Automotive Technologies for BS-III and BS-IV

R R Akarte
Former Chairman, SIAM Technical Committee on Emission &
Consultant Advisor, Tata Motors Ltd.

National Workshop on ‘Auto Fuel Policy – Way forward’

November 20, 2006
New Delhi

1 SIAM
 Contents:

• Emission Regulations and Auto Fuel Policy

• Technology progression

• BS III and BS IV technology requirements

• Challenges and issues, Next steps

2 SIAM
History Of Emission Regulations in India (Lead Introductions)
BS-IV
(SELECT CITIES)

Cabinet accepts Auto fuel policy

09, 2003 BS-III
(ENTIRE COUNTRY)??
CNG Buses Delhi

BS-II BS-III
(NCR) (11 CITIES)
Report by
Committee

BS-I BS-I BS-IV

CMVR 92
(NCR) (ENTIRE COUNTRY) Review
(DIESEL)

FAS (DIESEL)
CMVR 91 CMVR 96 (DIESEL)
Court Intervention Formation of
(PETROL) EVA & CC EMI
(PETROL) Committee

IDLE
EMISSION

1989 1992 1995 1998 2001 2004 2007 2010

3 SIAM
 Auto Fuel Policy (A Recap)

• Expert Committee Constituted by Government of India, headed by Dr R A Mashelkar,

(Director General, CSIR)
• Provides guideline road-map for new vehicles, with review to be done in year 2006
• Took an holistic view:
• Automobile Technologies
• Corresponding Fuel Quality
• Impact on Environment
• Social Cost
• Security of Fuel supply
• Emissions from in-use vehicles

• Guiding principles in respect of taxation of fuels:

To the extent auto fuels meet the recommended emissions norms, the choice of fuel should not be distorted by way of taxes.
Maintenance of relative prices with appropriate consideration to energy content should be a desirable goal of taxation policy.

• Recommendation by committee
Quote:
As elsewhere in the world, the Government should decide only the vehicular emission standards and the corresponding fuel specifications
without specifying vehicle technology and the type of fuel.
:Unquote

Report was approved by the Cabinet in October 2003

4 SIAM
 Change in Tailpipe Emissions
Petrol Passenger Car
Diesel Passenger Car 18 14

Regulated Pollutants (g/km)

16.3
16 fol
25
26 d red
Regulated Pollutants (g/km)

14
21.6 f old uc
20
red 12 11.68 tio
n (92
15 uc 10
tio .8%
10
n (96 8 )
.2% 6
5 7.9 ) 4 3.69
2.7
0 3.83 2.65
1.78 2 1.18
1.25 0.825
0
1991 1996 1999 2000 2005 2010 ? 2015 ?
1991 1996 1999 2000 2005 2010 ? 2015 ?
BS-I BS-II BS-III BS-IV
BS-I BS-II BS-III BS-IV

2 & 3 Wheelers Commercial Vehicles

35
Regulated Pollutants (g/km)

30.00

Regulated Pollutants
25.50 8 30 29.0
25.00 fol 7 fo
d red 25 ld re
duc

(g/kWhr)
20.00
uc 20 tion
tio (86.
15.00 n 15 13.96
12.25 3 %)
(8 8
10.00 8.10 %) 10 7.86
4.00 5 3.98
5.00 3.00
0
2005 2010 ?

)
I)
)
-I)
1991 1996 2001

-IV
-II
0.00 2000

96

-II
ge

ge

ge

ge
19

ta

ta

ta

ta
BS-III

S
1991 1996 2000 2005 BS-IV

tS
BS-I

tS

tS
t
ra

ra

ra

ra
ha

ha

ha

ha
(B

(B

(B

(B
00

02

05

10
20

20

20

20
Need to assess an impact on environment
5 SIAM
 The Law of Diminishing Returns
• The closer we get to the goal of zero emissions of a pollutant, the more costly it becomes to
eliminate each unit.
• Continued progress, however, requires using methods that are more and more expensive, and
remove smaller and smaller amounts of pollutants.
• At some point, the costs outweigh the benefits.

Source: ECO-SANITY, A Common Sense Guide to Environmentalism, Joseph L Bast et al

6 SIAM
 Technology Movement - Diesel
BS-III BS-IV

300 / 600 1000-

Injection 800-1000 1600- >2000
bar 1200 bar
Pressure bar (Electronic
1800 bar bar
(IDI / DI
s Mech injection injection (CR, UI)
Engines)
control)

4valves/cylinder,
Cylinder 2 valve/cylinder, inclined injector location centralised
head/ports
injection

Turbocharge Turbocharge
r Variable
r
Turbo Natural Geometry
(Optional With
system aspiration Turbocharger
waste-gate & intercooler
Intercooler)

After
treatment Simple With EGR &/or catalytic
With DPF / SCR
System exhaust converter

7 SIAM
Typical Common Rail System with Sensors and ECU

8 SIAM
 Significance of Common Rail

• Injection pressures are going up from 1000 to 1800 bar and beyond

• Common rail system is sensitive to fuel quality parameters such as

sediments, water content, particulate matter content, lubricity, any
other market abuse

• System Servicing needs to be done by authorised and trained staff

9 SIAM
 SCR and EGR options for NOx control
Sr. Parameters SCR EGR
No.
1 Components * Urea tank * EGR Valve
* Delivery Module * EGR Cooler
* Dosing Module * EGR Control
* Injection Nozzle
* ECU

2 NOx reducing potential Yes Adequate

3 Particulate after Not required for Euro-IV Required (POC / DPF)

treatment
4 Fuel economy impact 1- 3% benefit over EGR --
(urea consumption included)
5 Infrastructure Yes No
requirements for urea
6 Development Time High Low
7 System Complexity High Moderate SIAM
10
Selective Catalytic Reduction
Engine CAN Urea-SCR
link ECU
ECU

Air
Urea
Pump
Tank
T_in T_out
Urea
NOx injection

SCR catalyst

CO2, H2O, CO2, H2O,

CO, HC,
PM, NOx PM, NO/NO2 PM, N2
Exhaust
gas

DOC DOC SCR

2NO + O2  2NO2
SCR
4HC + 3O2  2CO2 + 2H2O 4NH3 + 4NO + O2  4N2 + 6H2O
Urea injection
2CO + O2  2CO2 8NH3 + 6NO2  7N2 + 12H2O
C + O2  2CO2

Relies on UREA for emissions reduction - Infra structure required

11 SIAM
 Significance of SCR Technology for Heavy Duty Application

• Improved fuel economy

• Necessary for Heavy Duty trucks particularly viewed against infrastructure

development

• In Europe, most of OEMs are with SCR at Euro-IV, notably being Daimler
Chrysler, Iveco, Volvo, DAF etc.

• Inevitable for Heavy Duty Euro-V and beyond

12 SIAM
 Particulate Filters

• Particulate burning through a secondary injection

• Fuel availability of less than 50 ppm sulphur content must
• High ash content in oil is deterrent for satisfactory operation of DPF
• Generally used on light duty diesel and passenger cars

13 SIAM
 Technology movement - Gasoline
BS-IV

Carburetor MPFI with MPFI with

Fuel Direct
with open EMS and multi-valve
system injection
loop system close loop 4 v/cyl, VVT

Mapped
EGR/3- Catalyst with
Exhaust EGR/Advanced Close coupled
way cat- early light-off
system EGR tolerant catalyst
con technology
processes

14 SIAM
 Gasoline Engines – BS IV Compliance Challenges

Exhaust Emissions – After Treatment & EMS Technology

Objective: To minimise engine warm up and catalyst light-off duration to reduce cold emissions.

• Close coupled catalyst with faster light- off components comprising of

optimized precious metal loading, wash coat and thin wall substrate.

• Thermally stable & durable catalyst substrate and wash coat

technology.

• EMS control strategy to enable rapid catalyst light- off, optimized open
loop – after start fuelling (trade off between CO/HC emissions,
driveability and catalyst light-off duration).

• Faster response oxygen sensors to enable quicker closed loop AFR

control.

SIAM
 Technology movement – CNG (3 & 4 Wheelers)

BS-IV
Stochiometric
combustion, Naturally
aspirated, 3 way Turbocharged
Engine
catalyst, , intercooled
mechanical/electronic
distribution systems

Low weight
gas cylinders
need to be
developed

16 SIAM
What fuel parameters need to be addressed for BS-III and BS-IV
norms?
Fuel Properties BS-III BS-IV Remarks

Cetane Number – Diesel 51 51 Higher Cetane number is desired (~53) to improve

cranking time, cold startability, exhaust emissions
and combustion noise
Max Sulphur content, ppm 350 50 Reduction in sulphur must for PM reduction and for
- Diesel after-treatment system. Europe is promoting 10 ppm.
Adulteration adversely impacts durability of emission
control system.
Lubricity, max, microns 460 460 Must for FIE durability. Adulteration adversly impacts
this requirement.

17 SIAM
Challenges & Issues, Next Steps

 Technology development
 Investment & Installation of manufacturing Plant and machinery
 Supply chain management
 Duality of norms

 Clean fuel at outlets

 Infrastructure of Urea
 Inspection & Maintenance Programme

- Cost

18 SIAM
 Thank You

Society of Indian Automobile Manufacturers

Core-4B, 5th Floor, India Habitat Centre
Lodi Road, New Delhi - 110 003
Tel.: 011- 24647810/11/12
Fax: 011- 24648222
E mail siam@[Link]
Website : [Link]

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