AdBlue Technology

By Dr Mark Cook

Technical ManagerAllen Group Limited

AdBlue – what is it ?

• A compound manufactured by combining Ammonia (NH3) with Carbon Dioxide (CO2) under high pressure and used traditionally as a fertiliser.

• Urea solution 32.5% urea / 67.5% water.

• Marketed as AdBlue and conforms to DIN V70070

NH2

|

C = 0

|

NH2

Abstract- Emissions of Diesel engines contain some hazardous components- Particulate and NOx-emissions can be reduced by the SCR technology (Selective Catalytic Reduction)- A reduction agent has to be injected into the exhaust upstream of a catalyst

Truck Market- SCR technology was used with Diesel engines since mid-80s- 1991 : joint development between DaimlerChrysler, MAN, Iveco and Siemens to use this technology on Heavy Duty Trucks (HDT)- SCR technology is meeting Euro 4 and Euro 5 European Regulations- SCR technology is now used by all main truck makers : Mercedes-Benz, MAN, Volvo, Renault, Mack, Iveco, DAF,… except Scania - SCR technology: key players are Bosch and Cummins Emissions Solutions (part of Cummins)

Reduction agent- Aqueous solution of Urea : commercial name is AdBlueTM conforms to DIN V70070- AdBlue is a non toxic and non smelling liquid- The AdBlue consumption is about 5% of the Diesel fuel consumption

History

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0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5

Cleaner ProductsEnvironmental Challenge

PM

(P

arti

cula

te M

atte

r) [

g/k

Wh

]

Euro 3

Euro 2

Euro 4Euro 5

US 07

US 02

2010

1996

NOx [g/kWh]

US

10

SCR system for trucksAdditional equipmentlocated close to the Fuel Diesel tank

Woking principle- injection of AdBlue inside exhaust upstream- NOx is reduced into N2 (Nitrogen) and H2O (water)- Spray of AdBlue in the exhaust : less than 0.1 second dwell time

Typical AdBlue pipe dimensions

AdBlue tank - pump feed: 8x1mm

AdBlue tank –pump return: 8x1mm

Pump – injector: 5x1mm

Basic Principle of Selective Catalytic Reduction (SCR)

AdBlue Hose Assemblies - Unheated

The technology is based on Cummins Emissions Solutions SCR system– Grundfos AdBlue pump (air activated)– SAE quick connector ports as specified by Allen Group

• Easy to install, no leak

– Ø6.30mm used on injection lines / 5x1mm tubing– Ø7.89 or 9.49mm used on feed / return lines (poke yoke) / 8x1mm tubing– Injection line is fluoropolymer lined for low friction (Allen design)

• Minimize AdBlue crystallization

– Validated by Cummins Emission Solution Europe

• Existing customers– 6 customers to date (including Leyland Trucks)

Injection Line (self purging, always unheated)

5x1mm tube

6.30mm SAE fitting

Injection nozzle

Exhaust with catalyst

Unheated Feed and Return Lines

Pump sideAdBlue tank side(with level sensor)

8x1mm tubing 7.89 / 9.49mm SAE fittingsPoke Yoked for installation

Key features

– Proprietary design– High bend radius – small envelope– PA12 core tube– Proprietary conductive polymer formulation– Insulating sheath to provide isolation from the vehicle– AdBlue resistant SAE J2044 quick fit connectors– Standard 2 pole / 4 pole electrical connectors– Water ingress resistant to IP67– Thermostatic control– Constant temperature sensing - reduced energy input via control box– Allen designed control box– Power input of 20W/m– Validation to Allen specification and customer standards– Developments with 5 OE customers

AdBlue Hose Assemblies - Heated

AdBlue Hose Assembly - Heated

ELECTICAL CONNECTION

QUICKCONNECTOR

PROPRIETARY CONSTRUCTION

CORRUGATED HOSE

Technical dataAt a power input of 20W/m down to an ambient temperature of -38˚C, the hoses are capable of melting frozen urea from within the tubes to enable dosing by the SCR system within 30 minutes of activation of the system by the operator.

Temperature data for heated AdBlue hose (Power = 20 W/m)

-45

-40

-35

-30

-25

-20

-15

-10

-5

00 5 10 15 20 25 30 35

Time (minutes)

23°C -40°C-36°C-30°C

Tem

perature (˚C)

AdBlue Hose Assembly - Heated

Advantages over competition (1)

Methods of heating AdBlue Hoses• Electrical heating

• Nissan Diesel, Volvo 3P, Leyland Trucks• Coolant water heating

• Scania

Differences in the heating methods• Electrical heating

1. AdBlue heating achieved by electrical power in a ‘cable’2. Consistent and rapid heating3. Will achieve emission regulations for Euro 6 engines

• Coolant water heating1. AdBlue heating achieved by hot coolant water in double skin hose2. Inconsistent and slow heating,

3. Will not achieve emission regulations for Euro 6 engines

Advantages over competition (2)

Competitors• ContiTech / SAE fittings: Bosch DINOX 2 – Electrical: Volvo• ContiTech / Voss fittings: Bosch DINOX 1 – Coolant: Scania• Nitta Moore / Voss 246 fittings: Bosch DINOX 1 – Electrical: Nissan

Advantages of Allen System over competition1. Compact hose design (less weight, high bend radius)2. SAE fittings (easy to install, disconnect, no leakage)3. Compatible with Bosch DINOX 2 and Cummins SCR system4. Lowest energy consumption of all electrically heated hoses5. Controlled heating, via control box6. IP67 rated7. EMC tested