Development of an Active Regeneration Diesel

Particulate Filter System Donaldson Company Inc.

Mike Anderson, Ted Angelo, Jason Hou, Mike Protas, Ed Steinbrueck, Wayne Wagner, Paul

Way, Wenzhong Zhang

DEER 2004

Regeneration Methodology

• Diesel Particulate Filter (DPF)

– Highly efficient but requires regeneration

• Passive DPF Technology

– Has limitations - need to verify each application

• Active DPF Technology

– Broader application, but more complex

– Keys to success

• Transient control, regeneration strategy, minimal fuel penalty, durability, ……..

DEER 2004

Fuel Injection Active Regeneration System

DPF

Exhaust gas

Diesel vapor

Heat

DOC

Fuel Injection Unit

• Diesel fuel provides regeneration heat source

• Preferred regeneration characteristics

– Faster, more uniform heat up of DPF

– Quick and efficient regenerations

– Uniform temperature distribution in DPF

• Preferred system characteristics

– Simple, single-leg system

• Compatible with NOx Systems

DEER 2004

Three Main Subsystems

Controller Fuel Delivery

Catalyst & Substrates

Active

System

• Target – precise control of DPF inlet temperature

• Input – transient exhaust mass flow and temperature

• Output – transient control of fuel delivery rate

• Best Control Method?– Empirical

– Model-based

Control Challenges

DOC

DPF

DPF

DOC

Time

DPF Inlet Temp

Exhaust Gas Temp

Fuel Flow Rate

Tem

p, M

ass F

low

Mas

s Flo

wT

emp

Exhaust Mass Flow

DEER 2004

Control Challenges• Problem: White smoke under some transient conditions

– Simple inputs (temperature, pressure) not sufficient

• Solution: Characterize system response through model

DEER 2004

Control MethodModel-Based Feed-Forward Adaptive Control

• Model-Based – Energy balance to model system (uses a few key inputs)

– Accounts for heat transfer, thermal inertia, transient effects, etc.

– Scalable to different size systems (substrate size, flow rates, etc.)

• Feed-Forward – Predicts energy (fueling rate) requirement to achieve desired DPF Inlet

temperature

– System responds very slowly (thermal delay) – feedback alone insufficient

• Adaptive – Learns and adapts over time

DEER 2004

Controller Features• Diagnostics

– Monitors and provides feedback on system status

– Archives key system parameters

• Service Tool– PC-based graphical user interface (GUI)

– Data logging function

– Trouble shooting tools

• Controller – Flexible implementation– Stand alone controller for Retrofit

– Software transferable to Engine ECU

– ECU can communicate with active system controller

DEER 2004

Fuel Delivery System• Performance Requirements

– Fast transient response

– Uniform temperature distribution

– Installation flexibility

• Self-contained, exhaust mounted unit

– Automotive-production components

• Fuel atomization and spray pattern

– Air-assist

– Vaporization at low air/fuel pressures

– Minimal air consumption

Good Atomization

Poor Atomization

DEER 2004

Catalyst, Substrates & Regeneration

• Diesel Oxidation Catalyst (DOC)– Conversion of fuel to heat

• Diesel Particulate Filter (DPF)– Catalyzed to enhance regeneration performance– Production intent is cordierite

• Regeneration Strategy– When and how to regenerate?

• Soot loading, duration, DPF inlet temperature, mass flow, frequency, etc.

– This topic is a presentation in itself

DEER 2004

Active System Testing• Dynamometer Tests

– 1995 Cummins M11

– 2002 Cat 3126

– 1988 Cummins L10

• Durability Bench Testing: Component durability

• Field Testing– Line Haul Fleet Truck - 1997 DDC Series 60

– Residential Refuse Hauler – 2002 Mack E7

• Future Test Plans– Larger Scale Field Testing this Fall

– Off-Road Field Test by December

DEER 2004

Dynamometer TestingRegeneration during FTP Cycle – CAT 3126

0

50

100

150

200

250

300

350

400

450

500

550

600

650

700

0 2 4 6 8 10 12 14 16 18 20

Time - Minutes

Tem

pera

ture

- de

gC

0

75

150

225

300

375

450

525

600

675

750

825

900

975

1050

Mas

s Fl

ow -

g/s

DOC Inlet TempDOC Outlet TempExhaust Mass Flow

FTP Transient Test Cycle- 0 to 5 min, NY non-freeway- 5 to 10 min, LA non-freeway- 10 to 15 min, LA freeway- 15 to 20 min, NY non-

DEER 2004

Dynamometer TestingRegeneration during FTP Cycle – CAT 3126

0

50

100

150

200

250

300

350

400

450

500

550

600

650

700

0 2 4 6 8 10 12 14 16 18 20

Time - Minutes

Tem

pera

ture

- de

gC

0

20

40

60

80

100

120

140

160

180

200

220

240

260

280

HC

Slip

- pp

m

DOC Inlet TempDOC Outlet TempSystem Out HC Engine Out HC

DEER 2004

Field Test Results: Line Haul Fleet Truck

• 1997 Freightliner FLD 120

– DDC Series 60 Engine (11.1 liter)

• System installed summer ’03

Fully Installed Active System

DEER 2004

-100-50

050

100150200250300350400450500550600650700

60 61 62 63 64 65 66 67 68 69 70 71 72 73 74

Time - Min

Tem

pera

ture

- de

gC

4090140190240290340390440490540590640690740790840

Mas

s Fl

ow -

g/s

DOC Inlet Temp. DOC Outlet Temp. Exhaust Mass Flow

Field Test Results: Line Haul Fleet Truck Active System Operation During Stop-&-Go City Driving

DEER 2004

• Difficult Application– Low temperature

– Extended idling

– Stop-&-go operation

– Passive filter?

• Mack LE-613 (300HP E7)

• Manual Loader ~ 400 residential pickups/day

• Active System Installed May 2004

Field Test Results: Refuse Hauler

DEER 2004

Fuel Delivery System

Fully Installed Active System

Field Test Results: Refuse Hauler

DEER 2004

85

135

185

235

285

335

385

435

485

535

585

635

685

0 1 2 3 4 5

Time - Hours

Tem

pera

ture

- de

gCField Test Results: Refuse Hauler

Exhaust Temperature Profile

Avg. Exhaust Temp – 203 degC

Time Above 300 degC – 9%

DEER 2004

85

135

185

235

285

335

385

435

485

535

585

635

685

0 1 2 3 4 5

Time - Hours

Tem

pera

ture

- de

gCField Test Results: Refuse Hauler

Regeneration Opportunities

DOC Inlet Temp

DOC Outlet Temp

DEER 2004

Field Test Results: Refuse HaulerFilter Regeneration

85

135

185

235

285

335

385

435

485

535

585

635

685

640 642 644 646 648 650 652 654 656 658 660 662 664 666 668 670

Tim e - M inutes

Tem

pera

ture

- de

gC

DO C In let Tem pDO C O utlet 1DO C O utlet 2DO C O utlet 3

DO C O utlet 4DO C O utlet 5DPF O utlet Tem p

DEER 2004

Summary

• Successful field-test demonstrations

– Regenerate DPF on very difficult low-temperature duty cycles

– Precise temperature control in transient (stop-&-go) operation

– Compact, non-intrusive exhaust installation

• Developed model-based feed-forward adaptive control

• Developed on-board fuel delivery system