Post on 28-Jun-2020
Dr. Georg Hüthwohl
A New Urea Dosing System for Passenger Cars
4th International Conference Selective Catalytic Reduction 2012 24 – 26 September 2012
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Introduction
Key requirements for AdBlue dosing
Results of catalyst efficiency with improved spray
System set up for passenger cars
Conclusion
Content
Hinduja Group India’s Premier Transnational Conglomerates
• Founded in 1914
• Headquartered in London
• Present in 10 business sectors
• Present in 35 countries
• Employs over 50,000 personnel
• Privately owned by the Hinduja Family
• Revenue of the Group is several billion dollars
Hinduja Automotive Ltd.
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Automotive Energy & Chemicals Banking & Finance IT & ITES
Media & Entertainment Real Estate Luxury Lifestyle
A joint venture between Ashok Leyland and Continental AG
A joint venture between Ashok Leyland and Alteams Group
Nissan Ashok Leyland Vehicles Ltd.
Construction equipment Ashok Leyland John Deere
Construction Equipment Private Ltd.
Albonair Company Hinduja Group Active in various industries
Major Centres and Establishments Europe : London, Paris, Geneva, Moscow United States : New York, Washington India : Mumbai, Delhi, Chennai, Bangalore, Hyderabad, Vizag Middle East : Dubai South East Asia : China, Philippines South America : Brazil Africa : Johannesburg, Cairo, Mauritius
Worldwide Locations
Hinduja Automotive Ltd.
Hinduja Automotive Landscape
Foundry Business
Engines & Gensets
Transmissions
Engineering Manufacturing
and Enterprise Services
Exhaust System Technology
Auto Electronics M&HCV Defence Mobility Buses
LCVs Construction equipment
Trucks Bus
Hinduja Automotive Ltd.
Med. & Heavy Comm. Vehicles Second Largest CV Maker in India
• Market Leader in Bus Segment
• Significant Presence in Medium and Heavy Duty trucks
• 6 Manufacturing Plants in India
• 2 Overseas manufacturing operations
• Joint venture in Sri Lanka
• Capacity of over 150,000 vehicles
Hinduja Automotive Ltd.
Company Profile - Bus
• Market Leader in Bus segment in India
• 2 dedicated Bus Manufacturing Plants
• Largest global fleet of CNG Buses in commercial operation
Hinduja Automotive Ltd.
Manufacturing Footprint
• 6 Manufacturing Plants in India
• 2 Overseas manufacturing operations
• Joint Venture in Sri Lanka
• Capacity of over 150,000 vehicles and aggregates
Ennore
Hosur 2
Hosur 1
Bhandara
Alwar Pantnagar
State of the art facilities and a flexible supply chain
Hinduja Automotive Ltd.
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Detroit, USA » Testing facilities » Sales » Customer Service
Dortmund, Germany » Headquarter » R&D » Sales » Customer Service
Taicang, China » Urea Dosing System assembly line » Housing assembly line » Sales » Customer Service
Chennai, India » Urea Dosing Assembly Line » Housing Assembly Line » Sales » Customer Service
Albonair - Company Overview Global Presence
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EURO 6 (e.g. Europe) EURO 4 (e.g. Emerging Markets)
Tier 4 Final (e.g. Off-Road vehicles) EURO 6 Passenger Car (e.g. Europe, USA)
Albonair Company Overview UREA Dosing Systems for Different Market Applications
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Key requirements for AdBlue dosing
Results of catalyst efficiency with improved spray
System set up for passenger cars
Introduction
Conclusions
Content
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System Spray Formation Characteristics
Pressure Atomizer (Airless)
» Energy for atomization from the liquid pressure
» Increase of pressure leads to improved spray quality
Twin Fluid Atomizer with internal mixing (Air Assisted)
» Energy for atomization from air pressure
» Typically high air consumption
Albonair’s Concept is based on: Twin Fluid Atomizer with external mixing (Air Assisted)
» Energy for atomization mainly from air pressure
» Low air consumption
» No contact between AdBlue and air in the dosing system / nozzle to avoid crystallization and deposits
Albonair UREA Dosing System Functional Advantages to competitors Spray Formation of Different AdBlue Dosing Systems
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Main Requirements for a UREA Dosing System
Technical Requirements Fine Spray avoiding big droplets for fast evaporation Homogeneous distribution of the DEF in the exhaust Precise dosing of small amounts of DEF Small size of the nozzle for easy packaging High temperature resistance
Solution Air assisted dosing nozzle with very low air consumption Droplet Size of only 15 µm SMD Temperature resistant without cooling up to 800
C exhaust temperature
No electric parts in the Nozzle Suited for close coupled position of the DEF dosing nozzle Electric air compressor for air supply (30 W power consumption) Mixer only for DEF distribution, not for droplet decomposition
Ø20 mm
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Key requirements for AdBlue dosing
Results of catalyst efficiency with improved spray
System set up for passenger cars
Introduction
Conclusions
Content
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Ø16mm
Albonair UREA Dosing System Injector Types - Connectors for AdBlue and Air hose have to be routed out of hot areas (>120° C)
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Packaging of the Dosing Nozzle in the Heavy Duty EURO 6 Exhaust System
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@Exhaust velocity 50 m/s and Low temperature (300
C)
» Even at 300
C small droplets of SMD 15 µm evaporate completely within 600 mm
» Very poor evaporation for big droplets SMD 70 µm
Evaporation Rates for Different Droplet Distributions
Albonair UREA Dosing System Functional Advantages to competitors
Point of
Measurement
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CFD-Analysis of the Spray Evaporation with the ALBONAIR Doser AdBlue is homogenously distributed and evaporates fast due to small droplet size
Conditions: Exhaust Gas Mass Flow: 170kg/h | Frequency: 2.1 Hz | Exhaust Gas Temperature: 260
C
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0%
20%
40%
60%
80%
100%
100% 25% 50% 75%
0%
20%
40%
60%
80%
100%
100% 25% 50% 75%
Ad
Blu
e D
eco
mp
osi
tio
n
» Signifikant increase of AdBlue Hydrolysis » Better Nox-Conversion at the SCR
Catalyst » Less deposits in the exhaust system
@ engine medium speed
@ engine high speed
Airless: NH3
Airless: HNCO
Albonair: NH3
Albonair: HNCO
Test Conditions: »Measurement HNCO and NH3 using FTIR
NH3 and HNCO decomposition improve with Albonair UDS
Albonair UREA Dosing System Functional Advantages to competitors
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90
100
175 195 215 235 255 275
NO
x-C
on
vers
ion
Rat
e (%
)
Temperature (°C)
Low Exhaust Mass Flow200 - 250 kg/h
Albonair
Airless
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50
60
70
80
90
100
175 195 215 235 255 275
NO
x-C
on
vers
ion
Rat
e (%
)
Temperature (°C)
High Exhaust Mass Flow600 - 1000 kg/h
Albonair
Airless
Catalyst Efficiency improved at low Exhaust Mass Flow - Little NH3-Slip
Albonair UREA Dosing System Functional Advantages to competitors
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First Test results from 3 different Passenger Car OEMs showed impressive NOx conversion results using Albonair’s System in comparison with BOSCH airless dosing system (Dated, 26.05.2012)
First evaluation Test results – Passenger Car apllication
Albonair UREA Dosing System Functional Advantages to competitors
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Key requirements for AdBlue dosing
Results of catalyst efficiency with improved spray System set up for passenger cars
Introduction
Conclusions
Content
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UREA Dosing System
NOx sensor
Exhaust System
Nozzle
Temp. Sensor
Air
Urea Suction Line (heated)
Actuators
Air Pressure Line
Urea Pressure Line
Temp. Sensor
Exh. Temperature (Pre)
Urea level/temp
Urea Quality
Air pressure
Urea pressure
Urea temperature
Air Filter
Afterteatment Control
AdBlue Tank
Actuators (Heating)
Engine Control Unit
Exh. Temperature (Post)
NOx
Albonair UREA Dosing System Schematics
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Tank System
Nozzle
Urea Dosing
System
Albonair UREA Dosing System System Overview - Schematics for Passenger Cars
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Membrane
Airpump incl. Pressure sensor
AdBlue Dosing Pump
AdBlue IN SAE
AdBlue OUT SAE
Air Out
AdBlue Pressure/Temperature Sensor
Electronics “Dosing”
Albonair UREA Dosing System AdBlue Pump
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122 mm 155 mm
115 m
m
Albonair UREA Dosing System Dimensions
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Key requirements for AdBlue dosing Results of catalyst efficiency with improved spray System set up for passenger cars
Introduction
Conclusions
Content
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Technical Aspects
» Optimized Distribution & Evaporation of AdBlue
» Fast evaporation of AdBlue droplets
» Improved catalyst efficiency especially at low temperatures
» No significant urea deposition in the system
Design Aspects
» Maintenance free – no service filters in the system
» Nozzle
» Compact design
» No mechanical parts
» No electrical parts
» High temperature resistant
» No possibility of congestion
Albonair UREA Dosing System Functional Advantages to competitors