Bio 3B: Biodiesel exhaust aftertreatment

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Presented by the National Biodiesel Board Biodiesel Technical Training Course BIO3B: Exhaust A:er Treatment and Biodiesel

Transcript of Bio 3B: Biodiesel exhaust aftertreatment

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Presented by the

National Biodiesel Board

Biodiesel  Technical  Training  Course  

 BIO3B:  Exhaust  A:er-­‐

Treatment  and  Biodiesel  

 

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Today’s  Topics  

 •  Changes  in  diesel  engine  emissions  regula4ons  •  Basics  of  diesel  engine  emissions  

–  Changes  in  hardware  required  by  emissions  regula4ons  –  Interac4ons  of  fuels  and  fuel  systems  

•  Methods  of  exhaust  a>ertreatment  •  Exhaust  a>ertreatment  &  biodiesel  •  Resources  

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•  Provide  access  to  industry  experts  for  more  detailed  ques4ons  and  answers  about  biodiesel  

•  Introduce  the  Na4onal  Biodiesel  Board’s  Diesel  Technician  Training  program  and  the  program  resources  to  the  audience  

•  Provide  quality  informa4on  about  biodiesel  and  diesel  emissions  

•  Provide  quality  informa4on  about  biodiesel  usage  and  today’s  diesel  exhaust  emissions  a>ertreatment

Learning  Objec4ves  

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•  Be able to answer general questions about biodiesel that you may be asked as a technician

•  Be able to answer questions about biodiesel emissions •  Be able to answer questions about biodiesel usage and

today’s diesel exhaust emissions aftertreatment •  Be able to make recommendations regarding biodiesel use

and vehicle maintenance

Learning  Outcomes  

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US  On  Highway  Emissions  Standards  

1988 1990

1991 1994

1998 2000

2002

2010 0.80

0.33 0.134 0

2

4 6

8

10

12

NO

x, g/

kW-H

r

8.05 6.7 6.7

5.4

3.3

1.5

0.013

14

16 14.4

2007

0.27

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Diesel  Emission  Reduc4ons  

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Fuel technology

Combustion technology

Aftertreatment technology

Fuel system technology

Better understanding of combustion

Alternate Fuels (Biodiesel) Low sulfur De-NOx

DOC

PM trap

Rate control High pressure Multi-injection

EGR technology Others

Control technology

Emission Reduction in Diesel Engines

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Exhaust  &  Emissions  Controls  

•  EGR:  Exhaust  Gas  Recircula4on  •  Cataly4c  converters  •  DPF:  Diesel  Par4culate  Filters  •  DOC:  Diesel  Oxida4on  Catalyst  •  SCR: Selective Catalytic Reduction (Urea)  •  Emissions  regula4ons  dicta4ng  changing  engine  and  fuel  injec4on  design  

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2010  standards  

•  Introduction of ultra-low sulfur diesel fuel in October 2006

• EPA emissions standard for 2007: •  Diesel particle filters (DPF) •  Increased levels of exhaust gas recirculation (EGR) and higher fuel

injection pressures

• Full EPA emissions standard in 2010: •  DPF, EGR, high pressure fuel injection

•  Exhaust catalysts for NOx reduction • NOx adsorber catalysts, unburned diesel fuel for operation

• Selective catalytic reduction (SCR) • Diesel Exhaust Fluid (DEF) needed for SCR operation

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Diesel  Par4cle  Filters  

•  Exhaust  flows  through  porous  wall-­‐flow  elements  –  PM  is  trapped  on  the  walls  of  the  filter  

•  When  exhaust  temperature  is  high  enough,  PM  is  burned  off  –  In  most  cases,  unburned  diesel  fuel  is  injected  to  accomplish  this  

•  Precious  metal  is  loaded  onto  filter  walls  to  lower  the  temperature  required  for  regenera4on  

•  Issues:  –  Regenera4on  at  low  temperatures/duty  cycles  –  Plugging  with  incombus4ble  materials  like  lube  oil  ash  

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Diesel  Par4culate  Filter  (DPF)  Maintenance  

•  Carbon  par?culates  are  burned  off  with  on-­‐board  regenera?on  

•  Ash  remains  in  the  DPF  and  must  be  removed  periodically  –  This  requires  removal  from  vehicle  

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Catalyzed  Diesel  Par4culate  Filter  (CDPFs)  

•  Uses  chemicals  in  exhaust  to  con?nuously  burn  carbon  in  Soot  Filter  

•  Must  s?ll  be  removed  to  clean  ash  

NO2 Oxidizes Soot in Filter 2NO2 + C CO2 + 2NO

Converts NO 2NO2

Soot Filter Platinum Catalyst

Exhaust Gas

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DPF  Regenera4on  

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SCR  Performance  

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Biodiesel  Tes4ng    

Cummins ISB 300 •  2002 Engine, 2004 Certification •  Cooled EGR, VGT Johnson Matthey CCRT •  12 Liter DPF •  Passively Regenerated System •  Pre Catalyst (NO2 Production)

•  Fuels: ULSD, B100, B20, B5

•  ReFUEL Test Facility •  400 HP Dynamometer •  Transient & Steady State Testing •  Cummins •  Soot Characterization •  Significant financial support for testing

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B20 results in substantial PM reduction even with DPF (data for 2003 Cummins ISB with Johnson Matthey CCRT on HD FTP)

B20 Testing

Reduction with DPF ranges from 20% to 70%, depending on basefuel, test cycle, and other factors •  Reduction in sulfate emissions •  Increased PM reactivity

Williams, et al., “Effect of Biodiesel Blends on Diesel Particulate Filter Performance” SAE 2006-01-3280

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Superb Results BPT

ULSD 360ºC B20 320ºC B100 250ºC

• BPT is 40ºC lower for B20 • Soot is more easily burned off of filter • B20 can be used for lower temperature duty cycle

• Regeneration rate increases with increasing biodiesel content

• Even at 5%, biodiesel PM measurably oxidizes more quickly

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NOx  Adsorber  Technology  

•  Filter  removes  par?cles  •  LNA  absorbs  NOx  on  lean  opera?on  •  Controls  switch  to  rich  opera?on  to  NOx  to  harmless  Nitrogen  •  Filter  regenera?on  and  LNA  regenera?on  are  separate  •  Complex;  costly;  &  fuel  economy  loss  

Filter

Diesel Injector

NOx Sensor

DOC Valves

DOC

Diesel Oxidation Catalyst

LNA

Bypass Reference: Volvo

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SCR  Performance  

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NOx  Controls  

• NOx  Adsorber  Catalyst/Lean  NOx  trap  – Catalyst  converts  all  NOx  to  NO2,  adsorbent  bed  “traps”  NO2  

– When  bed  is  saturated,  exhaust  forced    rich  – NO2  is  released  and  converted  to  N2  – Bed  also  traps  SO2,  but  doesn’t  release  it  

•  Near  sulfur  free  exhaust  is  needed  •  Higher  temps,  longer  4me  needed  to  release  sulfur  

– 90%+  conversion  is  possible  

• Selec4ve  Cataly4c  Reduc4on  (SCR)  – Used  for  industrial  NOx  control  for  years  – Requires  a  supplemental  “reductant”  – Typically  ammonia,  derived  from  urea  

•  “Diesel  Exhaust  Fluid”  – 80-­‐90%  reduc4on  efficiency  – Generally  sulfur  tolerant  

NOx adsorber catalyst (NAC) is also known as a lean-NOx trap (LNT)

SCR

NO

x +

NH

3 Se

nsor

Ure

a In

ject

ion

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Biodiesel  Tes4ng  with  LD  Emission  Systems  

•  Includes  two  emission  control  systems  and  two  fuel  blends  on  a  light-­‐duty  placorm  –  NAC/DPF  and  SCR/DPF  –  5%  and  20  %  biodiesel  blends  

•  Performance,  op4miza4on  and  durability  –  Aging  to  represent  2100  hours  of  opera4on  (approximately  120,00  miles  or  

full  useful  life)  for  B20  –  Emissions  evalua4ons  over  UDDS,  US06,  and  HFET–  tes4ng  by  EPA  –  Perform  engine  and  fuel  component  teardown  at  end  of  aging  

Engine: DCX OM646

Vehicle: Mercedes C200 CDI

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ULSD vs B20 – SCR

No statistical difference in NOx Conversion with B20

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Selec4ve-­‐Catalysts  Reduc4on  (SCR)  Aqueous Urea Solution Tank

Ammonia Slip

Catalyst Engine

1 2

3 4

5 6

T

Air Induction

Pump and Injector

Atomized Urea

Solution

Catalyzed Particulate

Filter

SCR Catalyst

Air to Air Cooler C

Reference: DDC

Turbo-Charge

NO EGR

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Selec4ve-­‐Catalysts  Reduc4on  (SCR)  

•  Uses  aqueous  Urea  instead  of  fuel  to  convert  NOx  to  Nitrogen  –  Requires  extra  tank  etc.  –  Must  add  Urea  distribu?on  system  to  supply  chain  

•  Reduced  EGR  or  no  EGR  •  Fuel  economy  gains  compared  to  NOx  Adsorber  •  Proven  durability  for  European  applica?ons  •  Favored  by  some  for  large  truck  and  sta?onary  applica?ons  

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How  Does  Biodiesel  Effect    Emissions  &  A>ertreatment  ?  

•  Fuel  System  –  Concern  over  deposits  and  corrosion  –  Addressed  by  ASTM  specifica?ons  

•  Engine  Emissions  –  Lower  HC  and  Par?culate  –  NOx  emissions  depend  on  duty  cycle    

•  A:ertreatment  hardware  /  durability  –  Easier  DPF  regenera?on  –  Studies  at  NREL  /  ORNL  show  no  adverse  effects  on  hardware  

durability  

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What  Will  Be  in  the  Marketplace?  •  All  of  the  above!  •  Par?culate  Traps  (or  Soot  Filters)  were  across  the  board  in  2007  

•  NOx  Adsorbers  are  on  some  pick-­‐up  truck  applica?ons  

•  SCR  is  favored  for  many  HD  truck  and  sta?onary  applica?ons  

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Biodiesel  and  A>ertreatment  Systems  

  Biodiesel  is  compa4ble  with  Diesel  Par4culate  Filters,  and  has  some  dis4nct  advantages:  •  Lowers  regenera4on  temperatures  •  Less  engine  out  par4culate  maher  •  May  provide  increased  performance  and  decreased  maintenance  vs.  ULSD  alone  

•  May  provide  increased  fuel  economy    

  Regenera4on  mode  is  important  •  Late  in-­‐cylinder  injec4on  may  cause  increased  fuel  dilu4on  of  engine  oil  and  limit  the  level  of  biodiesel  that  can  be  used  (i.e.  B20  or  B5)  

•  Most  US  heavy  duty  applica4ons  use  exhaust  stream  fuel  injec4on  which  is  compa4ble  with  B20,  perhaps  higher  blends  

•  Some  light  duty  OEMs  recommend  max  B5  at  present  

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Conclusion      

•  NBB,  the  US  Department  of  Energy,  and  the  engine  and  vehicle  manufacturers  are  expending  significant  resources  to  understand  how  biodiesel  blends  interact  with  new  diesel  emission  controls  

•  Detailed  tes4ng  thus  far  indicates  B20  and  lower  blends  are  compa4ble  with  both  diesel  and  NOx  a>er  treatment  –  Provides  benefits  in  some  cases  

•  B5  is  now  just  part  of  normal  D975  diesel  fuel    •  Addi4onal  study  is  underway  

–  Quan4fy  long  term  benefits  of  biodiesel  blends  –  Late  in-­‐cylinder  injec4on  impact  on  fuel  dilu4on  –  NBB  is  encouraging  OEM’s  to  publicly  support  B20  

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Biodiesel  Resources  

 www.biodiesel.org  • Biodiesel  Training  Toolkit    • News  Releases  &  Informa4on  Resources  

• Technical  Library,  Spec  Sheets  &  Videos  • OEM  Warranty  Posi4ons  on  Biodiesel  

•   U.S.  Diesel  Vehicle  List  

 www.BQ-­‐9000.org    • Lis4ng  of  BQ-­‐9000  Cer4fied  Companies  

 www.biotrucker.com  • Lis4ng  of  BioTrucker  retail  sites    

 www.biodieselautomo?ve.org  • Dedicated to information exchange for biodiesel & diesel technicians

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Thank You! Questions…?    

     Rachel  Burton    OEM  Diesel  Technician  Training    Program    [email protected]    Tel:  919-­‐444-­‐3495      

   

       Call  NBB  at  1-­‐800-­‐841-­‐5849  Visit  www.biodiesel.org  

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