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This paper presents experimental results of a 10.6L, three-cylinder opposed-piston (OP) operating on diesel fuel designed for heavy duty (Class 8) operation. The paper will describe the engine configuration and calibration of both catalyst light-off and high efficiency modes. Analysis based on measured results show the engine can comply with all 2027 California Air Resourced Board (CARB) and Environmental Protection Agency (EPA) requirements for CO2 and criteria emissions. Due to the ability of the OP Engine to combine low oxides of nitrogen (NOX) flux with high exhaust enthalpy for early catalyst light off, the engine can meet all 2027 CARB and EPA NOX standards with a current, state of the art conventional underfloor aftertreatment system. No additional emissions control technology is required.

The 2010 emission standards for heavy-duty diesel engines in the U.S. have established a limit for oxides of nitrogen (NOx) emissions of 0.20 g/bhp-hr., a 90% reduction from the previous emission standards. However, it has been projected that even when the entire on-road fleet of heavy-duty vehicles operating in California is compliant with the 2010 emission standards, the upcoming National Ambient Air Quality Standards (NAAQS) requirement for ambient particulate matter and ozone will not be achieved in California without further significant reductions in NOx emissions from the heavy-duty vehicle fleet. Given this, there is potential of further reduction in NOx emissions limit standards for heavy duty engines in the US. Recently there have been extensive studies and publications focusing on ultra-low NOx after treatment technologies that help achieve up to 0.02g/bhp-hr. at tailpipe [1].

In a recent paper, Opposed-Piston 2-Stroke Multi-Cylinder Engine Dynamometer Demonstration [1] published at the SAE SIAT in India in January 2015, Achates Power presented work related to the first ever opposed piston multi-cylinder engine fuel economy demonstration while meeting US 2010 emissions. The results showed that the research 4.9L three cylinder engine was able to achieve 43% brake thermal efficiency at the best point and almost 42% on average over the 12 modes of the SET cycle. The results from this test confirmed the modelling predictions and carved a very robust path to a 48% best BTE and 46.6% average over the cycle for a production design of this engine. With the steady state performance and emissions results achieved, it was time to explore other attributes.

Reducing the greenhouse emissions from on-road freight vehicles to meet the climate change mitigation objectives, has become a prime focus of regulatory authorities all over the world. Besides India, the United States, the European Union, Canada, Japan, and China have already established or planned heavy-duty vehicle efficiency regulations addressing CO2 and NOX emissions. In addition, Argentina, Brazil, Mexico, and South Korea are all in various stages of developing policies to improve the efficiency of their commercial vehicle fleets. For CO2 emissions reduction standards, the U.S. mandates 27% reduction by 2027, EU is calling for 15% reduction by 2025, China for 27% by 2019 over 2012 levels, and India is mandating 10%-15% reduction by 2021 for phase 2 of the new standard. There has also been considerable focus on further reduction in NOX emissions from current levels (0.2 g/hp-hr), to the proposed ultra-low NOx standards (0.02 g/hp-hr) in the U.S. for heavy duty engines by 2024.

Renewable fuels, such as the alcohols, ammonia, and hydrogen, have a high autoignition resistance. Therefore, to enable these fuels in compression ignition, some modifications to existing engine architectures is required, including increasing compression ratio, adding insulation, and/or using hot internal residuals. The opposed-piston two-stroke (OP2S) engine architecture is unique in that, unlike conventional four-stroke engines, the OP2S can control the amount of trapped residuals over a wide range through its scavenging process. As such, the OP2S engine architecture is well suited to achieve compression ignition of high autoignition resistance fuels. In this work, compression ignition with wet ethanol 80 (80% ethanol, 20% water by mass) on a 3-cylinder OP2S engine is experimentally demonstrated. A load sweep is performed from idle to nearly full load of the engine, with comparisons made to diesel at each operating condition.