MAN CNG Bus Presentation-05-2009

MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 1

MAN CNG Buses


MAN CNG BusesContent

1. MAN CNG bus history2. Actual CNG bus & engines portfolio3. MAN CNG buses – sales worldwide4. Actual CNG technology5. Concept Comparison6. New developments7. Advantages of CNG technology (compared to Diesel)8. Cost comparison9. Summary





MAN Gas BusesHistoryMAN Gas BusesHistory

1943 - First MAN Gas Bus, Augsburg


MAN Gas BusesHistory

1988 – SL 202 CNG Bus

1972 – LNG Bus for Munich Olympic Games 2001 – CNG Bus for Zwickau, Germany

2003 – CNG Bus for Frankfurt/Oder, Germany


MAN CNG BusesProducts


Milestones in the Development of MAN Natural Gas Engines

naturallyaspiratedengines

stoichiometric

1990 1995 2000 2005

turbochargedengines

lean-burnlean-burn/mix

E 2866 DUH01 E 2866 DF01 E 2866 DUH03

E 2866 DOH01

E 2866 LUH01

Euro 2-engines

Euro 3-engine

E 2876 LUH01

E 2866 DUH02 E 2876 LUH02E 2866 LUH02

EEV-engine





MAN CNG-Buses and CNG-Buseswith MAN-Natural Gas Engines





MAN gas enginesTechnology

- MAN gas engines are based on the mass produced MAN Diesel engine type D 28

- Most parts are identical to the Diesel enginesespecially the expensive ones as crankcase, crankshaft connection rods etc.

- Gas engines are dedicated engines with a lot of special features

MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 12TVA-N, 01.02.00

Otto-cycle Gas engine Diesel engine

Engine cross sectionGas engine – Diesel engine

Spark plug and special combustion chamber with lower

compression ratio

Diesel injector and combustion chamber with high compression

ratio


Features of MAN gas engines I

- Cylinder heads with armored valves and armored valve seats for low abrasion

- Optimized cylinder head cooling, especially good cooling of the spark plug

- Inlet valves with shaft sealing for minimized oil consumption- Outlet valve guides made from special material with self

lubricating quality for low abrasion- Valve tappets with hard metal plates for low abrasion of the cams- Special pistons and piston rings for low oil consumption- Piston rings with special coating for low abrasion


Features of MAN gas engines I I

- Bearing shells for con rods and crankshaft with non abrasive surface

- Water cooled exhaust gas manifold for naturally aspirated engines- Turbo charger with water cooled bearing house - Turbo charger equipped with waste gate - Engine management system Bosch Motronic GAS 1 - Long life Platinum/Iridium spark plugs (60000 km) - Exhaust gas aftertreatment with a three-way catalyst (at lean

operation oxidation only)

- Summary: the number of differences indicate it makes no sense toconvert Diesel to CNG engines !


ABS/ASR

Gearboxcontrol

Vehiclemanagement

computer (FFR)

MotronicME7-Gas1

enginemanagement

Accelerator pedal

Driveline

CAN CAN

Engine

CAN-structure of gas vehicles

MASTERSLAVE


Components of the Engine Management System Motronic ME7-GAS1

1

2

3

4

5

6

7

8910 15

11

12

13

14

17

161 Butterfly valve actuator2 Injection valves3 Control unit4 Phase sensor5 Speed sensor6 Boost air temperature sensor7 Boost pressure sensor8 Coolant temperature sensor9 Natural-gas pressure sensor10 Natural-gas temperature sensor11 Igniting stages12 Spark coils13 Hot film air mass sensor14 Knock sensors15 Proportional valve for wastegate16 Broad-band lambda sensors17 Exhaust gas temperature sensor


Functions of the Motronic ME7-GAS1

• Output control by means of electrically driven butterfly valve actuator and boost pressure control via waste gate control

• Fuel control using a completely electronic sequential gas injection system and an air mass

measurement system

• Ignition control using a map transistor ignition system with open-circuit high voltage distribution

• Safety functions as self surveillance and diagnostic of sensors and actuators • Engine starter control

• Lambda = 1 control for naturally aspirated engines by means of a broad band Lambda sensor

• Lambda = 1 or Lambda > 1 control for turbo charged engines by means of a broad band Lambda

sensor

• Cylinder individual anti-knock control with the help of two knock sensors • Idle speed filling control


Gas Mixer Unit of the Natural Gas EnginesE 2866 DUH03 and E 2876 LUH02

throttle valve

gas pressure sensor

gas temperature sensor

gas inlet

gas injectors (12 x)


Evaluation of the Central Gas Mixer Unit

8 excellent homogenity of the natural gas/air-mixture,very important for lean-burn operation

8 very compact component

8 very good accessibility of the gas mixer unit for service

8 good dynamic behaviour during transient engine operation

8 many identical parts of the gas mixer unit for the naturallyaspirated and the turbocharged engine version





EEV = Enhanced Environmentally friendly Vehicle

Fuel Engine type Engine concept Mixture Installation Power[kW]

Exhaust gas standard

E 2866 DUH03 naturally aspiratedthree-way-catalyst

stoichio-metric horizontal 180 EEV

CN

G

E 2876 LUH01/02turbocharged and

aftercooledthree-way-catalyst

lean-burn / mix horizontal 228 EEV *)

LPG

G 2876 DUH01 naturally aspiratedthree-way-catalyst

stoichio-metric horizontal 200 EEV

H2 H 2876 UH01 naturally aspirated

reduction-catalyststoichio-metric horizontal 150 EEV**)

*) gas grup limitatione

**) not jet certified

EEV- Gas Engines for Buses


Evaluation of Concepts for turbocharged Natural Gas Engines

acceptable ( between lean-burn and

stoichiometric)

high (in relation to lean-burn)goodFuel

consumption

acceptable costs

high costsexpensive materials are neededheat protection in the engine compartment isnecessary

acceptable costs Costs

acceptable thermal stressexhaust gas temperaturesslightly higher to these of a Diesel engine

very high exhaust gas temperatures (> 900 °C)

low thermal stressexhaust gas temperaturescomparable to these of a Diesel engine

Thermal Stress

very good emissionsfulfil Euro 5 and EEV-standard

excellent emissionsfulfil Euro 5 and EEV-standardsuitable for Euro 6

acceptable emissionssuitable for Euro 3 also Euro 4 with restrictionto the driveability

Emissions

Lean-burn/Mix-ConceptStoichiometric ConceptLean-Burn Concept


Differences between Lean-burn and Lean-burn/Mix -Concepts

Lean-burn Concept

8 Operation of the engine in thecomplete operation map with highexcess air

8 Lambda value between 1,3 and 1,65 depending on engine load

8Stoichiometric operation of theengine in a part of the operationmap

8 Switch over to operation with highexcess air depending on the loadand the speed of the engine

8 Lambda value between 1,0 and 1,65 depending on the engine load

Lean-burn / Mix Concept


CH4 [g/kWh]

NOx [g/kWh]

NMHC [g/kWh] CO [g/kWh]

Particles [g/kWh]0,65

0,40 3,0

2,0

0,02

4,0

1,00

0,10

0,30

1,80

0,005

0,50

4,20

Euro 3-Natural Gas Engine

E 2866 LUH02

EEV-Natural Gas Engine

E 2876 LUH02

The Way from an Euro 3- towards an EEV-Natural Gas Engine with Turbocharger

EEV-Limits

Lean-Burn Concept Lean-Burn/Mix Concept


0,50

The Way from an Euro 3- towards an EEV-Natural Gas Engine with Turbocharger


Natural Gas Engine E 2876 LUH02, turbochargedand intercooled, EEV

Number of cylinders: 6Displacement: 12,8 lPower output: 228 kW/2000 rpmTorque: 1250 Nm/1000 - 1700 rpmExhaust gas standard: EEV

Concept features: central gas mixer unitgas injection system Motronic ME7-GAS1lambda ≥ 1 -controlthree- way catalyst


Function Chart of Natural Gas Engine E 2876 LUH02

vehiclemanagementcontroller

gas cylinders

pressure regulator

sensors

gas mixer unit

silencer withthree-way-catalyst

spark coils

throttlevalve

engine control unit

Lambdasensors

air masssensor

air by-pass

turbocharger waste-gate

intercooler


Performance diagram of Natural Gas Engine E 2876 LUH02

Motor-Typ.: E 2876 LUH01Leistung : 228 kW bei 2000 1/minDrehmoment : 1250 Nm bei 1000 - 1700 1/minKraftstoffverbrauch : 208 g/kWh DAEQNenndrehzahl : 2000 1/minAbnahme nach 80/1269 EWG

Leistungsdiagramm E2876LUH01

Verb

rauc

h [g

/kW

h] D

AEQ

200

210

220

230

240

250

260

270

280

Drehzahl [1/min]600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100

Dre

hmom

ent [

Nm

]

700

800

900

1000

1100

1200

1300

1400

Leis

tung

[kW

]

70

80

90

100

110

120130

140

150

160

170

180190

200

210

220

230240





New developments„Small“ CNG engine E08


Performance diagram of theTurbocharged Gas Engine E 0836 LOH01

Highlights:

Euro 6 & OBD 2 compliant

206 kW (280 bhp)

1000 NM (900-1900 1/min)

New optimized ECU





5,45

0,78

1,60

5,00

1,60

4,00

0,55

1,10

3,50

0,3

4,00

0,55

1,10

2,00

0,30

3,00

0,40

0,65

2,00

0,200,150,00 0,05

0,40

0,050,25

0,05 0,10

1,90

0,05

0,00

1,00

2,00

3,00

4,00

5,00

6,00

CO NMHC Methane NOx Particles

Gas

eous

em

issi

ons

[g/k

Wh]

Euro 3Euro 4Euro 5EEVE 2866 DUH03, Lambda =1, EEVE 2876 LUH02, lean-burn/mix, EEV

Range of variation dependson the composition of thetest gases

EEV = EnhancedEnvironmentally friendlyVehicles

ETC = EuropeanTransientCycle

0,10

0,20

0,30

0,00

0,16

0,03

< 0,005

Par

ticle

s [g

/kW

h]

Exhaust-Gas Emissions of EEV-Natural Gas Engines in the ETC

Homologation values, rounded

0,02


Exhaust-Gas Emissions Euro 3 to Euro 6ETC

Overview: legal requirements for heavy duty vehicles – Euro 3 to Euro 6

ETC: European Transient Cycle


Specific Fuel Consumption and CO2-Emission in the European TransientCycle (ETC)

100

121

132125

10093

10196

0

20

40

60

80

100

120

140

D 2876 LF with SCR E 2866 LUH02 E 2866 DUH03 E 2876 LUH02

Spec. fuel consumptionCO2-emission

EEV EEV EEVEURO 3

[%]

Specific fuel consumption = Diesel equivalent


Particle Size Distribution in the Exhaust Gas of Diesel and Natural Gas EnginesTest cycle: ESC

1,00E+08

1,00E+09

1,00E+10

1,00E+11

1,00E+12

1,00E+13

1,00E+14

1,00E+15

1 10 100 1000

electrical mobility diameter [nm]

dN/d

logD

p[1

/kW

h]

Diesel-engine, Euro 2, raw exhaust gasDiesel-engine, Euro 2, after CRTCNG-engine, EEVindoor air


Advantages of CNG technologyFocus: Biogas

Overview: environmental performance of buses


Advantages of CNG technologyFocus: Biogas





Cost comparison

Source: MAN NL





Advantages of CNG technology

CNG/LPG Exhaust gas emissions are significantly better than Diesel

emissions

CNG/LPG engines are quieter than Diesel engines (up to -2 dB(A) less)

Worldwide known resources for natural gas expected to last up to 300

years

Biogas provides the optimal fuel reference greenhouse effect and local air

quality

CNG as fuel provides a higher safety standard than Diesel !


Advantages of CNG technology

MAN Nutzfahrzeuge AG Author Title of presentation DD Month YYYY 44

Thank you for your attention.

Documents

MAN CNG Bus Presentation-05-2009