clean air bus transport

Clean Air Bus Transport

Future proof and sustainable technologyRobert Staimer, SRNB, Israel, January 2013

2< >Robert Staimer MAN CNG Buses January 2013MAN Truck & Bus AG

MAN CNG BusesFuture proof and sustainable technology

Environment:

Diesel Diesel Hybrid Electric Hydrogen Compressed Natural Gas (CNG) Compressed BioGas (CBG)

Infrastructure

Gas Supply Gas Equipment Service & Health & Safety



Natural Gas

is the world’s fastest growing alternative fuel.

Why ?



CNG vs. Conventional Liquid Fuel

Environmental Benefits Improved Safety Increased Efficiency Optimum Availability Economic Advantages



The number of Natural Gas Vehicles is growing exponentially and currently at the rate of over 250,000 vehicles per month.

No of Natural Gas Buses increased by 31% in the last year.From 317,000 to 401,000

These include buses, HGVs, light vans, refuse trucks and passenger cars, FLTs,

By 2020 the number of gas vehicles is expected to exceed 65,000,000


MAN CNG BusesAgenda

1 MAN CNG bus history

2 Actual CNG bus & engines portfolio

3 MAN CNG buses – sales worldwide

4 Actual CNG technology – Euro 6

5 Advantages of CNG technology (compared to Diesel)

6 Cost Calculation

7 Summary


MAN CNG 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

A74 EGO Ankara

A23 Augsburg

A26 Stockholm

A26 Liechtenstein

A21 Nürnberg

A23 Saarbrücken


MAN CNG BusesAgenda




4 Actual CNG technology - Euro 6


6 Cost Calculation

7 Summary


MAN CNG BusesCNG Product Portfolio

1) also available as Lion`s City L LE with 2 or 3 doors2) height with standard CNG storage system3) height with optional CNG storage system4) also available as Lion`s City G LE with 2 or 3 doors5) also available as Lion`s City GL LE with 2 or 3 doors


MAN CNG BusesCNG product portfolio – cont`d

18 / 18,75 m low floor chassis – articulated bus

12 m low floor chassis - solobus

12 m low entry chassis - solobus


MAN CNG BusesComponent overview

CNG storage- and fuel supply system

Wide range of storage systems available

Highest safety standards available (cylinders & supply system)

ECE R-110 certified

EEV-/ Euro VI engine

turbocharged engine, 12.8litres310 bhp / 1.250 Nm (LUH07) 272 bhp / 1.050 Nm (LUH08)

Low noise level

Fuelling system

fill nozzle with safety system

filling duration similar to Diesel bus


MAN CNG Busesengine development milestones


MAN CNG BusesAgenda






6 Cost Calculation

7 Summary


MAN CNG Busessales figures worldwide 2000 - 2012

Country UnitsAustralia 175Finland 31France 2Germany 724Great Britain 37Italy 65Luxembourg 34Mexico 1Netherland 559Norway 211Austria 21Poland 29Portugal 294Russia 3Sweden 867Switzerland 35Slovakia 1Spain 555Turkey 1289Total 4993

611

431

289

520

334

209

488

177

125

80

145

182196

2000 2001 2002 2003 2004 2005 20112006 2007 2008 2009 2010 2012

CNG Sales


MAN CNG BusesCNG share 2009 - 2011

Lion`s City Sales – Sales Region Northern & Southern Europe (except Benelux, Germany, Iberia, Holland, France)

1809,0

1234,0

1467,0

555,0

251,0

419,0

0

200

400

600

800

1.000

1.200

1.400

1.600

1.800

2.000

2009 2010 2011

Diesel CNG & LPG

23,5 %

share

16,9 %

share

22,2 %

share


MAN CNG BusesAgenda






6 Cost Calculation

7 Summary


MAN CNG BusesDynamics in emission legislation Euro 1 – Euro 6

0,5

0,4

0,3

0,2

0,1

0,00 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 9,0 10,0

Euro I (1993)

Euro II (1996)

Euro III (2000)

Euro IV (2005)

EEV (2009)

Euro V (2008)

Euro VI (2013)

NOx [g/kWh]

Part

icle

s [g

/kW

h]


MAN CNG BusesEnvironmental Aspects

ETC / WHTC

CO NMHC Nox CH4 PM particle number

NH3 (ppm)

(g/kWh) (g/kWh) (g/kWh) (g/kWh) (g/kWh) (10 11/ kWh)

Euro III limit 5,45 0,78 5 - 0,16 - -

Euro IV limit 4 0,55 3,5 - 0,03 - -

Euro V limit 4 0,55 2 - 0,03 - -

EEV limit 3 0,4 2 - 0,02 - -

Euro VI limit 4 0,16 0,46 0,5 0,01 6 10

MAN E 2876 - EEV 0,72 0,04 0,02 0,02 0,003 - -

MAN E 2876 - Euro 6 0,3 0,02 0,31 0,14 0,001 2,59 8,86


6,00 *

10,0010,00

0,460,500,16

4,00

0,0

2,0

4,0

6,0

8,0

10,0

CO NMHC Methan NOx Partikel NH3 Partikelzahl

g/kWh g/kWh g/kWh g/kWh mg/kWh ppm 10E11

Em

issi

onen

MAN CNG BusesWHTC emission limits - Euro 6

WHTC = World-wide Harmonised Transient Cycleweighting: 14% cold + 86 % hot

* Diesel engine limits, particle number limit for CNGs expected until 31.12.2012


4,00

0,160,50 0,46

10,00

0,28 0,02 0,22 0,38

1,25

7,12

2,14

10,00

6,00 *

0,0

2,0

4,0

6,0

8,0

10,0

CO NMHC Methan NOx Partikel NH3 Partikelzahl

g/kWh g/kWh g/kWh g/kWh mg/kWh ppm 10E11

Em

issi

onen

EURO VI (WHTC - Grenzwert)

E 2876 LUH07

MAN CNG Buses WHTC test results

WHTC = World-wide Harmonised Transient CycleWichtung: 14% kalt + 86 % warmPrüfgas: G25, Emissionwerte inklusive Verschlechterungsfaktoren

* Diesel engine limit. Particle no. limit for CNG engines expected 31.12.2012


MAN CNG Busesemissions CNG engine E2876 LUH - Euro 6

WHTC = World-wide Harmonised Transient Cycleweighting: 14% cold + 86 % hot

* Diesel engine limits, particle number limit for CNGs expected until 31.12.2012

0,0

2,0

4,0

6,0

8,0

10,0

12,0

[g/kWh] [g/kWh] [g/kWh] [g/kWh] [g/kWh] [ppm] 10 11

CO THC CH4 NOX PT/PM NH3 PTN

Emissions of CNG engine E2876LUH 07‐Euro 6WHTC

Euro 6 limit

Fuel: GR ‐ Measured

Fuel: G25 ‐ Measured


Challenges of EURO VI for HD Vehicles Trends Influencing EURO VI Heavy Duty Legislation

global harmonization world-wide harmonized heavy duty certification (WHDC, gtr № 4) world-wide harmonized OBD (WWH-OBD, gtr № 5) harmonization of OBD communication (ISO 27145)

100%

EIII EIV EV EVI *ETC

8% 6,25%

PMNOx persistent legislative focus on emission reduction

necessity of exhaust after-treatment increasing system complexity (engine, exhaust after-treatment)

vehicle operation / on-road capabilities further focus on transient & real world engine operation (WHTC) inclusion of engine cold start into certification process focus on on-road capabilites/ in-service confomity (PEMS/IUPR)

torque

speed

driver notification / inducement noticeability of emission faults (discriminatory display strategy) emphasis on importance of NOx reduction (driver inducement) roadworthiness in terms of emissions (roadside check ISO 27145)


MAN CNG BusesEuro 6 test cycle

World-wide Harmonised Heavy-Duty Certification Procedure (WHDC)

split into:

1. stationary test

WHSC (World-wide Harmonised Stationary Cycle)

2. transient test

WHTC (World-wide Harmonised Transient Cycle), 2 parts:

1. cold engine start2. hot engine start after 10 min


MAN CNG BusesWHTC engine rpm and torque progression - E2876LUH07

N [1

/min

]

400

600

800

1000

1200

1400

1600

1800

2000

Zeit [s]0 200 400 600 800 1000 1200 1400 1600 1800

M [N

m]

-400-200

0200400600800

100012001400

Zeit [s]0 200 400 600 800 1000 1200 1400 1600 1800


DurabilityLegislation demands persistent low exhaust emissions (i.e. performance of the exhaust gas aftertreatment) over a mileage of 700.000 km or 7 years for trucks > 7,5 t as well as 300.000 km or 5 years for buses and coaches.

In Service Conformity, ISC = proof of durability

WWH-OBD / EURO VI-OBDexhaust system check (filters, catalysts) for existence and functioncontrol of all exhaust emission relevant actuators and sensors

PEMS-measurementsEmission measurements on vehicles on the road , carried out in defined time intervals and in accordance with test cycles , which fulfill certain criteria (city/ intercity /highway mix), Installation of a certified measuring system (PEMS, Portable Emission Measurement System), reporting through standardised software.

Repair and Maintenance Instructions, RMIOEMs are obliged to make repair & maintenance instructions accessible for certified persons

Conformity of production, COPCheck of production quality by means of emission measurements of 1 % of series enginesGuarantee of quality from outside supplier parts by means of supplier COP.

MAN CNG BusesEURO 6 challenges for HD vehicles


WWH-OBD functions control of exhaust emission system for correct performance control of exhaust emissions

General demands

control of all electric wires to ECU control of components and sensors reference electrical faults (cable break, battery or earth shortage) and plausibility check Conducting functional tests and check of components fault display by means of MIL (Malfunction Indicator Lamp) and storage in ECU fault memory Accessibility of fault memory by means of standardized, free vendible diagnostic devices

Realized control function for EGC4: catalyst diagnosis check of oxygen storage ability inside catalyst

MAN CNG Busestechnical solutions / WWH-OBD functionalities


EURO VI challengesfault classification

C

B2

B1A

fault class, priority (MIL)

Em

issi

onen

(WH

TC k

alt/w

arm

)emission limits

OBD-treshold

Fault classification:A: expected excess of OBD-limit

B1: emission relevant, OBD-limit may be exceeded, but unclearimpact on emission

B2: emission relevant, withoutexceeding OBD-limits

C: emission relevant, withoutexceeding legal emission limits

NOx[g/kWh]

CO[g/kWh]

THC[g/kWh]

NH3[ppm]

particle mass[mg/kWh]

no. ofparticles[#/kWh]

emission-treshold

0,46 4 0,66 10 10 (6e+11)

highest OBD -limits

1,2 --- --- --- 25 ---


MAN CNG BusesTechnology

Otto-cycle Gas engine Diesel engineSpark plug and special

combustion chamber with lower compression ratio

Diesel injector and combustion chamber with high compression

ratio


MAN CNG BusesTechnology comparison Diesel vs. CNG (Otto)

Features of MAN CNG enginesExternal mixture forming: Natural gas injected into

compressed intake air, forming mixture upstream of combustion chamber.

Externally induced ignition: mixture being ignited in cylinder by means of spark plug

Engine power regulation: engine power regulated through mixture quantity. The amount of gas/air mixture is being controlled by means of a throttle valve and charge air pressure

Features of MAN-Diesel enginesInternal mixture forming: during intake stroke only air

will enter combustion chamber. Mixture forming by means of Diesel fuel injection

Self ignition: Intake air heated up during compression, leading to self-ignition of injected Diesel fuel, without external igniter

Engine power regulation: engine power regulated through mixture quality. Depending on engine speed the amount of intake air stays almost constant. Only quantity of injected fuel varies

1

2

3

Spark plug

Diesel Injector

Combustion chamber


MAN CNG BusesE 2876 LUH


MAN CNG BusesTechnology

E2876LUHNumber of cylinders: 6Displacement: 12,8 lPower output: 228 kW / 2000 rpmTorque: 1250 Nm/1000-

1700 rpmExhaust gas std: Euro 6

E0836LOHNumber of cylinders: 6Displacement: 6,9 lPower output: 206 kW /2000 rpmTorque: 1000 Nm/900 -

1900 rpmExhaust gas std: Euro 6


MAN CNG BusesEGC4 - Technology


MAN CNG BusesEGC4 – load sensoring

sensor signals used to make air mass flow meter redundant


MAN CNG BusesLiner Technology

Type I Type II Type III - Dynecell® Type IV

Type III cylinders are manufactured from seamless, thin aluminum liners, wrapped with carbon fibre laminateadvantage: weight saving up to 70 %

Type IV cylinders are full plastic liners wrapped with fiberglass/carbon


MAN CNG BusesSafety Aspects

What makes the CNG bus so safe ?

European regulation ECE-R110, StVZO, German pressure cylinder regulation, safety and accident prevention regulations are fulfilled

Individual inspection of every vehicle prior to start of operation (by officially certified inspector)

Filing nozzle with integrated check valve and shut-off valve

Fuel lines and unions made of stainless steel, gas tight

Liners Aerospace proven materials Operating pressure 200 bar, test pressure 300 bar, rated pressure 500 bar – Safety factor 2,5 ! Cylinder lifetime 20 years without need for intermediate inspection

Solenoid valves shut off fuel supply when ignition is switched off

Cylinder valves equipped with Flow limiter PRD (pressure relieve device): melting fuse will prevent cylinders from overpressure (in case of

fire)


MAN CNG BusesAgenda



3 MAN CNG buses – sales figures



6 Cost Calculation

7 Summary


MAN CNG BusesEuro 6 strategies / Diesel & CNG comparison

Euro 6 Diesel requires EGR & SCR technologies to be combined:

Euro 6 CNG only requires 3-way catalyst !


MAN CNG BusesEnvironmental Aspects - cont`d

Limit values & emissions busdrive trains (ETC)

0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

PM (g

/kW

h) Euro 3 2000

Euro 4 2005EEV

Euro 5 2008

Euro 6

EEV stoichiometric CNG

EEV diesel closed soot trap

Hybrid diesel closed soot trap

Euro 5 diesel closed soot trap

EEV Lean burn CNG

Euro 4 Diesel PM-Kat

Euro 3 Diesel



Overview: environmental performance of buses



!

!


MAN CNG BusesAgenda






6 Cost Calculation

7 Summary


MAN CNG BusesFinancial Aspects-/ Cost comparison

1. vehicle costs (complete vehicle, Lion`s City)

,0

20,0

40,0

60,0

80,0

100,0

120,0

140,0

160,0

180,0

vehicle investment for different drive technologies [%]

A37 Diesel

A37 Hybrid

A21CNG

+ 63

+ 19



2. fuel costs

Calculation basis: 10 year period annual mileage: 60.000 km Diesel cost: 1,40 EUR per litre CNG cost: 1,00 EUR per kg fuel consumption: 50/50 % mix from SORT 1 and SORT 2 values

0

50000

100000

150000

200000

250000

300000

350000

400000

450000

Diesel: CNG:

Fuel cost comparison[EUR]



,0 €

50000,0 €

100000,0 €

150000,0 €

200000,0 €

250000,0 €

Hybrid Gas Diesel Diesel

maintenance costs [EUR]

preventive maintenancecosts [EUR]

repair costs [EUR]

3. repair & maintenance comparison

Calculation basis:• 10 year period• annual mileage: 60.000 km• labour rate & parts cost to German

standards

0

20

40

60

80

100

120

140

Hybrid /D08 CNG / E28 Diesel / D20 Diesel / D08

Maintenance costs for Diesel and alternative drive technologies [%]

+9+26

+1


MAN CNG BusesAgenda






6 Cost Calculation

7 Summary


MAN CNG BusesSummary

The cleanest, CO2 neutral, reliable, non-fossil and affordable solution for public transport:

• Buses readily available• Proven reliable technology• Highest well to wheel efficiency on CO2 reduction• Lowest PM emission• Lowest NOx emission• Low noise production• No link with food chain discussion



The cleanest, CO2 neutral, reliable, non-fossil and affordable solution for public transport:

• Euro 6• No AdBlue• No battery packs, disposal of, replacement• no spillage risks• future proof – biogas option• manure, municipal waste, food waste – not crop reliant• biogas can be fed directly into the gas main


MAN CNG BusesBackup

Backup


MAN CNG BusesProspects

The European Union has set the target of increasing the share of biofuels and so-calledalternative fuels, including natural gas, in traffic to 10 and 20 %, respectively, by 2020.

A European project called GasHighWay has been established, aiming to the realisationof a comprehensive network of filling stations for these fuels spanning Europefrom the north, Finland and Sweden, to the south, Italy - in other words: the GasHighWay



Biofuel comparison – how far will biofuel made from crops grown on 1 hectare take you ?



Biomethane plants in Germany

Number of plants Capacity [m3/h]

numberestimated number

capacityestimated capacity


Combined Heat & Power

(CHP)

MAN CNG BusesFocus: Carbon Footprint


World reserves of fossile energy

Mittelwerte aus verschiedenen Quellen

0 50 100 150 200 250 300 350 400 450

Kohle

Erdgas

Erdöl

1000

uncertainty range ofresources

years

Crude oil

Natural gas

Coal


??


Thank you for your attention !

clean air bus transport

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