E-Heater Performance for Aftertreatment Warm-Up in a 48V Mild-Hybrid Heavy-Duty Truck over Real Driving Cycles

High-efficiency and low-emissions heavy-duty (HD) internal combustion engines (ICEs) offer significant GHG reduction potential. Mild hybridization via regenerative braking and enabling the use of an electric heater component (EHC) for the aftertreatment system (ATS) warm-up extends these benefits, which can mitigate tailpipe GHG and NOx emissions simultaneously. Understanding such integrated hybrid powertrains is essential for the system optimization of real-world driving conditions. In the present work, the potential of a low engine-out NOx (1.5–2.5 g/kWh range) ‘Low-NOx’ HD diesel engine and EHCs were analyzed in a 48V P1 mild-hybrid system for a class 8 commercial vehicle concept and compared with those in an EPA-2010-certified HD diesel truck as a baseline under real-world driving cycles, including those from the US, Europe, India, China, as well as the world harmonized vehicle cycle (WHVC). For analysis, an integrated 1-D vehicle model was utilized that consisted of models of the ‘Low-NOx’ HD engine, the stock ATS, and a production EHC. For the real driving cycles, ‘GT-RealDrive’-based vehicle speed profiles were generated for busy trucking routes for different markets. For each cycle, the effects of the Low-NOx and EHC performances were quantified in terms of the ATS warm-up time, engine-out NOx emissions, and net fuel consumption. Depending on the driving route, the regenerative braking fully or partly neutralized the EHC power penalty without a significant impact on the ATS thermal performance. For a two-EHC system, the fueling penalty associated with every second reduction in the warm-up time FCEHC (g/s) was several-fold higher for the real driving routes compared with the WHVC. Overall, while a multi-EHC setup accelerated the ATS warm-up, a single EHC integrated at the SCR inlet showed minimized EHC heating power, leading to a minimized fueling penalty. Finally, for the India and China routes, being highly transient, the P1 hybridization proved inadequate for GHG reduction due to the limited energy recuperation. A stronger hybridization was desirable for such driving cycles.