euro 3 Euro 3 Euro 4 with PM- Euro 4 with GD-
KAT KAT

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 48


MAN’s New Engine Technology:
D08 CR – Technical information an customer‘s benefits
Engine line D0834/36
Diesel engine with direct injection with 4,6
respectively 6,9 l swept volume
Common-Rail-Injection with EDC7 engine
management system
Several models with cooled external EGR
The 206 HP 4 Cylinder engine comes with
twin turbo chargers

 Customers benefit‘s:
Engines with high output in power and torque
Long intervals between oil-changes of up to
80.000 km (long distance transport)
Favourable torque curve and start trait
Quiet engine (esp. at partial load)
Low fuel consumption – highly environmental
friendly

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 49


MAN’s New Engine Technology:
D20 CR – Technical information an customer‘s benefits
Engine line D2066 CR
Economical 10,5-l-engines with state-of-the-art
technology – Especially the Common-Rail-Injection
guarantees low consumption combined with high
performance
The D2066 CR offers fuel economy of up to 5 %
compared to the older D28
Lowest engine mass in the 430 HP category
(967 kg dry weight) – hence biggest payload
advantage
Long intervals between oil-changes of up to
120.000 km (long distance transport)
Use of cooled external EGR in all D20 models
Approx. 1,5 Mio km until major engine overhaul is
necessary
 Customers benefit‘s:
Low fuel consumption
Big payload advantage due to low engine
weight
First time ever in a
commercial vehicle: Oil Cylinderhead in one piece Very little downtime due to long maintenance
pump as a Trochoid-Pump
intervals

MAN Nutzfahrzeuge AG H. Gossner, M. Bayer Euro4/Euro5/EEV 12. Dez 2008 50

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