Driving toward cleaner air: Innovations in aftertreatment for regulation compliance

Truck driving on highway

Emission regulations have become crucial in reducing the environmental impact of heavy-duty vehicles. The implementation of U.S. Environment Protection Agency’s (EPA) 2027 emission standards in North America is expected to be a significant milestone in this ongoing endeavor, drastically lowering nitrogen oxide (NOx) emission limits by over 80%. The standards also dictate the extension of the emissions useful life (EUL) of vehicle components to ensure sustained compliance and performance.  Today's NOx and EUL requirements have remained unchanged for over a decade, presenting new and significant challenges to an industry accustomed to established standards. Addressing EPA27 regulations will require a system-level approach, integrating both the engine and aftertreatment systems, with careful optimization between the two. This article will explore two potential solutions.

System trade-offs significantly influence design choices for both the engine and aftertreatment, as these components must work in tandem to ensure optimal performance, serviceability and configurability for customers. Since 2007, Cummins Inc.'s Engine Business has partnered with Cummins Emission Solutions (CES) to develop system designs in North America that meet EPA regulations while prioritizing customer needs. The 2027 product lineup will introduce a new aftertreatment architecture, the Twin Module, built on proven solutions and adaptable configurations that minimize impact on customer chassis. When paired with the EPA 2027 X15 engine, which retains cooled Exhaust Gas Recirculation (EGR) and in-cylinder hydrocarbon dosing, the Twin Module is powered by a 48V alternator that enables the CES-designed electric heating system. This integration, featuring a belt-driven alternator and the application of electric heat in the aftertreatment, allows the 2027 solutions to meet lower emissions requirements without compromising engine performance or durability. As with the current Single Module system, the Twin Module continues CES’s commitment to ease of serviceability and customer configurability.

engine renderingaftertreatment rendering

CES Electric Heating System to Meet EPA27

According to Bethany Huckaby, Product Manager - CES, her team “is focused on the best way to apply appropriate technologies for the combination of critical factors: what does the regulation demand, what does the engine need and what does the market require.” For the EPA27 regulations in North American On-Highway markets, the system will utilize electric heat — along with other design changes — to deliver emissions performance in a “future proof” manner. This approach allows the EPA 2027 engines to concentrate on their performance without the added concern of thermal management required for aftertreatment.

Leveraging the advantages of electric heating technology makes sense in North America's On-Highway space for several reasons. By developing its own electric heaters specifically designed for heavy-duty commercial environments, CES is equipping customers with scalable solutions for the future. The Twin Module systems can apply heat to the exhaust "on-demand" and precisely where needed, ensuring accurate thermal management without compromising engine performance. This leads to improved engine efficiency—and consequently better fuel economy—across all potential operating conditions that a truck may face in North America. If future regulations continue to tighten emissions standards, the system architecture is already prepared to meet those requirements with minimal space claim adjustments, preventing customers from needing to redesign their chassis entirely.

Much like the earlier aftertreatment products, the Twin Module is designed to offer a comprehensive range of configuration options for customers. Utilizing electric heaters reduces the additional catalyst volume required resulting in a more compact system, and the assemblies can be arranged in several ways through a host of configurable product options. CES recognizes that maximizing flexibility in vehicle integration is crucial as the EPA27 regulations demand enhanced performance for longer durations than ever before.

CES Technologies for Euro 7

Another example of a CES solution that balances regulatory demands with engine and market needs can be found in Europe, where the implementation of Euro 7 emission regulations will begin in 2027. While these new regulations are less stringent than EPA 2027, they still require significant reductions in NOx and particulate number (PN) compared to Euro 6 levels. Additionally, Europe has introduced legislation specifically aimed at reducing CO2 emissions across fleets. The Vehicle Energy Consumption Calculation Tool (VECTO) mandates that original equipment manufacturers (OEMs) offer a broader range of powertrain solutions, enabling fleets to achieve a mandated percentage reduction in CO2 emissions (at the vehicle level) compared to a 2019 baseline. The target for 2025 is a 15% reduction in CO2 at the vehicle level. The 2030 target was recently revised from 30% to 45%, posing a significant challenge given the current infrastructure's readiness to support battery electric vehicles (BEV), hydrogen internal combustion engines (H2 ICE), and hydrogen fuel cells (HC FC) in the heavy-duty market. Meeting both Euro 7 limits and VECTO requirements is a considerable undertaking, requiring vehicle manufacturers to offer a variety of powertrain solutions, including a mix of clean diesel, hybrid, BEV and H2 ICE technologies.

Cummins Emission Solutions supports OEMs in their path to cleaner diesel solutions with a robust portfolio of components, including DEF and hydrocarbon dosing systems, mixers, e-heaters, and DEF filters. For North America, EPA27 poses an exciting opportunity to leverage existing technologies while incorporating the CES electric heating system. The European market is also expected to generate a huge demand for innovative aftertreatment solutions driven by the Euro 7 regulations. CES continues to assess its options for Euro 7 solutions while actively collaborating with major OEMs to provide reliable, high-quality components that support their individual needs.  As global emissions regulations become increasingly stringent, Cummins is well-prepared to address these unprecedented challenges with solutions that meet the diverse demands of different markets and customers.

Cummins Components Business Unit

Components Business Unit

Cummins Custompaks are being used for water management as Thailand struggles with its water crisis

CustomPak on site

Water crisis

Sixty Cummins Inc. CustomPaks are in service in Thailand as part of a critical water management plan aimed at easing the country’s water crisis – a crisis that has caused enormous economic and social damage and stirred conflict among communities.

Over the past several decades, Thailand has continually faced water problems caused by severe drought. Water reserves in dams and reservoirs are insufficient while water resources are often contaminated with toxins caused by urban communities and the industrial and agricultural sectors.

Severe flooding is a threat, too, at a time when the realities of climate change are hanging over the country.

As a result, the allocation of precious water resources, which must be shared among various stakeholders including new and existing industry, large and small agriculture, and cities and villages has become a flashpoint.

Kittithanapat Engineering Co. (KTP), has been involved in the water management system since 1996, working closely with authorities such as the Royal Irrigation Department, Department of Water Resources, Bangkok Metropolitan Authority and others.

CustomPaks on site

600 hp CustomPaks

To help KTP meet its often urgent requirements, Cummins DKSH (Thailand) has recently supplied 60 Australian-built CustomPaks – 45 powered by Cummins’ X15 engine rated at 600 hp, and 15 powered by the QSL9 rated at 325 hp. These fully self-contained powerpacks are emissions certified to Tier 3.

The CustomPaks are coupled to hydraulically-driven, large-volume submersible water pumps sourced by KTP from US company Moving Water Industries (MWI); KTP is the exclusive distributor in Thailand for these MWI Hydroflo pumps.

Prior to Cummins’ involvement, KTP was using another diesel engine brand but service support wasn’t up to the standard required.

Long-serving KTP engineer Kittisak Thanasoot says Cummins DKSH’s reputation for technical and aftersales support along with the reliability of the Cummins product were a key reason behind KTP’s decision to specify the CustomPaks for the Royal Irrigation Department.

The ability of Cummins DKSH to respond to short delivery times was also important.

“Supplying large quantities of high horsepower diesel engines for emergency situations such as flash flooding can be a challenge for KTP,” says Kittisak Thanasoot.

“Responding to the needs of the government agencies to manage such problems in a timely manner and with least impact on communities, KTP has found the answer in our partnership with Cummins DKSH.”

Power, pride and passion

Parked semi truck

The switch back to Cummins power has been beneficial for iconic New Zealand company Uhlenberg Haulage. It's all about whole-of-life costs.

Uhlenberg Haulage is closing in on 60 years in business, having been founded in 1966 by Mike and Carol Uhlenberg.

Based in Eltham, Taranaki, in New Zealand’s North Island, the operation is today owned and operated by their sons Chris, Daryl and Tony Uhlenberg.

Describing the Uhlenbergs as “old school family truckies”, Daryl talks about the company’s time-honored journey with a definite tone of pride, especially the work of his parents in laying the foundations for what is today an iconic fleet in its own right.

Cummins Inc. made its debut in the Uhlenberg fleet in 1971 with an NH250 powering a second-hand Kenworth K923 used in logging. A second Kenworth, a new W924 with a Cummins NTC335, followed soon after hauling an LPG tanker.

The Uhlenberg operation today comprises 40 prime movers and a variety of trailing gear to cater for the myriad of a jobs the fleet is involved in.

A number of Peterbilts feature in the fleet although Kenworth is now the brand of choice with six new units to be delivered over the next 12 months to cater for business growth.

Cummins’ X15 Euro 5 engine rated at 550 or 600 hp is the preferred power specification, with 18 red engines currently in the fleet.

Uhlenberg family in front of truck

Whole-of-life support

“The switch to Cummins has been a very good experience for us. We have nothing but praise for the Cummins organization,” says Daryl.

“The whole-of-life picture is the key thing for us and we’ve got that nailed with the support we get from Cummins – parts availability, scheduled maintenance, life expectancy and in-frame rebuilds.

“So the red engines turn up, we run them to life, which is 900,000 to 1.2 million kilometers, and then Cummins does an in-frame overhaul in a timely manner. If there’s an issue, parts and support are close by.

“The support we get from Cummins Palmerston North is fantastic, second to none.”

Daryl recently looked under a Kenworth that was in the workshop for a service and was surprised to see no oil leaking from the one-million-kilometer X15. “I remember when I was a fitter we had to wear a raincoat when working under a truck,” he jokes.

Fuel agnostic

Acknowledging that the push to decarbonize is now “very real”, Daryl likes the idea of Cummins’ fuel agnostic concept where one base internal combustion engine, optimized to run on diesel, can also be customized to run on ultra-low and zero-carbon fuels like renewable natural gas and hydrogen.

“My father was a pioneer of linehaul trucking in New Zealand and he always embraced new technology. He was never scared of it,” he says.

“I tend to be a little more cautious but I can see where a 500 hp natural gas or hydrogen engine would work for us in short haul applications,” he admits. “We’re certainly willing to look closely at these alternative fuel technologies when suitable infrastructure is in place.”

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