John Campbell Director On-Highway Engine Products March 16, 2004 American Trucking Association Technology & Maintenance Council.

John CampbellDirector

On-Highway Engine Products

March 16, 2004

American Trucking Association

Technology & Maintenance Council

2007 Emissions Requirements

• PM = 0.01 g/bhp-hr– Requires Particulate Filter

• NOx + HC = 1.2 g/bhp-hr– Assumes Use of Phase-In Provision– Requires NOx Aftertreatment, Advanced

Combustion, or Both

• Crankcase Emissions Counted As Part of Cycle Emissions

– Drives Closed Crankcase Filter and/or Closed Crankcase

• On-Board Diagnostics (OBD)– OBD Changed to EMD (Engine

Manufacturers Diagnostics)– Monitoring Performance of Engine

Components– Warning Light to Dashboard Fault – Isolation to Component Level

• Emissions System Useful Life– 435,000 Miles for HD– 185,000 Miles for MR

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0 1 2 3 4 5 6 7

NOx (g/bhp-hr)

Par

ticu

late

s (g

/bh

p-h

r)

‘91

‘94‘98‘02

ACERT

‘07‘10

EngineModifications

EngineModifications

U.S.

Cat Will Follow the 2007/2010Phase-In Provision

ACERT™ Is The Foundation for 2007 / 2010

• Our Technology Strategy & Approach– Build Upon 2003 ACERT™– Continue to Enhance Engine Performance While Incrementally

Introducing Aftertreatment– Investigate Multiple Particulate Technologies– Provide Best Value To Customer and Least Disruptive Technology to

Truck OEMs

1998Engine

Add:– Split Inj– Oxicat

10/02Bridge

Add:– Adv Comb– Flex Fuel

System– Diesel Part Filter– Thermal Mgmt

2007ACERT

10/03ACERT

Add:– VVA– Series

Turbo

– Adv Comband NOx Aftertreatement

2010ACERT

Particulate Matter (PM) Reduction

Technologies

Engine Out Particulate Matter (PM) Reduction

Lower Engine Out PM is an Enabler for Passive or “Less Active” Diesel Particulate Filters (DPF)

Less Soot Into The Filter Translates Into Lower Fuel Consumption Penalties for Regeneration

Developing Strategies to Reduce Engine Out PM Combustion Development Fuel Injection Improvements Better Fuel Air Mixing

Cycle NOx (g/hp-hr)

0

0.04

0.08

0.12

0.16

0.2

0.24

0.28

0 0.5 1 1.5 2 2.5 3

Continue ImprovementsE

ng

ine

-Ou

t C

yc

le P

M (

g/b

hp

-hr)

Advanced Fuel / Combustion

System

Cycle NOx (g/hp-hr)

Current Fuel / Combustion

System

Ceramic Filter with Engine Thermal Management for Regeneration

Highest Filtration EfficiencyLowest 1st Cost Best Fuel Economy

Challenge: “Cold” Applications

Temperature, Pressure Sensors

Quick Disconnects

ECM/EMD

CeramicFilter

Prime Path: Engine + EMD System

(Electronic Control Module/Engine Manufacturers Diagnostics)

Temperature, Pressure Sensors

System Design for Engine Thermal Management

100ºC 200ºC 300ºC 400ºC 500ºC 600ºC

System Requirements for Thermal Management & Regeneration

Short Setback Single Can

Preferred

Engine Measures to Avoid Low Exhaust TempECM Tracking of Emissions & Thermal HistoryControl System Logic to Trigger Thermal Events

ACERTOxidation

Catalyst

Not Too Hot,Not Too Cold

2007After-treatment

Bring OnThe Heat !

Ceramic orMetallic

Filter

ThermalSource/Diffuser

HeatGenerator

Secondary Path: Self-Regenerating PM Filter

HeatGenerator

Quick Disconnects

ControllerECM/EMD

Internally “Active” Regeneration; Filter is Heated by Auxiliary Means

Regenerate Under All Conditions

Challenge: Cost & Complexity

Temperature, Pressure Sensors

Temperature, Pressure Sensors

Aftertreatment InstallationRound Filters are the Standard

Oval Configurations to be Explored but Considered High Risk

Setback Distance Will Be Important Specifying Short Converter Setbacks will Enable Lower Cost Components &

Better Fuel Consumption Solutions Target 5 Feet from Turbo Outlet to DPF Inlet (Heat Retention) Back-of-Cab and Side-of-Cab Mounting Not Probable

Target Is Single Can Lower Cost, Better for Regeneration

Filter System Needs to Be Serviceable Ash Removed at Specified Interval Filter System Designed for Easy Service Location must be Accessible

Oxides of Nitrogen (NOx)

Reduction Technologies

NOx Reduction Options (2003)

2003ACERTEngine

Aftertreatment NOx Technology OptionsEngine NOx Technology

NOxAdsorber

UreaSCR

DeNOxCatalyst

AdvancedDiesel

Combustion

• Engine-Out NOx Measures Reduce Size / Cost of Aftertreatment

• Aftertreatment Options Need to be Evaluated for Maturity and Cost

• Combination of Engine Out and Aftertreatment may Provide Best NOx Reduction Value Path

TC

TC

ParticulateFilter

NOxAT

Engine Measures for NOx Reduction (2004)

• Caterpillar Continues to Expand the Envelope On Engine Out Performance

• ACERT has Further Ability to:– Reduce NOx & PM Emissions– Improve Fuel Consumption and

Heat Rejection

• Modifications for Engine Out NOx:– Fuel Systems– Air Systems– Piston/Ring/Liner Designs– MorElectric Initiative Systems Possible

AdvancedCombustion

Closed Crankcase Ventilation System(CCV)

Closed Crankcase Ventilation (CCV) System Design Options

ParticulateFilterT

C

TC

Option 3:

Filter and Vent to Atmosphere

CCVFilter

System

CCVFilter

System

Option 2:

Filter and Route toExhaust Upstream of DPF

Pump /One-Way

Valve

CCVFilter

System

Option 1:

Filter and Routeto Air Intake

Manufacturers Expected to Control Crankcase Emissions by:

Routing to Intake Routing to Exhaust Stream

Upstream of the Aftertreatment

2007 Requirement Crankcase Emission Control Exception for

Turbocharged Heavy-Duty Diesel Engines Eliminated

Crankcase Emissions Treated Same as (i.e., Added to) Other Exhaust Emissions

CCV FilterComponent

2007 System Architecture

2007 System ArchitectureHeavy Duty

TC

TC

TC

TC

ParticulateFilter

AT

AA

C

PreCooler

HigherPressureInjectionSystem

Variable Valve Actuationw/ Thermal Management

FunctionSeries

Turbo Chargers

W/ or W/OAuxiliaryDevice

CCV Filter

System

Option 1

2007 System ArchitectureMidrange

TC

TC

DieselParticulate

Filter

AT

AA

C

Higher PressureInjectionSystem

Device forThermal Management

Function

ConventionalTurbo Charger

W/ or W/OAuxiliaryDevice

CCV Filter

System

Option 1

Timelines

R S20062003 2004 2005

Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4Q1 Q2 Q3 Q4

C15

C13Production

Customer Evaluation Engines

Additional Customer Evaluation Engines

Field Test Engines

OEM Engines

2007 HD Program Timeline

2007 MD Program Timeline

20062003 2004 2005

Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

C7

C9

OEM Engines

Field Test Engines

Customer Evaluation Engine

Additional Customer Evaluation Engines

Production

Caterpillar Conclusions

Finalizing Technologies for 2007

Diesel Particulate Filter Required

Engines Available for Fleet Purchase Mid - 2005