As chief technical officer for leading mid-range diesel engine manufacturer International Truck and Engine Corporation, Patrick Charbonneau is on the front line of diesel engine technologies. Diesel Data recently spoke with Charbonneau to find out what technologies International – and the industry – are focusing on in the next five years to improve diesel engine emissions and promote the viability of diesel power in both commercial and consumer applications.

From his office at the International diesel engine manufacturing facility and technical center in Melrose Park, Ill., Patrick Charbonneau looks out over a lush green lawn giving rise to to the occasional deciduous tree.

Just across the lawn is North Avenue, a main thoroughfare extending into downtown Chicago, constantly moving with commuters on their way to suburban jobs and truckloads of freight picking up loads from the many industrial complexes. This, the quintessential American road, is International’s easel, upon which the company is creating a new vision: clean diesel.

In the past year alone, International has introduced several new diesel engine technologies on its International® VT 365 and Power Stroke® Diesel V-8 engines. These engines incorporate cooled exhaust gas recirculation (EGR), an EVRTÔ electronically-controlled turbocharger, and new hydraulic rail fuel injection system, all engineered to work together to lower emissions and meet International’s core engineering goals: durability, reliability and quality, and cost objectives.

With these advanced fuel and air management systems, today’s diesel engines used for medium duty trucks, school buses and heavy duty pickups and SUVs are light years ahead of diesels of the 70s. But according to Charbonneau, by 2007, diesels made by International will be even quieter, have no smell or smoke, and produce ultra-low emissions. For businesses and consumers concerned about the high costs of transportation, including fuel, repairs, and resale value, this is good news. Drivers who carry heavy loads on a regular basis – like many of those passing the Engine Group headquarters each day – diesel engines burn fuel more efficiently, are more reliable and require less repairs than comparable gas engines.

1) Another advancement of the injection system, using higher injection pressures and multiple injections for more efficient combustion,
2) An evolutionary step on the turbochargers,
3) An enhanced EGR system, and
4) The introduction of particulate filters and NOx adsorbers.

“In 2007, every diesel engine in North America – light or heavy – will have a particulate filter on it,” said Charbonneau. Green Diesel Technology® school buses in California already use the filters, which are certified with California’s Air Resources Board (ARB) and EPA to meet the 2007 standard today. NOx adsorbers are the next step in aftertreatment technology. International is currently running vehicles with these NOx traps in its captive fleet, and will realize the technology on the road in the next few years.

The greatest enabler of these diesel technologies is ultra-low-sulfur diesel fuel. The availability of such fuel is mandatory to meet emissions goals for diesel-powered vehicles. Currently, ultra-low-sulfur diesel fuel is available to centrally-fueled fleets in California and on the East Coast, and it is mandated for public consumption by mid-2006.

Now and in the future, diesel engine manufacturers are using cooled EGR to recirculate some of the exhaust gas into the engine intake. This helps reduce peak temperatures in the cylinder where NOx is formed. Cooled peak cylinder temperatures ultimately reduce NOx production, which in turn reduces ozone and smog in the environment. “This technology has been used in diesel passenger cars, particularly in Europe, for a few years,” says Charbonneau. “It is a known technology that lowers NOx and will be an integral part of diesel engine design in the future.”

International diesel engines are designed with an all-new EGR system integrated into the engine, instead of bolted on the outside. According to Charbonneau, this system approach is the key to making diesel engines a success in America – the engine, electronics, aftertreatment and fuel now combine to become an ultra-low emissions system to achieve the goals of International, the industry, ARB and the EPA.

In the next five years and beyond, North Avenue in Melrose Park and other roads across the country will be quieter, smoke-free and more pleasant to drive – thanks to advancements in diesel technologies led by Charbonneau and Engine Engineering at International.

Ford@Off-Road.com