Solid SCRSolid SCR Demonstration Truck ApplicationDemonstration Truck Application

MarekMarek

TaturTatur, Dean , Dean TomazicTomazic

––

FEV Inc.FEV Inc. FigenFigen

LacinLacin, Henry Sullivan, Adam , Henry Sullivan, Adam KotrbaKotrba

––

TennecoTenneco

Solid SCR Demonstration Vehicle Presentation Outline

Introduction SCR and SSCR Basics SSCR System Layout 1st

Generation

2nd

Generation

Test Results Bench Setup Vehicle

Summary

Solid SCR Demonstration Vehicle Introduction

Project ObjectiveDemonstrate the feasibility and performance of the

FEV Solid SCR (Ammonium Carbamate) Technology, retrofitting a 2004.5 Dodge Ram and measuring emissions reductions in steady state and transient conditions both in the lab and real-world environments

Solid SCR Demonstration Vehicle Introduction

SCR Technology Basics

CyanuricAcid

(HNCO)3

Pyrolysis: +

Sublimation

CyanuricAcid

(HNCO)3

Pyrolysis: +

Sublimation

AmmoniaCarbamate

NH4 CO2 NH2

Subl

imat

ion

Pyro

lysi

s:

+

AmmoniaCarbamate

NH4 CO2 NH2

Subl

imat

ion

Pyro

lysi

s:

+

Urea (NH2)2 CO

HNCO AmmoniaNH3Hydrolysis: + H2O

Pyrolysis: +

Pyrolysis: +

The designation SCR refers to Selective Catalytic Reduction technologies relying on ammonia as the reductant. Since ammonia is difficult to handle on a vehicle, reductantsthat form ammonia under exhaust gas conditions are preferably used for vehicle application purposes:

Hydrolysis: + H2 O

Solid SCR Demonstration Vehicle SCR Basics

Ammonium Carbamate

air

liquid NH3

Reactor

high pressure air supply

urea for further processing

CO2

Ammonium carbamate

is produced directly from CO2 and ammonia

at about 180 bar and 230°C 2NH3 + CO2 (NH2-CO2)-(NH4)

Ammonium carbamate

is a byproduct of urea production. As base for the production of urea liquid ammonia and gaseous CO2 are being used.

Both products are introduced into a reactor. The reactor walls of this more than 27 m high tower consist basically out of two metals. The outer layer is made from carbon steel and the inner layer is stainless steel with a wall thickness of about 6 mm.

Solid SCR Demonstration Vehicle SCR Basics

Ammonium Carbamate

Under heat (~ 230°C) and pressure (~ 180 bar) ammonium carbamate

is formed. Utilizing dehydration in presence of acid and heat ammonia carbamate

is converted in urea and water. Additional dehydration and processing produces a white granulate.

Solid SCR Demonstration Vehicle SCR Basics

Mass / 1g NO

Volume @ Density

Pure Ammonia (liquid Phase):

0.57 g

0.93 cm³

@ 0.61 g/cm³

Solid Urea:

1 g

0.75 cm³

@ 1.34 g/cm³

Urea / Water Solution (34.4% / 65.6%):

2.9 g

3.0 cm³

@ 0.97 g/cm³

Ammonia Carbamate:

1.3 g

0.81 cm³

@ 1.6 g/cm³

Metal Ammine 1.2 g

1.0 cm3

@ 1.2 g/cm3

MetalAmmines

108 %81 % 323 % 87 %

Solid Urea AmmoniaCarbamate

AdBlueLiquid

Ammonia

100 %

In order to fulfill the demand for AdBlue refill within reasonable (service) intervals and e.g. also fulfill legislative demands, quite large

AdBlue storage volumes are required

In order to fulfill the demand for AdBlue refill within reasonable (service) intervals and e.g. also fulfill legislative demands, quite large

AdBlue storage volumes are required

Solid SCR Demonstration Vehicle SCR Basics

First Generation System

SCR Catalyst

µ-Controller

Pump

Exhaust Gas

GaseousReductant

Pressure-

and/orTemperature TransmitterSolid

Reductant

Heat Transfer Medium

HeatExchangerSupply Pipe

Container

Dosage Valve

Solid SCR Demonstration Vehicle SSCR System Layout

System Comparison 1st

Generation

Solid SCR Demonstration Vehicle SSCR System Layout

Solid Reductant Container w/ PTFE Isolation

Control Unit with PTFE Isolation

100 mm

130 m

m

V

1 L

Solid SCR Demonstration Vehicle SSCR System Layout

System Comparison 2nd

Generation

All used sensing components are automotive production parts, i.e. heater is cabin heater, temperature sensors are RTD’s,

pressure sensors are differential pressure and boost pressure sensors

System Installation 2nd

Generation

Reactor

Feed Pipe and Dosing Valve

Pressure/TemperatureSensor

Pump Housing

Heater

Solid SCR Demonstration Vehicle SSCR System Layout

Solid SCR Demonstration Vehicle SSCR System Layout

System Comparison

New dosing valve is embedded in the heat transfer medium

Valve has the same temperature as the oil

No dosing valve heater necessary

Old dosing valve was outside the reactor

Extra dosing valve heater was necessary

1st

Generation

2nd

Generation

Solid SCR Demonstration Vehicle SSCR System Layout

System Comparison

NH3 feed line

2nd

Generation

1st

Generation

NH3 feed line

Unheated spots and elbows can cause line

plugging

Straight lines, all heated internals including valves

and lines

2nd

Generation System operates without:

Amplifier

AADI Box

Thermocouple Transformer Unit

ES 1000

Solid SCR Demonstration Vehicle SSCR System Layout

System Comparison

Tem

pera

ture

[°C

]

20

30

40

50

60

70

80

90

100

Syst

em P

ress

ure

[mB

ar]

800

1100

1400

1700

2000

2300

Time [s]0 100 200 300 400 500 600 700 800

Diff

eren

tial P

ress

ure

[mba

r]

500

750

1000

1250

1500

System Temperature System Pressure Differential Pressure

Bench Test Results:

warm up (working fluid: diesel)Pump onHeater on Reactor activated Dosing valve open

System pressure

Differential Pressure

NH3 activation temperature

Solid SCR Demonstration Vehicle Test Results

Solid SCR Demonstration Vehicle Test Results

Initial Vehicle Results with 2nd

Generation SystemN

Ox

Con

vers

ion

[%]

0

10

20

30

40

50

60

70

80

90

100

Time [%]0 10 20 30 40 50 60 70 80 90 100

City Driving Freeway Driving Highway Driving

n

M

n

M

n

M

Solid SCR Demonstration Vehicle Summary

SSCR system proved to be functional in vehicle environment

Transition from 1st

to 2nd

generation

successfully completed Refinement of 2nd

generation currently

ongoing First test data indicates acceptable

conversion efficiencies with new hardware

Chassis dynamometer tests to validate the system performance

The authors of this presentation would like to thank

Jason Jaques

of UMICOREfor providing technical support and the

catalyst hardware and

Ark Kalinowski

et al. of PI Shurlockfor assisting in the controls development in

this project