2010 MidRangeEngines
2
0.0
0.5
0.01
US98
0.0 0.02 0.03 0.04 0.04 0.04 0.06 0.07 0.08 0.09 0.10 0.11 0.12
US04
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0Global On-Highway Standards
EURO IV
EURO V
NO
x –
g/H
P-hr
Particulate – g/HP-hr
US07
US10
EURO VI
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2007 ISB & ISC/ISL
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Integrating Critical Subsystems
Air Handling & EGR
Electronic Controls
Fuel Systems
Combustion Aftertreatment
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Introducing the ISB6.7 & ISC8.3/ISL9
The Right Technology for 2010!
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2010 ISB6.7
Improved Combustion SystemIncreased Power DensityBest-in-class Fuel EconomyAdvanced VG TurbochargerImproved Cooled EGR Subsystem/Cooling CircuitFully Integrated Electronic ControlsNew Cummins Aftertreatment System Improved Reliability
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ISB6.7 Cooled EGRImproved EGR
Cooler Improved Cold-Side
EGR ValveImproved EGR
MeasurementNew Intake Connection forBetter EGR Mixing
ElectronicsCM2250MD withA/T, EGR/AH ControlsNew Wiring Harness
Cooling System ChangesImproved EGR
Coolant FlowCooling Circuit Rebalanced with increased flow to critical areasNew Coolant Circuit for SCR Components
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ISB6.7
Open Crankcase Ventilation
Coalescing FilterFed to Atmosphere
VGT TurbochargerImproved Coolant
Plumbing Improved EfficiencyLead Free Bearings
Combustion System
Improved Combustion System and Optimized Calibration for Lower Engine Out Particulates
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2010 ISC8.3/ISL9
Improved Combustion SystemIncreased Power DensityHeavy Duty Design- Replaceable Liners
Advanced VG TurbochargerImproved Cooled EGR Subsystem/Cooling CircuitFully Integrated Electronic ControlsNew Cummins Aftertreatment System Improved ReliabilityComparable Fuel Economy
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ISC8.3 & ISL9 Cooled EGRImproved Cold-Side
EGR ValveImproved EGR
MeasurementNew Intake Connection for Better EGR Mixing
Cooling System ChangesCircuit Rebalance for SCR System heating & coolingNew Coolant Circuit for SCR Components Electronics
CM2250MD withA/T, EGR and AH ControlsNew Wiring HarnessNew Temperature and Pressure Sensor
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ISC8.3 & ISL9
VGT TurbochargerImproved
Efficiency Combustion System
Improved Combustion System and Optimized Calibration for Lower Engine Out Particulates
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2010 MR Engine Platforms & Ratings
ISC8.3/ISL9 260-380 HPISB6.7 200-325 HP
Cummins Aftertreatment System
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Cummins Aftertreatment System
Cummins Particulate Filter
Diesel Oxidation Catalyst
Wall-Flow Filter
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Cummins Aftertreatment SystemSelective Catalytic Reduction
(SCR) Catalyst
Decomposition Reactor
Diesel Exhaust Fluid (DEF) Dosing Valve
Cummins Particulate
Filter
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Cummins Aftertreatment System
EGR
NOxSCR ENGINE-OUT
TAIL-PIPE OUTSCRSCR
PMFilter
ENGINE-OUT
TAIL-PIPE OUT
PMPMFilterFilter
0.20.01
PM
Cummins Particulate Filter Selective Catalytic Reduction (SCR)Catalyst
DEF Dosing Valve
Decomposition Reactor
Diesel Exhaust Fluid (DEF) Update
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What is Diesel Exhaust Fluid (DEF)?
Diesel Exhaust Fluid (DEF) is the reactant for the SCR system- Urea is solid at room temperature- DEF is prepared by dissolving solid Urea to create 32.5% solution in purified water
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Diesel Exhaust Fluid (DEF)
Primary reactants for DEF production:- Ammonia (NH3)- Carbon Dioxide (CO2)
Raw materials used to produce NH3 & CO2 include:- Natural Gas- Coal- Other Petroleum Products
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How Much Diesel Exhaust Fluid (DEF) Will I Use?
Approximately 2% DEF consumption
Every 50 gallons of
fuel = 1 gallon of DEF
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Diesel Exhaust Fluid (DEF) Availability and Accessibility
Plastic 330 Gal Tote
Plastic 55 Gal Drum
Disposable 275 Gal Tote
Bulk
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European Pump Pricing
03/2007
Country€ / Litre $/Gal (exch 1.59)
Austria 0.44 2.65Belgium 0.52 3.13Denmark 0.51 3.07Finland 0.52 3.13France 0.43 2.59Germany 0.49 2.89Italy 0.57 3.43
Luxembourg 0.56 3.37Netherlands 0.46 2.77
Spain 0.63 3.19Sweden 0.58 3.49
UK 0.43 3.31
Pump price without tax
Average = $3.09 a Gallon
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Cost Structure for U.S. DEF
Retail Cost Structure ~ DEF Solution
Raw ~ urea
Blending
Packaging
Transportation
Retail Dispensing
U.S. DEF Cost Structure
26%
11%
17%
34%
12%
0%10%20%30%40%50%60%70%80%90%
100%
2008
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Projected 2010 U.S. DEF Pricing
DEF Pump prices: - $2.50-$3.50 gallon (Fleet pricing will likely be less)
200 - 300 gallon containers (IBC’s):- $2.00-$2.50
Bulk delivery (Tanker): - Less than $2.00/gallon (Pricing will likely vary by region)
No estimate for jug pricing at this time
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DEF Infrastructure
Major investments in DEF production to serve the on-highway market are currently being made and will be in place in 2010.- Pilot has announced it will carry DEF at the pump.- Flying J, TravelCenters of America & Love’s will carry DEF, but still determining at what level.
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All Outlets
Cummins Outlets - RedOEM Outlets – GreenParts Distribution Centers (PDC) – BlueIndependent Distribution - Yellow
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How Can I Determine how Much DEF I will Use?
Example…Medium Duty
Annual miles for average truck = 20,000 miles
MPG for average truck = 10 mpg
20,000 miles / 10 mpg = 2,000 gallons diesel fuel per year
DEF usage @ 2% of fuel consumption = 40 gallons of DEF / year
40 gallons / 10 gallon tank (average size) = 4 DEF fill-ups / year
Example Only
Common DEF Misconceptions
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Myth #1 - DEF degradation will be a major problem.
As with many automotive fluids, DEF will degrade over an extended period of time.The shelf life of DEF is dependent on storage temperature and exposure to sunlight.When stored as recommended (between 11°F and 86°F), DEF shelf life will be greater than one year.For typical school bus use, that includes a period of inactivity in the summer, DEF degradation will not be an issue.
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Myth #2 – DEF is toxic.
DEF is a non-toxic, non-polluting and non-flammable substance.Poses no serious risk to humans, animals, equipment or the environment when handled properly.The product is slightly alkaline with a pH of approximately 9.0.SCR systems are designed fully compatible to DEF’s properties.
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DEF Properties
Acidic pHDEF is safe to handle and store– Non-toxic– Non-polluting– Non-flammable
When stored at extreme temperatures, neither DEF nor Urea become toxic
DEF is slightly alkaline with a pH of approximately 9
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Myth #3 – Frozen DEF will render a Vehicle Unusable.
The freezing point of DEF is 11 degrees F.
SCR system is designed to provide heating for the DEF tank and supply lines.
If DEF freezes, start up and normal operation of the vehicle is not inhibited.
DEF is not damaged or destroyed if it is frozen and is fully usable when thawed.
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Myth #4 – DEF is Difficult to Use.
Cummins will provide installation recommendations on tank size based upon EPA guidelines
DEF consumption is expected to be approx. 2% of fuel consumption dependent on vehicle operation – duty cycle, geography, rating, etc.
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Myth #5 – DEF will be difficult to find.
DEF will be readily available for customers to purchase
Cummins is working with industry partners to ensure DEF is readily available.
Cummins is working to ensure availability of DEF through our distributor and dealer network.
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Diesel Exhaust Fluid (DEF)
Diesel Exhaust Fluid is 32.5% strength urea water solution with high purity requirements.
The specification of Diesel Exhaust Fluid is currently defined according to the DIN 70700 and the ISO 22241-1 specifications.
Water purity: ISO grade 3, produced for example by single distillation, de-ionization, ultra-filtration or reverse osmosis.
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The 32.5% wt urea water solution provides the lowest freezing point while also maintaining the solution in constant phase.– Urea and water freeze together at 11° F so the frozen solution
has the same 32.5% wt.– When thawed, it will remain at the same concentration of urea
solution feeding the SCR system.
What happens at different concentrations of Urea:– Greater concentrations → Urea freezes before water– Reduced concentrations → Water freezes before Urea
Why 32.5% for DEF?
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Cummins Aftertreatment System Architecture
DEF Dosing Valve sprays a fine mist of DEF into hot exhaust stream
Decomposition occurs in 3 steps within the Decomposition Reactor• Step 1: Evaporation• Step 2: Thermolysis• Step 3: Hydrolysis
Cummins Particulate Filter Selective Catalytic Reduction (SCR) Catalyst
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DEF Storage
Shelf life of DEF is a function of ambient storage temperature.
ISO Spec 22241-3 details the Storage, Handling and Shelf Life minimum expectations for DEF throughout the distribution chain.
Expectations for shelf life as defined by ISO Spec 22241-3 are the minimum expectations for shelf life when stored at constant temperatures.
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DEF Freeze Point
Freezing of DEF begins at approximately 11°F.
Once the DEF has melted, it can be used without problem. The first melted drop has the same consistency as defined in the Diesel Exhaust Fluid specification.
The SCR system is designed to provide heating for the DEF tank and supply lines which will reduce the melting time for frozen DEF.
If DEF freezes, start up and normal operation of the vehicle is not inhibited so the operator is not impacted.
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DEF Storage & Handling Recommendations
Storage temperature below 86° F is recommended to maintain shelf life
Storage temperature above 11° F is recommended to avoid freezing
The maximum temperature of stored diesel exhaust fluid on the vehicle should not exceed 122º F
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DEF will degrade in time depending on temperature and exposure to sun light.
Stated shelf life is based on continuous exposure to heat and sunlight. - Continuous exposure is unlikely.
Concerns over ‘shelf-life’ have been over-stated.
DEF Storage & Handling Conclusions
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DEF Quality System -API Certification
Proposed DEF quality seal.- Currently, the seal has not yet been approved.
Most likely it will feature the full name “American Petroleum Institute (API)” in a square quality seal.
In-Cylinder solution
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Cummins Integrated Solution Advantages
Increased Power Density
Stronger Performance
Increased Reliability
Comparable Fuel Efficiency
Minimal Installation Impact
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Disadvantages of In Cylinder Technology
Fuel Economy Significantly Compromised
Throttle Response/Driver Satisfaction Significantly Compromised
Horsepower and Power Density Significantly Compromised
Significant Increase in Heat Rejection
Complex System Integration– Higher EGR Flow
– Air Handling System
– Vehicle Cooling System
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Disadvantages of In Cylinder Technology
Fuel Economy Significantly Compromised– 5-9% loss
– Combustion Efficiency degradation:• Higher engine pumping losses
• Increased intake & exhaust manifold pressures
• Increased Particulate Filter regenerations
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Disadvantages of In Cylinder Technology
Horsepower and Power Density Significantly Compromised
– Deterioration of 50 – 100 hp for same displacement
– Higher EGR flow & EGR controls compromises engine performance
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Disadvantages of In Cylinder Technology
Significant Increase in Heat Rejection
– 20% increase
– Higher EGR flow:• Multiple EGR coolers on & off engine
• Larger vehicle cooling package– Major redesign of radiator / Charge Air Cooler / Fan
systems
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Disadvantages of In Cylinder Technology
Engine Life-to-Overhaul significantly reduced
– Higher EGR flow produces excessive acidic condensation:• Corrosion of internal engine systems
• High rate of lube oil contamination
– Negative impact on Durability
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Cummins is Ready for 2010!
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The Right TechnologyProduct for Every NeedDepend On Cummins
Our Commitment