1

High Efficient SCR for SCR only Applications for NRMM

Rolf Brück, Emitec GmbH

Introduction

Challenges to achieve high efficient SCR

SCR Dosing System

Evaporation and Mixing Pipe

Close coupled compact SCR-System

Conclusion

Agenda

Heavy Duty /NRMM – Emission Standards (ETC) & -

Technology Shift of Priorities P

M [

mg

/kW

h]

NOx [g/kWh] 1

60

30

4 2 6

EU V EU IV

0 3

Engine Technology

EU VI; NRMM >130 kW Stage 3 B

NRMM EU Stage IV

SCR 80 % NRMM Stage IIIB (2012)

NRMM EU IIIB

SCR 80 % EU VI

Heavy Duty /NRMM – Emission Standards (ETC) & -

Technology Shift of Priorities P

M [

mg

/kW

h]

NOx [g/kWh] 1

60

30

4 2 6

EU V EU IV

0 3

Engine Technology

EU VI; NRMM >130 kW Stage 3 B

NRMM EU Stage IV

SCR 80 % NRMM Stage IIIB (2012)

NRMM EU IIIB

EU VI

Heavy Duty /NRMM – Emission Standards (ETC) & -

Technology Shift of Priorities P

M [

mg

/kW

h]

NOx [g/kWh] 1

60

30

4 2 6

EU V EU IV

EU VI

0 3

Engine Technology

EU VI; NRMM >130 kW Stage 3 B

NRMM EU Stage IV

NRMM EU IIIB

SCR >92 -95 %

Introduction

Challenges to achieve high efficient SCR

SCR Dosing System

Evaporation and Mixing Pipe

Close coupled compact SCR-System

Conclusion

High Efficient SCR for SCR only Applications for NRMM

Challenges and demands for SCR- Emission control

technologies across various applications

Thermodynamic Challenges

Heat up during cold start low temperature condition

Start of AdBlue Injection

AdBlue-Decomposition

Challenges and demands for SCR- Emission control

technologies across various applications

Thermodynamic Challenges

Heat up during cold start low temperature condition

Start of AdBlue Injection

AdBlue-Decomposition

NH3/ NOx Uniformity

SCR “Light-Off”

SCR Conversion Limitation SCR Kinetic Limitation NH3/ NOx

Limitation NH3 storage

Challenges and demands for SCR- Emission control

technologies across various applications

Priorities

PC / LD / MD NEDC RDE /(NTE)

FTP

US06

JC08

Non-Road NRMM

NRSC

NRTC cold

NRTC.Warm

HD On-Road Steady State

ETC

WHTC cold

WHTC warm

FTP

JE05

Thermodynamic Challenges

Heat up during cold start low temperature condition

Start of AdBlue Injection

AdBlue-Decomposition

NH3/ NOx Uniformity

SCR “Light-Off”

SCR Conversion Limitation SCR Kinetic Limitation NH3/ NOx

Limitation NH3 storage

Priorities

PC / LD / MD NEDC RDE /(NTE)

++ +++

+ ++ + ++ >80

FTP ++ + ++ + ++ >80

US06 ++ + >80

JC08 ++ + ++ + ++ >80

Non-Road NRMM

NRSC ++ >95

NRTC cold + ++ ++ ++ ++ > 80

NRTC.Warm + ++ + > 95

HD On-Road Steady State + >93

ETC + ++ ++ >93

WHTC cold ++ ++ ++ ++ ++ >70

WHTC warm ++ ++ ++ ++ >80

FTP + + ++ ++ ++ >80

JE05 ++ + ++ ++ ++ >80

Thermodynamic Challenges

Heat up during cold start low temperature condition

Start of AdBlue Injection

AdBlue-Decomposition

NH3/ NOx Uniformity

SCR “Light-Off”

SCR Conversion Limitation SCR Kinetic Limitation of NH3/ NOx

Limitation NH3 storage

Challenges and demands for SCR- Emission control

technologies across various applications

Fundamantal Steps for AdBlue Decomposition

and Technology for System Optimization

1. Step: evaporation of Water: {(NH2)2CO •7H2O}fl {(NH2)2CO}fl + 7 H2O

2. Step: thermolysis of Urea: {(NH2)2CO}fl HNCO + NH3

3. Step: hydrolysis of isocyanic acid: HNCO + H2O CO2 + NH3

11

steps from AdBlue towards ammonia:

Adblue® droplet penetration on surface evaporation & thermolysis

1. + 2. reaction steps

AdBlue droplet interaction on surface

Technologies for Optimization: Hydrolysis: Usage of Hydrolysis Catalyst / Mixer NH3 – Distribution: Optimization of Mixing pipe and mixing

design

0

10

20

30

40

50

60

70

80

90

100

0 100 200 300 400

NO

x C

on

ve

rsio

n R

ate

[%

]

Temperature [°C]

NO2 / NO

50% / 50%

NO2 / NO

0% / 100%

Temperature

Range at low

load operation

0

1

2

3

4

5

6

Engine Out behind DOC behind SCRN

O,

NO

2 [

g/k

Wh

]

NO

NO2

NOx- SCR-Efficiency as Function of NO2-Ratio

12

Standard SCR- Reaction with NO: 4 NO + O2 + 4 NH3 4 N2 + 6 H2O

“fast“ SCR-Reaction with NO+NO2: 2 NO2 + 2 NO + 4 NH3 4 N2 + 6 H2O

Reaktionen bei der NOX – Reduktion durch SCR:

Emissions during ETC

- 30%

NO2

NO2

NO2

NO

Calculated NOx-Reduction and NH3 Slip as Function of

NH3-Uniformity and AdBlue-Dosing Rate

70

75

80

85

90

95

100

0,88 0,9 0,92 0,94 0,96 0,98 1

NOx-Reduction

NH3-Uniformity

Alpha = 1.00

Alpha = 0.95

Alpha = 0.90

Alpha = 0.80

0

10

20

30

40

50

60

0,88 0,9 0,92 0,94 0,96 0,98

NH3- Slip

NH3-Uniformity

Calculated NOx-Reduction and NH3 Slip as Function of

NH3-Uniformity and AdBlue-Dosing Rate

70

75

80

85

90

95

100

0,88 0,9 0,92 0,94 0,96 0,98 1

NOx-Reduction

NH3-Uniformity

Alpha = 1.00

Alpha = 0.95

Alpha = 0.90

Alpha = 0.80

80

85

90

95

100

0 5 10 15 20 25 30

NH3-Slip

NO

x-C

on

vers

ion

[%

]

short tube

long tube

NOx = 200ppm

DeNOx Performance as Function of NH3- Uniformity

SCR

AdBlue

DOC

SCR AdBlue

DOC short tube

long tube

Short tube

Long tube

Influence of System Design on NH3-Uniformity

and DeNOx- Performance

0

20

40

60

80

100

120

70 80 90 100

NH

3-s

lip

[p

pm

]

NOx-conversion [%] T= 410°C

NOx = 350 ppm

SV.SCR = 58.000 1/hr S-tube

straight tube

S-tube

straight tube

Introduction

Challenges to achieve high efficient SCR

SCR Dosing System

Evaporation and Mixing Pipe

Close coupled compact SCR-System

Conclusion

High Efficient SCR for SCR only Applications for NRMM

Emitec SCR-Dosing system Gen III

In Tank SCR-Dosing system

Gen III

Customized Tank for the application

Emitec Gen III System Description

All in One Integration

Suction lance

Temperature sensor

Urea filter

Level sensor

Tank heater

Heated suction line

External DCU

Installation cost:

Electrical harness

Fixing devices

Lines connections Quality sensor

Ringfilter

Electrical Connector

Connector to Injector

Emitec Dosing System Gen III; OutsideView

Pump

PTC Heater

Level-/Quality Sensor

Pressure Sensor

Pressure Control Valve

Electronic

Emitec Dosing System Gen III; InsideView

Introduction

Challenges to achieve high efficient SCR

SCR Dosing System

Evaporation and Mixing Pipe

Close coupled compact SCR-System

Conclusion

High Efficient SCR for SCR only Applications for NRMM

Mo

tor

Dre

hm

om

en

te

ng

ine

to

rqu

e

Motor Drehzahlengine speed

low temperature area

• fast start of dosing

• excellent evaporation of droplets

• low risk for depositions

+ static mixer

UDP + MX Metalit

+ Hydrolysis Catalyst

Thermal Challenges for AdBlue Injection within Engine Map

Engine Speed

Torq

ue

NOx Efficiency with Optimised Airless Dosing Layout

Summary of Sweep Test

86

88

90

92

94

96

98

100

0,85 0,9 0,95 1 1,05

NO

x E

ffic

ien

cy

Alpha (-) Test conditions: constant speed / torque

• constant temperature and massflow and exhaust gas

condition

• exhaust gas 714 kg/h, T = 420 °C, NOx = 543 ppm;

NO2/NOx = 0,27

theoretical AdBlue® demand for (alpha = 1) = 1100 ml / h

setup with Fe-Zeolithe catalyst [Ø242 x (110 + 110)] 10,1 ltr

dosing rate 1000 ml / h 1200 ml/h (alpha = 0,9 ... 1,1)

Introduction

Challenges to achieve high efficient SCR

SCR Dosing System

Evaporation and Mixing Pipe

Close coupled compact SCR-System

Conclusion

High Efficient SCR for SCR only Applications for NRMM

Compact SCR System for Heavy Duty and Non Road

Mobile Machineries

DOC LS/PE-Metalit®

Compact SCR System for Heavy Duty and Non Road

Mobile Machineries

AdBlue-Injector

DOC LS/PE-Metalit®

- Robust design

based on mass production

- gasoline injector

- Spray pattern can

adapted to application

Reductant Delivery Unit (Urea Injector)

Water Cooling for highest

Off Road demands

Compact SCR System for Heavy Duty and Non Road

Mobile Machineries

AdBlue-Injector

Mixing Element / Hydrolysis Catalyst DOC

LS/PE-Metalit®

Comparison of a Mixer / Hydrolysis Catalyst regarding

Deposits at Low Temperature AdBlue Injection

Variant 1 with

Mixing Element

Variant 2 with

Hydrolysis Catalyst

N= 1200 1/min; Md = 215 Nm

Exhaust Mass: 326 kg/h; T = 230°C

AdBlue-Dosage = 560 g/h, α = 0.8

Compact SCR System for Heavy Duty and Non Road

Mobile Machineries

AdBlue-Injector

Mixing Element / Hydrolysis Catalyst DOC

LS/PE-Metalit®

SCR- Catalyst LS-Metalit®

Compact SCR System for Heavy Duty and Non Road

Mobile Machineries, Demonstrator

close coupled

DOC + 1. stage SCR

2.Stage

SCR

SCR only System Layout

Motor

DOC (2,2 ltr) static mixer

SCR 1 (6,5 ltr)

SCR 2 (4,0 ltr)

close coupled

NOx T NOx T

NOx

1. Stufe 2. Stufe

0 Total velocity [m/s]

10

Flow / NH3 Distribution @ Close Coupled SCR Catalyst

UI = 0,96

Cumulated NOx Emissions at alfa = 1 during NRTC

0 2 0 0 4 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0

0

1 0 0

2 0 0

3 0 0

0

5

0 . 0

3 0 . 0

6 0 . 0

9 0 . 0

time [s]

Acu

mu

late

d N

Ox [

g]

Acu

mu

late

d N

Ox [

g]

Acu

mu

late

d A

dB

lue [

g]

AdBlue-Mass

NOx Tailpipe

NOx after 1. Stage

NOx engine out

Accumulated NOx Emissionen after 1st and 2nd SCR Stage

during NRTC Test

1. SCR Stage

2.SCR Stage

post SCR 2

94,6 %

91,1 %

0 2 0 0 4 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0

0

3 0

6 0

9 0

0

3

time [s]

Acu

mu

late

d N

Ox [

g]

Acu

mu

late

d N

Ox [

g]

Total NOx Reduction and NH3 Slip during NRTC Test

Tailpipe

NH3 concentration

(no NH3 slip catalyst)

SCRa

94,6 %

time [s]

0 2 0 0 4 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0

0

3 0

6 0

9 0

0

1 0 0

NH

3 [

pp

m]

Acu

mu

late

d N

ox [

g]

Introduction

Challenges to achieve high efficient SCR

SCR Dosing System

Evaporation and Mixing Pipe

Close coupled compact SCR-System

Conclusion

High Efficient SCR for SCR only Applications for NRMM

Splitting of the Functions: Hydrolysis and NOx-Reduction

H-Kat H-Kat

MX MX

DEF (fluid) [(NH2)2CO•7H

2O]fl

gaseous NH3 + CO2 + H2O

Slip-Cat

Red

. C

at

LS

/PE

R

ed.

Ca

t L

S

Red

. C

at

LS

Hydrolysis-Function ☺

D 934 D 936 D 856 D 9508

One System Layout for several Engines and Applications

LTM Ober- / Unterwagen

LB LTR LR LRB LRS LHM HS

LPS HPS 2 Sizes of exhaust systems

~ 50 Applications

1 Pump 1 Injector

41

High Efficient SCR for SCR only Applications for NRMM

Rolf Brück, Emitec GmbH