ACARP wall -flow DFP project - Coplin

1 © Confidential Orbital Corporation Ltd

September 2017

ACARP

Wall-Flow DPF Project

27th Mechanical Engineers Safety Seminar


Today’s presentation • Review some key findings from the ACARP

project(s) to develop wall-flow DPF tech

• Share particulate and emission results

Best approach to underground air quality is

point source control; ventilation is only a remedy

Today Tomorrow The Future


Australian Coal Industry Challenges

Underground coal mining has largely electrified many operations, but diesel

engines are still used for load-haul-dump (LHD) vehicles and man transporters.

<150oC • Tailpipe exhaust

• All surfaces

Ambient CH4 • Comply at elevated levels

• Shutdown at excessive levels

Pollutants • Particulate

• Ultra-fines

• Gaseous

Explosion Proof • Certification


About ACARP…

ACARP – Australian Coal Industry’s Research Program; formerly Australian Coal Association Research Program

Fundamental research projects

Applied research projects

Commissioned projects

A$0.05 per tonne

collected from all

black coal

produced in

Australia

Access to

R&D

taxation

rebates and

generated

research

Nominal

ACR budget

~$18m/year;

100% industry

funded

ACARP &

Industry Monitors • Bevan Kathage

• Shayne Gillett

• Steve Coffee

• Dr Bharath Belle

• Andy Withers


About Orbital…

• Over 30 years of experience in:

• Mechanical design and prototype

• Engine testing and development

• Electronic design and production

• Control system design

• Engine systems manufacture

• A track record of supporting

global customers

• ISO9001 quality assurance


Project Outline

ACARP project C25073 was proposed by industry

stakeholders seeking an exhaust aftertreatment solution that:

• Enhances worker health through improved underground

air quality; and

• Reduces operational costs associated with currently

implemented diesel particulate emissions systems.

2017 will see the industrialisation

of the system for commercial trials,

including a DPF monitoring system

▲ Typical Load-Haul-Dump (LHD) vehicle used in underground coal


What is a Wall-Flow DPF?

Images © Johnson Matthey Catalysts Inc.

2HC + O2 2CO

2 +H

2O

2CO + O2 2CO

2

2NO + O2 2NO

2

Oxidation

Chemistry

Wall-Flow Filter Technology


Removal of Soot via CCRT Regeneration

Images © Johnson Matthey Catalysts Inc.

1

2C + O2 2CO

2 ~600°C

2NO + O2 2NO

2 With coated filters

2

C + 2NO2 CO

2 + 2NO 250-300°C

3


Approach to Development

• Given explosion risks for product innovation in a

working coal mine an alternate approach to

development was adopted

• Characterisation of LHD operations in a working

mine were used to develop a series of real world

engine cycles for use during development

• Development was then undertaken off-line using a

state-of-the-art engine test facility, with hardware

transferred to the mine for confirmation testing

150oC


Developed Test Cycles

▲ Comparison of Regulatory and Fleet

Based profile of LHD engine operation

(Steady State engine testing points)

▼ Transient cycle representing a variety of

LHD operations in underground coal

mining composited into a single cycle

15%

15%

15%

10%

10%

10%

10%

15%

50%7 Mode

9%

4% 3%

13%

15%

6%

53% 8 Mode

9% 13% 12% 5%

3%

2%

3%

-100

100

300

500

700

900

1100

1300

500 700 900 1100 1300 1500 1700 1900 2100 2300 2500

En

gin

e T

orq

ue

(N

m)

Engine Speed (rpm)

NRSC (ISO 8178 C1, Regulatory Cycle MDG43)

Custom 7 Mode Steady Cycle (fleet survey)

Custom 8 Mode Steady Cycle (fleet survey)

En

gin

e T

orq

ue (

Nm

)

Engine Speed (rpm)

0

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000

2100

2200

0

500

1000

1500

2000

2500

0 200 400 600 800 1000 1200 1400 1600 1800

Engi

ne T

orqu

e (N

m)

Engi

ne S

peed

(rpm

)

Cycle Time (s)

Engine Speed (rpm)

Engine Torque (Nm)

Laying Cable

Lightly loaded bucket

up incline

Raising heavilyloaded bucket

Draggingroad leveller

up incline

Unloadedup incline

Unloaded down decline

Cycle Time (s)

En

gin

e S

pee

d (

rpm

)

En

gin

e T

orq

ue

(N

m)


Heavy Duty Engine Development Facility

Data acquisition

(temp and press)

Exhaust

Extaction

Exhaust Flow

by Horiba PTFM

Gravimetric PM,

Partial Dilution

4x Samples

AC Dyno

for Transients

Water Brake Dyno

for Steady State

Floating testing

bed for vibration

dampening

Fire Suppression

System

Intake Air,

with optional LFE

Data acquisition

(custom and

high-speed)

Onosokki

Fuel Flow Meter

Horiba gaseous

emissions

(next room)

Underfloor

coolant control

Precision

Torque Flange

Underfloor

coolant control

Intake

intercooling

(also underfloor)

Intake

intercooling

(also underfloor)

Fuel Conditioning

LNG Flow Meter


PM reductions in excess of 95% over both

regulated and real world cycles with the selected DPF.

Results – Particulate Mass (PM2.5)

NRSC NRTC


▲ Conventional wet scrubber and

disposable filter system

▲ Proposed layout of the wall-flow filter system

meeting underground coal regulations

System Changes

Diesel Engine

Wet Exhaust

Scrubber Combination of water cooling and insulation to control surfaces below

150oC

Turbo D

OC

DP

F

Particle filtered exhaust, and below 150oC

Insulating jacket on DOC/DPF module to

control surface below 150oC

Combination of water cooling

and insulation to control surfaces

below 150oC

Diesel Engine

Wet Exhaust

Scrubber

Filter Basket

Optional oxidation catalyst

T u r b o

Particle filtered exhaust, and below 150oC

Water jacket on exhaust to control

surface below 150oC


System Surface Temperature

▲ Comparison of Proof-of-Concept CCRT DPF

with Insulated Surface Temperatures

▲ FLIR thermal images for 9.5”

Insulated DPF at 1200rpm Full-Load

(the highest EGT point; images

shown from Entry to Exit)

1 2

4 3


Project Milestones – Completed C25073 Project Activity

Phase 1 Part 1 - Onsite Duty Cycle Analysis and development of custom test cycles

Part 2 - Engine Setup/Baseline and Correlation to Real World

Part 3a - Hot System DOC+Filter

Phase 2 Part 3b - Preliminary (Aboveground) Site Trial (hot system)

Part 4 - P1 Design Engineering - Cold exo-surface DOC/Filter System

Part 5 - P1 Cold System PoC/Development P1 is first level prototype; where proof-of-concept is demonstrated.


Next Project Milestones – C26070 Project Activity

Phase 1 Part 6a - Industrialisation Design - DPF, pipework and basic monitoring

Part 6b - On-Engine Validation and Durability Testing of P2* system

Part 6c - Field Trial of P2* system incl. Support and Monitoring System Software Refinement

Phase 2 Part 7a - Emissions Certification Testing

Part 7b - Safety Certification Testing

* System level P2 is second level prototype; which will have the form, function and performance of

a production intent design but will not be made off production tooling/fixtures.


Newstan Surface Trial – July 2017


Summary

• ACARP C25070 has successfully demonstrated

that a wall-flow DPF system can be engineered to

meet the requirements of underground coal.

C26070 is continuing the work

• Characterisation of LHD operations in a working

mine were used to develop a series of real world

engine cycles for use during development

• Development was then undertaken off-line using a

state-of-the-art engine test facility, with hardware

transferred to the mine for confirmation testing

150oC


Acknowledgements: ACARP and Industry Monitors

Contact Info

Website: www.orbitalcorp.com.au Nick Coplin [email protected]

+61-8-9441-2379


www.orbitalcorp.com.au

+61-8-9441-2311

▲ CAD – Design Engineering ▲ CFD / FEA / Analysis

▲ Prototyping and Supply

▲ Fuel System Testing ▲ Alternative Fuels – NG, Bio ▲ Engine Test – 3hp to 800hp

▲ Vehicle Fitout & Modification ▲ Failure Analysis & Metrology

▲ Embedded Electronics

Date post:	22-Jan-2018
Category:	Government & Nonprofit
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ACARP wall -flow DFP project - Coplin

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