Advanced Petroleum Based Fuels- Diesel Emission Control ...0.08 0.10 NOx [g/mile] 0.0 0.2 0.4 0.6...
Transcript of Advanced Petroleum Based Fuels- Diesel Emission Control ...0.08 0.10 NOx [g/mile] 0.0 0.2 0.4 0.6...
Advanced Petroleum Based FuelsAdvanced Petroleum Based Fuels--Diesel Emission Control Diesel Emission Control
(ABPF(ABPF--DEC) UpdateDEC) UpdateShawn D. Whitacre
June 1, 2005
Presented at 4th Japan Clean Air Program Conference – Tokyo, Japan
Advanced Petroleum Based Fuels – Diesel Emission Control Study
Government/Industry Sponsorship
Participating Companies/OrganizationsAutomobile:DaimlerChryslerFordGMToyota
Government:CARB/SCAQMDDOEEPA NRELORNL
Emission Control:Argillon ArvinMeritorBentelerClean Diesel Tech.CorningDelphiDonaldson Co.EngelhardJohnson MattheyMECANGKRhodiaRobert Bosch Corp.STT Emtec ABTenneco Automotive3MUmicore
Energy/Additives:American Chemistry
CouncilAPIBPCastrolChevron OroniteChevronTexacoCibaConoco-PhillipsCromptonErgonEthylExxonMobilInfineumLubrizolMarathon AshlandMotivaNPRAPennzoil-Quaker StateShell Global SolutionsValvoline
Engines:CaterpillarCummins Detroit DieselEMAInternational Truck
& EngineJohn DeereMack Trucks
Technology:Battelle
APBF-DEC Projects
NONOxx Adsorber/DPFAdsorber/DPF SCR/DPFSCR/DPF LubesLubes
SwRI
Caterpillar C12
No vehicle
FEV SwRI Ricardo AEI
CumminsISB
1.9L TDI 6.6L Isuzu Duramax
15L Cummins ISX
Audi A4 Avant
Chevrolet Silverado
Project Summaries
NOx Adsorber/DPFPassenger Car Platform
• FEV Engine Technologies• Vehicle: Audi A4 Avant• Engine: 1.9L TDI• Catalyst aging study completed
– 2200 hour aging– Final report: Summer 2005– Evaluation of criteria and unregulated
pollutants and air toxins
Project Objective
TIER 1:
after 100,000 miles
4 NOx 1.25 g/miles
4 PM 0.1 g/mile
TIER 2 BIN 5:
after 120,000 miles
4 NOx 0.07 g/miles
4 PM 0.01 g/mile
PM [g
/mile
]
0.00
0.02
0.04
0.06
0.08
0.10
NOx [g/mile]0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4
Diesel Future II:Advanced Engine Control &Advanced Aftertreatment (NAC + DPF)
TIER 2BIN 5
TIER 2BIN 8
EU 4
EU 3
TIER 1
Audi A4 1.9 l TDIStation Wagon
European Certification
Development Catalyst Configuration and SpecificationsEmission Control System
EngineExhaust
Pre-Catalyst
UnderbodyNAC CDPF
ECS-A: DOC + NACECS-B: NACCell Density: 400 cpsiVolume: 1.34 LDiameter: 4.16 inchLength: 6 inchWall Thickness: 4.5 mil
All ECS: CDPFCell Density: 200 cpsiWall Thickness: 14 milSubstrate Material: SiCVolume: 2.5 LDiameter: 5.66 inchLength: 6 inchCell Geometry: Square
SubstrateMaterial: Cordierite
Cell Geometry: Square
All ECS: NACCell Density: 350 cpsiWall Thickness: 5.5 milVolume: 2.5 LDiameter: 5.66 inchLength: 6 inch
Test Cell Emission PerformanceFTP Cycle (Un-aged System)
System A
System B
0.005
0.010
0.015
0.020
0.025
0.030
0.035
0.040
NOx [g/mi]0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45
Tier 2 Bin 5 *
CO[g/mi]
PM[g/mi]
Euro 4
* EMISSION LIMITS AFTER 120,000 MILES
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
HC [g/mi]0.125 0.1 0.075 0.05 0.025
Tier 2 Bin 8 *
Tier 2 Bin 8 *
CO at 4.2 g/mi
Tier 2 Bin 5 *
Euro 4
Passenger Car Platform – Aging Results(LA4 Composite)
40%
50%
60%
70%
80%
90%
100%
0 50 100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000
1050
Age (hours)
NO
x C
onve
rsio
n
LA4 Composite(D15) LA4 Composite(BP15)Desulfation
More details: SAE 2005-01-1755
NOx Adsorber/DPFSUV Platform
• Southwest Research Institute• Vehicle: 2002 Chevrolet Silverado• Engine: 2002 Isuzu Duramax 6.6L• Catalyst aging study completed
– 2000 hours– Final Report: Summer 2005– Evaluation of criteria and unregulated
pollutants and air toxics
Project Objective
0
1
2
3
4
5
6
Emis
sion
s (g
/mile
)
THC NOx CO PM
Stock (with EGR)
Stock (no EGR)
Target (Tier 2,Bin 5)
FTP Drive Cycle Only
-99%
-88%
Emissions Control System
DuramaxNAC1SFI1
SFI2
Oxi-Cats1,2,3
DieselBurner
DPF
NAC2
NAC1
Volume (2nd Generation System):3.5L x 2 + 7L x 2 + 3.5L + 12.5L = 37.0L Front Oxi NAC Rear Oxi DPF
ECS : Eng = 5.6:1NAC : Eng = 2.1:1
0
50
100
150
200
250
300
350
400
0 200 400 600 800 1000 1200 1400Time, seconds
Tem
pera
ture
(°C
)
Downpipe Location (Average = 162°C)
Targeted Temperature Window for >90%
NAC NOX Reduction Efficiency
Measured Exhaust Temperature - On-Vehicle
Approach 2: Supplemental Energy-Diesel Burner
Supplemental Energy-Diesel Burner
Diesel Burner DetailsEngine Exhaust In
Combustion Chamber Location
Burner Head
Diesel Burner Management
0
100
200
300
400
0 200 400 600 800 1000 1200 1400Time, seconds
Gas
Tem
pera
ture
at C
atal
yst ,
°C
More details: SAE 2004-01-0584
Program AchievementsLow Hours, <1ppmS DECSE Fuel
0
1
2
3
4
5
NO
x M
ass
Emis
sion
, g/m
ile
HLA HFET US06
Baseline EO EO with EGR Integrated ECS
-98% -97%
-83%
SUV Platform – Aging Results(LA4 Composite)
80%
85%
90%
95%
100%
0 50 100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000
1050
1100
1150
1200
1250
1300
1350
1400
1450
1500
1550
1600
1650
1700
1750
1800
1850
1900
1950
2000
2050
Age (hours)
NO
x C
onve
rsio
n
LA4 Composite (D15) LA4 Composite (BP15) Standard-D 15Desulfation
NOx Adsorber/DPFHeavy-Duty Platform
• Ricardo, Inc (Chicago)• Vehicle: None• Engine: 2002 Cummins ISX 15L• Catalyst aging study completed
– 2000 hours– Final report in progress
Project Scope• Develop system capable of meeting
2010 emissions standards:- 0.20 g/bhp.h NOx and 0.01 g/bhp.h PM
• Develop sulfur management strategy• Conduct 2000 hour catalyst aging test
- Transient and steady-state evaluations of:- Regulated emissions- Currently unregulated emissions
Test Engine• Cummins ISX 15L• 475 hp Rating• DOHC 4V central
EUI• Cooled EGR, VGT • Advanced electronic
controls• 2002/2004 Base
engine out emissions(pre-production)
Emission Control System
CumminsISX
NAC1
DOCDOC
DPF
NACDPF
NAC
NOx Sensors
NOx Sensor
Full Flow System(no bypass)
Device Dimensions (Diameter x Length)
Volume
Upstream DOC 12” x 6” 11.1 L DPF (x2) 12” x 14” 25.9 L (51.8 L total) NOx Adsorber Catalyst (x2)
12” x 12” 22.2 L (44.4 L total)
Clean-up DOC 12” x 6” 11.1 L Total Volume: 118 L
Aging Results - NOx
FTP Composite NOx
0.00.51.01.52.02.5
0 250 500 750 1000 1250 1500 1750 2000
Age (hours)
NO
x (g
/bhp
-hr)
NOx Mean Desulfation
Engine-out Level
More details: SAE 2005-01-1760
Trends Analysis - NOx
0
0.2
0.4
0.6
0.8
1
1.2
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Aging Hou rs
NO
x (g
/bhp
-hr)
Fresh Pre-Desulfat ion A verage Post- Desulfation
EPA 2010 standard
Heavy-duty SCR/DPF(Southwest Research Institute)
• Vehicle: none• Engine: Caterpillar C12 w/ LPL EGR• Two systems evaluated:
– System A: 6000 out of 6000 hours– System B: 6000 out of 6000 hours– Also testing NOx sensor durability
SCR - System Design
INTAKE MANIFOLD
MANIFOLD
ATA
A
FTER
CO
OLE
R
C12 DIESEL ENGINE
EXHAUST
AIR FILTER
FLOW BALANCING
VALVES
EXHAUST
EXHAUST FLOW
SENSORS
CB-DPF AR
CB-DPF AL
SCR AL
SCR AR
UREA INJECTION
UREA INJECTION
EXHAUST DAMPER
CLEANUP CATALYST
LPL EGR PICKUP
INTA
KE
THR
OTT
LE
T (IMP)
N
TPS
PRESSURE CONTROL
UREA PUMP
UREA INJECTION CONTROLUREA
EGR COOLER
EGR VALVE
LPL EGR
Heavy-duty SCR/DPF Aging Study(HD FTP Composite NOx 8-ppm S fuel)
Effects of Aging on NOx (Composite)(Mean and 95% Prediction Interval)
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
A B A B A B A B A B
0 200 2000 4000 6000
Unit / Age (Hours)
NO
x (g
/bhp
-hr)
Lubricants Project
Phase IPhase I
Determine the impact of lubricant properties and composition on engine-out/catalyst-in emissions
Determine if lubricant formulation impacts the performance and durability of NOx adsorber catalysts
Phase IIPhase II
Lubricants Project Status• Phase I Completed in 2003• Final Report available• Phase II Testing completed Aug 2004• Final reporting underway•• Detailed results to be presented in Detailed results to be presented in
later sessionlater session
Future Direction• APBF-DEC projects to wrap up in 2005• At present time, no formal plans to
continue the activity• Anticipate future collaborative activities
in fuels and lubricants research:– Fuels for advanced combustion– Non-petroleum based fuels– Lubricant impact on PM