Improved Lifetime Pressure Drop Management For DuraTrap® RC … · 2014-03-10 · Krishna...

Krishna AravelliKrishna Aravelli, Josh Jamison, Kim Robbins, , Josh Jamison, Kim Robbins, Natarajan Gunasekaran, Achim HeibelNatarajan Gunasekaran, Achim Heibel

24 August 2006

Diesel Technology DevelopmentDiesel Technology DevelopmentScience and Technology,Science and Technology,

Corning Inc.Corning Inc.

Improved Lifetime Pressure Drop Management ForImproved Lifetime Pressure Drop Management ForDuraTrapDuraTrap®® RC FiltersRC Filters

With Asymmetric Cell Technology (ACT)With Asymmetric Cell Technology (ACT)

Deer Conference 2006Deer Conference 20062

OverviewOverview

• Introduction & Objectives

• Materials & Testing Methodology

• Results & Discussion– Engine Testing– Post Test Analysis

• Conclusions


Tightening of future emission legislationTightening of future emission legislation-- After treatment & advancements in engine technologyAfter treatment & advancements in engine technology

US legislation (on-road HDD) requires PM reduction to 10% of its current levels by 2007


Diesel Emissions Control SystemsDiesel Emissions Control Systems

Integrated system Integrated system ““FutureFuture””

HC & CO

FiltersFilters

CatalyzedCatalyzed

SubstratesSubstrates

Catalyzed

SubstratesSubstrates

CelcorCelcor®® LFA substratesLFA substratesCell geometries:Cell geometries:

DuraTrapDuraTrap®® filtersfiltersCO 100/17, 200/12CO 100/17, 200/12

RC 200/19, 270/16 ACT*RC 200/19, 270/16 ACT*200/12, 300/8,200/12, 300/8,300/5, 400/7300/5, 400/7

CelcorCelcor®® LFA substratesLFA substratesCell geometries:Cell geometries: 300/5, 300/8, 300/5, 300/8,

400/4, 400/7400/4, 400/7

* Asymmetric Cell Technology* Asymmetric Cell Technology

PM NOx


Diesel Particulate Filters needed for low PM emissionsDiesel Particulate Filters needed for low PM emissions-- WallWall--flow monolith filters as primary choice of industryflow monolith filters as primary choice of industry

• Honeycomb substrate with checkerboard plugging

• PM trapped on/inside walls

• Periodic regeneration of combustible fraction of the PM

© Corning Inc.© Corning Inc.

Source: Diesel Technology Forum websiteSource: Diesel Technology Forum website


Ash accumulation in DPFAsh accumulation in DPF-- NonNon--combustible fraction of PM accumulates in the filtercombustible fraction of PM accumulates in the filter

•• Typical Ash components areTypical Ash components are– Sulfates, phosphates, oxides of calcium, zinc, magnesium etc

• formed by combustion of lubricating oil additives like detergents, acid neutralizers, anti-wear agents, corrosion inhibitors …

– Metal oxides (Fe, Cu, Cr, Al) from wear • From the engine or the exhaust system

•• Ash accumulation & composition varies significantly, depending uAsh accumulation & composition varies significantly, depending uponpon– engine type and runtime– Operating conditions,– type of fuel & additives, – lubricating oil & additives– metallurgy of the exhaust system components


Ash implication on performance & mitigationAsh implication on performance & mitigation• Accumulated ash increases the flow resistance through the filter

– Increased back pressure• Higher fuel consumption• Lower power output & dynamic response• Lower heat rejection (exhaust)

• Reduction of effective filter volume – Lower soot capacity

• Higher regeneration frequency

• Mitigation– Filter design

• Filter geometry • Channel geometry

– Periodic Ash cleaning


Asymmetric Cell TechnologyAsymmetric Cell Technology-- Channel design for improved ash storage capacityChannel design for improved ash storage capacity

• Larger inlet channel volume• Equal bulk density similar regeneration performance• Similar physical properties• Equal mechanical and thermo-mechanical durability

performance compared to Standard, due to proprietary design

• Potential to use a smaller filter volume


Service interval for DPFsService interval for DPFs-- Impact of DPF design aspectsImpact of DPF design aspects

Filter Volume

DPF

Cle

anin

g In

terv

al

ACT design

Standarddesign

Significant increase in service interval for ACT design than standard.


ObjectivesObjectives

Characterize Pressure drop with ash accumulation Characterize Pressure drop with ash accumulation for DuraTrapfor DuraTrap®® RC (onRC (on--engine)engine)

Demonstrate performance benefit of ACTDemonstrate performance benefit of ACT

Evaluate the impact of long term engine exposure Evaluate the impact of long term engine exposure on material stability/durabilityon material stability/durability


MaterialsMaterials-- DPFs evaluated in current studyDPFs evaluated in current study

–– DuraTrapDuraTrap®® RC RC •• Uncatalyzed Uncatalyzed •• Filter Volume :17 LitersFilter Volume :17 Liters•• Filter dimensions Filter dimensions

ØØ10.510.5””x12x12””•• ddh,inleth,inlet / d/ dh,outleth,outlet = 1.0= 1.0

–– DuraTrapDuraTrap®® RC ACT*RC ACT*•• Uncatalyzed Uncatalyzed •• Filter Volume :17 LitersFilter Volume :17 Liters•• Filter dimensions Filter dimensions

ØØ10.510.5””x12x12””•• ddh,inleth,inlet / d/ dh,outleth,outlet = 1.3= 1.3

INLET CHANNEL

OUTLET CHANNEL

DuraTrap®RC 200 19 27 0.053 0.053

DuraTrap®RC ACT* 270 16 34 0.051 0.038

Cell Diameter [in.]Design/Geometry Cell Density

[CPSI]

Web Thickness

[mils]Inlet OFA [%]


Test Cells specificationsTest Cells specificationsAsh Loading Test Cell:Ash Loading Test Cell:

Cummins N14 Cummins N14 –– 6 cylinder6 cylinder--InlineInline–– Rated Power :460 HP @ 1800RPMRated Power :460 HP @ 1800RPM–– Torque at rated : 1300lbTorque at rated : 1300lb--ft.ft.

•• MidMid--west Eddywest Eddy--current Wetcurrent Wet--gap dynamometergap dynamometer

•• UEGO SensorsUEGO Sensors

Characterization Test Cell:Characterization Test Cell:Volvo D12 (MY2003)Volvo D12 (MY2003)

–– 6 Cylinder6 Cylinder--InlineInline–– Rated Power :460 HP @ 1800RPMRated Power :460 HP @ 1800RPM–– Torque at rated : 1300lbTorque at rated : 1300lb--ft.ft.

•• MidMid--west Eddywest Eddy--Current WetCurrent Wet--Gap dynamometerGap dynamometer•• UHEGO SensorsUHEGO Sensors•• EmissionsEmissions--RawRaw ((CO, CO2, NO/NOx, O2,THC)CO, CO2, NO/NOx, O2,THC)


System laySystem lay--out for DPF evaluationout for DPF evaluation

CDPF(∅10.5”x12”)

DOC(∅10.5”x6”)

AirAir

Crankcase Crankcase ventilationventilation

IntercoolerIntercooler

LFELFE

TurboTurbo SFISFI

AirAir

Crankcase Crankcase ventilationventilation

IntercoolerIntercooler

LFELFE

TurboTurbo SFISFI


Ash accumulation cycleAsh accumulation cycle-- accelerated by load profile and low DPF volume/engine power outaccelerated by load profile and low DPF volume/engine power outputput-- high load factor ~0.74; >70% of accumulation time in Mode 3 high load factor ~0.74; >70% of accumulation time in Mode 3

0 1 2 3 4 5 6 7 8 9 100

500

1000

1500

2000

0 1 2 3 4 5 6 7 8 9 100

500

1000

1500

2000

0 1 2 3 4 5 6 7 8 9 100

10

20

30

Time [Hours]

Speed[RPM]

Torque[lb-ft]

Exh. Flow[Kg/hr]

DPF Inlet Temp[°C]

∆p[kPa]

Mode 1

Mode 3

Mode 2 Mode 4SF I SF I


0

5

10

15

20

25

30

35

40

0 50 100 150 200 250 300Ash Cycle Number

∆p

[kPa

]

Mode 1 (High Speed Low Load)Mode 2 (Med. Speed Med. Load w/SFI)Mode 3 (High Speed High Load)Mode 4 (Med. Speed Med. Load w/SFI)

Pressure drop development with ash accumulation Pressure drop development with ash accumulation -- Initial pressure drop increase moderate Initial pressure drop increase moderate -- More pronounced pressure drop impact with higher cycle number More pronounced pressure drop impact with higher cycle number

Failed Failed injectorinjector

DuraTrap ® RC-ACT


Ash accumulation vs. Oil ConsumptionAsh accumulation vs. Oil Consumption-- Ash accumulation tracks well with oil consumptionAsh accumulation tracks well with oil consumption-- Ash finding rate in the DPF about 55Ash finding rate in the DPF about 55--60%60%

0

200

400

600

800

1000

1200

0 20000 40000 60000 80000 100000 120000 140000Cummulative Oil Consumption [g]

Cum

mul

ativ

e A

sh a

ccum

ulat

ed [g

]


Reason for lower ash finding rateReason for lower ash finding rate

0.8890.921Sulfur Content, wt%1.831.69Ash Content, mass %

Aged (500 hrs) Ash OilFresh Ash Oil

0.1

1

10

100

1000

10000

Al Sb Ba B Ca Cr Cu Fe Pb Mg Mn Mo Ni P Si Ag Na Sn Zn K Sr V Ti Cd

Fresh Ash Oil Aged (~500 hrs) Ash Oil

PPM


Pressure Drop: Pressure Drop: Fundamental InfluencesFundamental Influences

Exhaust gas

Exhaust gassootash

1

Key Parameter Filter characteristics

1 Inlet losses (Contraction) Mainly OFA Geometry

Contribution

3 Frictional losses from flow through wall and soot & ash layer

Permeability of wall (also fraction of soot & ash), wall thickness, filtration area Wall properties & geometry

3

4 Frcitional losses along the outlet channel wall Mainly hydraulic diameter of channel, length Geometry

4

5 Outlet losses (Expansion) Mainly OFA Geometry

5

2

2 Frictional losses along the inlet channel walls Mainly hydraulic diameter of channel, length Geometry


0

5

10

15

20

25

30

35

500 1000 15000

5

10

15

20

25

30

35

500 1000 15000

5

10

15

20

25

30

35

500 1000 1500

DuraTrap®RC ACT

0

2

4

6

8

10

12

14

0.0 2.0 4.0 6.0 8.0

DuraTrap® RC 200/19

Ø10.5"x12"

Pressure drop effectsPressure drop effects-- Geometric and microGeometric and micro--structural impactstructural impact

0

2

4

6

8

10

12

14

0.0 2.0 4.0 6.0 8.0

DuraTrap® RC ACT 270/16

DuraTrap® RC 200/19

Ø10.5"x12"

No Ash

∆p [k

Pa] @

1250

m³/h

r & 2

00°C

Soot Load [g/l]

DuraTrap®RC

∆p [k

Pa] @

200°C

Exhaust Flow [m³/hr]

6g/l Soot

3g/l Soot

0g/l Soot


Pressure Drop as a function of FlowPressure Drop as a function of Flow-- Increasing advantage of ACT design at all operating flows with Increasing advantage of ACT design at all operating flows with increasing increasing ash & soot in the filterash & soot in the filter

0g/l Ash0g/l Ash

0

5

10

15

20

25

30

35

500 1000 15000

5

10

15

20

25

30

35

500 1000 15000

5

10

15

20

25

30

35

500 1000 1500

DuraTrap®RC ACT

0

5

10

15

20

25

30

35

500 1000 1500

DuraTrap®RC ACTDuraTrap®RC

∆p [k

Pa] @

200°C


DuraTrap®RC

∆p [k

Pa] @

200°C


6g/l Soot

3g/l Soot

0g/l Soot

40g/l Ash40g/l Ash

0

5

10

15

20

25

30

35

500 1000 1500

∆p [k

Pa] @

200

°C


DuraTrap®RC ACTDuraTrap®RC DuraTrap®RC ACTDuraTrap®RC

6g/l Soot

3g/l Soot

0g/l Soot

0

5

10

15

20

25

30

35

500 1000 1500

∆p [k

Pa] @

200

°C


DuraTrap®RC ACTDuraTrap®RC DuraTrap®RC ACTDuraTrap®RC

6g/l Soot6g/l Soot

3g/l Soot3g/l Soot

0g/l Soot0g/l Soot


0

5

10

15

20

25

30

0 10 20 30 40 50 60Cummulative Ash Level [g/L]

Pres

sure

Dro

p [k

Pa] @

125

0m³/h

r & 2

00°C

∆∆p increase with ash loadingp increase with ash loading–– Higher pressure drop for ACT in the clean stateHigher pressure drop for ACT in the clean state–– Roughly 30% increase in the ash capacity with ACT design Roughly 30% increase in the ash capacity with ACT design

0g/l 0g/l SootSoot

6g/l 6g/l sootsoot

Ash membrane prevents Ash membrane prevents deep bed filtrationdeep bed filtration

AshAsh

Reduction in effective Reduction in effective filter volume due to filter volume due to increasing ash plug increasing ash plug AshAshAshAsh

Rapid increase Rapid increase in PD due to in PD due to significant significant reduction in dreduction in dhhwith soot due to with soot due to ashash AshAsh


Detailed view of the bottomDetailed view of the bottom-- Low density ash/voids present in between ash plugsLow density ash/voids present in between ash plugs-- Lower concentration of high density ash in near skin channelsLower concentration of high density ash in near skin channels

Skin

AA

D

B

11””

C

A

D

B

11””

C

A

BB CC DD

OutletOutlet

44””

DuraTrapDuraTrap®® RCRC


Inle

t

Out

let

Ash distribution evaluation after dissectionAsh distribution evaluation after dissection-- Large low density ash plug near the outlet of the filter Large low density ash plug near the outlet of the filter -- High density ash layer on the wall (increasing from inHigh density ash layer on the wall (increasing from in-- to outlet)to outlet)

DuraTrapDuraTrap®® RCRC--ACTACT


Chemical Analysis of ash in the filterChemical Analysis of ash in the filter-- Similar ash composition over the length of the filterSimilar ash composition over the length of the filter

0.01

0.1

1

10

100

Al Ca Fe Mg Mn P Pd Zn

%w

t.

Inlet Middle Outlet


Time Temperature distributionTime Temperature distribution--1720 on engine hrs. [DuraTrap1720 on engine hrs. [DuraTrap®® RC] >> equivalent to number of regenerations for ~300k milesRC] >> equivalent to number of regenerations for ~300k miles-- 2640 on engine hrs. [ACT] >> equivalent to number of regenerati2640 on engine hrs. [ACT] >> equivalent to number of regenerations for ~420k milesons for ~420k miles

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

0 200 400 600 800 1000Temperature[°C]

Cum

mul

ativ

e Ti

me

[H]

DuraTrap®RC - 200/19DuraTrap®RC- ACT -270/16

0.0001

0.001

0.01

0.1

1

10

100

1000

0-100

100-2

0020

0-300

300-4

0040

0-500

500-6

0060

0-700

700-8

0080

0-900

900-1

000

Temperature [°C]

Tim

e [H

]

DuraTrap®RC-200/19 DuraTrap®RC- ACT -270/16

DPF

1111””

DPF

1111””


PostPost-- testing physical Integritytesting physical Integrity-- Both filters showed no integrity degradationBoth filters showed no integrity degradation

Shown: DuraTrapShown: DuraTrap®® RC ACTRC ACT


Smoke Number Smoke Number -- DuraTrapDuraTrap®® RC ACT filterRC ACT filter-- excellent filtration performance over ash accumulationexcellent filtration performance over ash accumulation-- filtration improves with ash accumulationfiltration improves with ash accumulation

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0 10 20 30 40 50 60Ash load [g/l]

FSN

[-]

Soot slip during clean-out650-700ºC


Summary & ConclusionSummary & Conclusion• On-engine ash accumulation testing of DuraTrap® RC

– Highest oil consumptions at high speed & load– Lube oil consumption linearly correlated to ash acc. in DPF– Lifetime ∆p for DPF includes three phases:

• Conditioning, filter volume reduction, inlet channel throttling

• Successful demonstration (on-engine) durability of DuraTrap® RC filters• Std: 1720 engine hours [regen. equivalent of ~300Kmiles]• ACT: 2640 engine hours [regen. equivalent of ~420Kmiles]

• 30% ash storage advantage of DuraTrap® RC 270/16 ACT compared to standard design


ReferencesReferences• Young D M, et. Al., “Ash Storage Concept for Diesel

Particulate” SAE 2004-01-0948• Merkel G A, et al., “Thermal durability of wall-flow ceramic

diesel particulate filters” SAE 2001-01-0190• Diesel Technology Forum website

http://www.dieselforum.org• EPA – website http://www.epa.gov

-- Krishna AravelliKrishna Aravelli

Improved Lifetime Pressure Drop Management For DuraTrap® RC … · 2014-03-10 · Krishna...

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