ECT 2019Technologies & Solutions for upcoming Genset Applications

ECT 2019, Pune, November 13th, 2019Dr Alain Ristori

Agenda

• Umicore short introduction

• Global NRMM technical trend Worldwide

• CPCB IV + legislation update

• Main challenges for India

• What are the best system layouts for India (P>56kw)

2ECT 2019

Who we areA global materials technology and recycling group

One of three global

leaders in emission control

catalysts for light-duty and

heavy-duty vehicles and for

all fuel types

A leading supplier of key

materials for rechargeable

batteries used in electrified

transportation and portable

electronics

The world’s leading recycler

of complex waste streams

containing precious and other

valuable metals

3ECT 2019

4

Automotive Catalysts

Precious Metals Chemistry

CATALYSIS

Rechargeable Battery Materials

Cobalt & Specialty Materials

Electroplating

Electro-Optic Materials

ENERGY & SURFACE

TECHNOLOGIES

Precious Metals Refining

Precious Metals Management

Jewelry & Industrial Metals

RECYCLING

Who we areOur Group structure

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5

Automotive Catalysts

Precious Metals Chemistry

CATALYSIS

Who we areAutomotive catalysts – global catalyst market

ECT 2019

Our driversGlobal emission legislation HDD nonroad

6ECT 2019

TREM/CEV IV TREM/CEV VTREM/CEV III

CPCB IV +

7

System layouts for genset worldwideUpcoming Systems with current and announced legislations (up to 2025)

560 kW

56 kW

19 kW

ECT 2019

Europe Stage V US Tier4b China Stage IV CPCB IV +

CPCB IV + (July 2021)

8

Test cycle conditions: steady state (D2-5 mode)

Overall very much comparable to Tier IVf/Stage IV

(Draft from March 2019)

Power (Kw) CO

(g/Kwhr)

HC

(g/Kwhr)

NOx

(g/Kwhr)

PM

(g/Kwhr)

Smoke

(m-1)

NH3

(ppm)

P < 8 3.5 7.5 0.3 0.7

8 ≤ P < 19 3.5 7.5 0.3 0.7

19 ≤ P < 56 3.5 4.7 0.03 0.7 25

56 ≤ P < 560 3.5 0.19 0.4 0.02 0.7 10

560 ≤ P < 800 3.5 0.19 0.67 0.03 0.7 10

ECT 2019

CPCB IV + (July 2021)

9

Test cycle conditions: steady state (D2-5 mode)

Overall very much comparable to Tier IVf/Stage IV

(Draft from March 2019)

Power (Kw) CO

(g/Kwhr)

HC

(g/Kwhr)

NOx

(g/Kwhr)

PM

(g/Kwhr)

Smoke

(m-1)

NH3

(ppm)

P < 8 3.5 7.5 0.3 0.7

8 ≤ P < 19 3.5 7.5 0.3 0.7

19 ≤ P < 56 3.5 4.7 0.03 0.7 25

56 ≤ P < 560 3.5 0.19 0.4 0.02 0.7 10

560 ≤ P < 800 3.5 0.19 0.67 0.03 0.7 10

ECT 2019

CPCB IV + (July 2021)

10

Test cycle conditions: steady state (D2-5 mode)

Overall very much comparable to Tier IVf/Stage IV

(Draft from March 2019)

Power (Kw) CO

(g/Kwhr)

HC

(g/Kwhr)

NOx

(g/Kwhr)

PM

(g/Kwhr)

Smoke

(m-1)

NH3

(ppm)

P < 8 3.5 7.5 0.3 0.7

8 ≤ P < 19 3.5 7.5 0.3 0.7

19 ≤ P < 56 3.5 4.7 0.03 0.7 25

56 ≤ P < 560 3.5 0.19 0.4 0.02 0.7 10

560 ≤ P < 800 3.5 0.19 0.67 0.03 0.7 10

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Incredible IndiaWhy is India a unique market?

Umicore confidential

• Today the power supply situation is still showing a deficit

• Can this be shortly solved even for the remote location?

Power Demand & Supply Imbalance…

Application Varieties…

• The range of application is quite large

• Telecom towers will contribute for a big amount of gensets

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One of the coldest place in the world with

temperature down to -45°C…

… but also one of the hottest in the world with temperature up to

+50°C in Rajasthan …

Kangchenjunga 8,586 m (28,169 ft)-SikkimKuttanad-Kerala−2.2 m (−7.2 ft)

Incredible IndiaWhy is India a unique market?

ECT 2019

End Customer Voices

Voices What it does mean to ATS

Fuel efficient Low back pressure

If possible no active temperature management (DeSOx & PM regeneration)

Good conversion performance at low temperature

Compact Design with high Power to

Weight Ratio

Compact Catalyst –High performance at high space velocities

Easily serviceable & low on

maintenance cost

Low or no down time due to ATS for malfunction indication

Low Adblue consumption

Competitive price Competitive catalyst technologies

State of the art technology for

operations in low/high ambient temp.

and high altitude

High and low temperature good activity required (DeNOx)

High Thermal robustness

ECT 2019

ATS Challenges

Genset

Duty Cycle

Legislative & statutory reqts.-

Noise/Canopy rise in

temp./Block loading/Bad

fuel

Cost of Ownership(Oil

Dilution(ODI)/Serviceability)

Zero Down time

End User Awareness

ATS Packaging

ECT 2019

Legislation cycle

15

Genset ISO 8178 -D2-Cycle

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• 5 engine operation points

• Torque variation from 10-100% at rated engine speed

• Reduced weighing factors for the extreme conditions

<200°C

500<T<600°C

Legislation cycle

up to 700°C

Application duty cycle

Inlet ATS T°

Legislation cycle

16

Genset ISO 8178 -D2-Cycle

ECT 2019

• 5 engine operation points

• Torque variation from 10-100% at rated engine speed

• Reduced weighing factors for the extreme conditions

<200°C

500<T<600°C

Legislation cycle

up to 700°C

Application duty cycle

Inlet ATS T°

Which SCR technologie for which application?

17

SCR Technology comparison

Example 1: no thermal management

ECT 2019

10% load 25% load 50% load 75% load 100% load 110% load

Inlet ATS T° V-SCR DOC + V-SCR DOC + FeSCR DOC + Cu-SCR

Average NOx conversion

needed for this

application

Te

chn

olo

gie

not sta

ble

at su

ch te

mp

era

ture

Te

chn

olo

gie

not sta

ble

at su

ch te

mp

era

ture

Te

chn

olo

gie

va

lidate

dfo

rsu

ch t

em

pe

ratu

reT

echn

olo

gie

va

lidate

dfo

rsu

ch te

mp

era

ture

Which SCR technologie for which application?

18

SCR Technology comparison

Example 1: no thermal management

ECT 2019

10% load 25% load 50% load 75% load 100% load 110% load

Inlet ATS T° V-SCR DOC + V-SCR DOC + FeSCR DOC + Cu-SCR

Average NOx conversion

needed for this

application

Te

chn

olo

gie

not sta

ble

at su

ch te

mp

era

ture

Te

chn

olo

gie

not sta

ble

at su

ch te

mp

era

ture

Te

chn

olo

gie

va

lidate

dfo

rsu

ch t

em

pe

ratu

reT

echn

olo

gie

va

lidate

dfo

rsu

ch te

mp

era

ture

• V-SCR cannot cover the high and low temperature points and is not stable at 110% load

• DOC + V-SCR bring additionnal benefit at low temperature but is not stable at 110% load

• DOC + Fe-SCR is not sufficiantly efficient at low temperature

• DOC + CuSCR is fulfilling all the criteria

• Only Cu-SCR and Fe-SCR technologies can survive to the 110% load if >600°C

10% load 25% load 50% load 75% load 100% load 110% load

Example 1Inlet ATS T°

Example 2Inlet ATS T°

Which SCR technologie for which application?

19

SCR Technology comparison

Example 2: with temperature management

ECT 2019

240°C

510°C

<600°C

10% load 25% load 50% load 75% load 100% load 110% load

Inlet ATS T° V-SCR DOC + V-SCR DOC + FeSCR DOC + Cu-SCR

Which SCR technologie for which application?

20

SCR Technology comparison (with and w/o NO2 generation from DOC)

Example 2: with temperature management

ECT 2019

Average NOx conversion

needed for this

application

Te

chn

olo

gie

va

lidate

dfo

rsu

ch te

mp

era

ture

Te

chn

olo

gie

va

lidate

dfo

rsu

ch te

mp

era

ture

Te

chn

olo

gie

va

lidate

dfo

rsu

ch te

mp

era

ture

Te

chn

olo

gie

va

lidate

dfo

rsu

ch te

mp

era

ture

10% load 25% load 50% load 75% load 100% load 110% load

Inlet ATS T° V-SCR DOC + V-SCR DOC + FeSCR DOC + Cu-SCR

Which SCR technologie for which application?

21

SCR Technology comparison (with and w/o NO2 generation from DOC)

Example 2: with temperature management

ECT 2019

Average NOx conversion

needed for this

application

Te

chn

olo

gie

va

lidate

dfo

rsu

ch te

mp

era

ture

Te

chn

olo

gie

va

lidate

dfo

rsu

ch te

mp

era

ture

Te

chn

olo

gie

va

lidate

dfo

rsu

ch te

mp

era

ture

Te

chn

olo

gie

va

lidate

dfo

rsu

ch te

mp

era

ture

• V-SCR cannot cover the low temperature point but may be sufficient for this application

• DOC + V-SCR can cover all load conditions

• DOC + Fe-SCR can cover all load conditions

• DOC + CuSCR is fulfilling all the criteria

• All technologies can fulfill the 110% load criteria if the temperature is lower than 600°C

Conclusion

• DOC+Cu-SCR is the best „one fit all layout“ but it is also…

… very sensitive to fuel quality

… high cost technology

• DOC+Fe-SCR is very efficient at high temperature but less efficient than Cu-

SCR at low temperature

• DOC+V-SCR is a very robust and cost effective solution but it does not fit to

all applications (high temperature resistant technologies on corrugated

substrates are limited to 600°C long exposure)

• V-SCR is a very robust, simple and cost effective solution. It can be used

case by case depending on both cold and hot operation points

ECT 2019

Thank you!