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SINOx Emissions Control ® Review on SCR Catalysts Dr.- Ing. Bernd Amon 3 rd Aaqius & Aaqius Paris’ Forum 28 Sep 2004, Paris & Strategies Solutions Control of diesel emissions: 2 SINOx ® Emissions Control Automotive Applications / BA / 2004-09-28 Content Introduction - About SCR Technology “Euro4” SCR Systems - Current Status Advanced SCR Technology Combined Emission Control Strategies • Conclusions 3 SINOx ® Emissions Control Automotive Applications / BA / 2004-09-28 About SCR Technology SCR (Selective Catalytic Reduction) is a well-established and well-known technology to reduce exhaust emissions in various stationary applications all over the world Automotive Application 4 SINOx ® Emissions Control Automotive Applications / BA / 2004-09-28 Strategies to Reduce Diesel Emissions Europe PM [g/kWh] EU 3 (2000) 0.16 0.12 0.08 0.04 1 2 3 4 5 NO x [g/kWh] EU 5 (2008) EU 4 (2005) BSFC SCR SCR EGR DPF BSFC NOx / PM / BSFC Tradeoff
Transcript

1

SINOx Emissions Control®

Review on SCR Catalysts Dr.- Ing. Bernd Amon

3rd Aaqius & Aaqius Paris’ Forum28 Sep 2004, Paris

&Strategies SolutionsControl of diesel emissions:

2

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

Content

• Introduction - About SCR Technology

• “Euro4” SCR Systems - Current Status

• Advanced SCR Technology

• Combined Emission Control Strategies

• Conclusions

3

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

Power Plants

Gas Turbines

Marine Engines

Stationary Engines

About SCR Technology

SCR (Selective Catalytic Reduction) is a well-established and well-known technology to reduce exhaust emissions in various stationary applications all over the world

Automotive Application

4

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

Strategies to Reduce Diesel Emissions

Europe

PM[g/kWh]

EU 3 (2000)

0.16

0.12

0.08

0.04

1 2 3 4 5

NOx[g/kWh]

EU 5 (2008) EU 4 (2005)

BSFC

SCR SCR

EGR

DPF ∆ BSFC

NOx / PM / BSFC Tradeoff

2

5

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

Impact of Emission Control Strategies on Fuel Consumption and Operation Costs

Fuel Consum ption Euro 4

105

93100 102

60

70

80

90

100

110

120

Euro 3 EGR +DPF

SCR LNT +DPF

BSFC

[%]

Fuel Consum ption Euro 5

107

94100

107

60

70

80

90

100

110

120

Euro 3 EGR +DPF

SCR LNT +DPF

BSFC

[%]

Assumptions:• Fuel Consumption Baseline: 33 l/100km• Lifetime of Truck: 500.000 km• Costs: Diesel: 0,90 €/l;AdBlue: 0,65 €/l• Urea / Fuel for SCR (Euro5): ∼ 6%

Fuel penalty LNT+DPFFuel benefit SCR

Urea consump. Cost advantage

∼10,000 €∼9,000 €

∼6,500 € ∼12,500 €S

ourc

e: A

CE

A R

epor

t , A

CEA

, 200

3

6

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

Diesel Engine

EDC

SCR-Cat.

SCR SystemAdBlue

Dosing Tank

NOx, O2

AdBlue(NH2) 2CO Cleaned

Exhaust

N2, H2O

Exhaust

HC, PM HC, PM

Function of SCR SystemAnnouncement of ACEA (July 2003):„The European heavy-duty commercial vehicle manufacturers have finally chosen SCR technology to comply with ...Euro4 and Euro5.“• Optimum reliability• Stable performance and extended durability• Compatibility with engine technology and other aftertreatment devices• And above all high effectiveness at reasonable costs

7

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

SCR Components on the TruckSINOx®

SCR Catalyst

Urea Tank with Pump Unit Urea Nozzle to Exhaust Pipe

Urea Metering Unit

Compressed Air Supply

8

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

NOx Reduction - European Steady State Cycle (ESC)

0

500

1000

1500

2000

2500

3000

1 2 3 4 5 6 7 8 9 10 11 12 13

0

10

20Mode

Diesel engine: 12l, 330 kW / SCR Catalyst: 300 cpsi, 26.4 ltr., w/o oxid. and slip cat

NH3 [

ppm]

NOx [

g/h]

NOx before catalyst: 9.2 g/kWhNOx after catalyst: 1.9 g/kWh

NOx reduction: 79%

3

9

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

0 300 600 900 1200 1500 1800

NOx Reduction - European Transient Cycle (ETC)

NH3 [

ppm]

NOx [

g/h]

1000

2000

3000

0

10

NOx before catalyst: 11 g/kWhNOx after catalyst: 2.3 g/kWh

NOx reduction: 81%

Time [sec]

Diesel engine: 12l, 330 kW / SCR Catalyst: 300 cpsi, 26.4 ltr., w/o oxid. and slip cat

10

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

NOx Reduction - European Steady State Cycle (ESC)

0

500

1000

1500

2000

2500

1 2 3 4 5 6 7 8 9 10 11 12 13

0

10

20Mode

Diesel engine: 12l, 290 kW / SCR Catalyst: 300 cpsi, 35 ltr., w/o oxid. and slip cat

NOx before catalyst: 7.5 g/kWhNOx after catalyst: 0.9 g/kWh

NOx reduction: 88%

NH3 [

ppm]

NOx [

g/h]

11

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

SCR Components on a Passenger Car

Exhaust systemOxydation catalyst Urea tank

SCR catalyst

Urea nozzle

Cat. Housing

12

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

NOx Reduction - Passenger Car Application

NOx-e

miss

ion [%

]

EUDC NEDC

-80 %-80 %

-65 %-65 %

100

80

60

40

20

0

Engine out emissionwith SCR

-77%-77%

NEDC

Engine with optimised calibration

Engine without optimised calibration

4

13

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

Advanced SCR Technology

• Euro 4: conservatively designed SCR catalyst volume due to an open loop control configuration; uncertainties like estimation of NOx engine out emissions, urea injection pump metering error, etc. must be covered.

Diesel Engine

EDC

SCR-Cat.

SCR SystemAdBlue

Dosing Tank

• Introduction of 2nd generation SCR systems:Sensors (NH3 or NOx) will allow better NOx performance of given SCR systems by enhancing the dosing control strategies.

NOx/NH3SensorNOx

Sensor

14

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

Development of NOx and Ammonia Sensors

Source: Siemens/NGK

Source: Delphi

NOx Sensor

Ammonia Sensor

On Road results (Class 8 truck; HD 12-ltr.) SINOx® SCR Catalyst + Prototype NOx Sensor from Siemens/NGK

Source: Ford, DEER Aug 2003

Comparison of Ammonia measured at tailpipe using FTIR with that predicted by the ammonia sensor

15

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

NOx Reduction with SCR closed loop control

open loop closed loop open loop closed loop

100

90

80

70

60

50

40

30

NOx c

onve

rsion

[%]

ESC ETC

Euro 4

Euro 5

Source: TNO, SAE 2004-01-0154

Calculated NOx conversion with open loop and closed loop control over different cycles

Increase in NOx conversion of approx. 15% (abs.)

16

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

Combined System DPF + SCR

Diesel Engine

EDC

SCR-Cat.

SCR SystemAdBlue

Dosing Tank

Reduction of > 80% NOxwith SCR

• SCR technology can be combined with various emission control technologies like EGR, DPF and Oxidation Catalyst

Filter System

Oxi-Cat. (opt.) DPF

Reduction of > 90% PMwith DPF

• Combined systems of SCR and DPF provide for highest conversion rates of PM and NOx to comply with post Euro 5, US 2007/2010 and Jap. PNLT Regulations

5

17

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

NOx/PM Reduction with Combined DPF/SCR System

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.1

EngineOut

SCR DPF +SCR

HC

[gr

/bhp

-hr]

81%99%

& HCare below the US 07 emission limits

FTP results of an Class 8 truck engine; HD 12-ltr. 4 valve/cyl. inline-6 Diesel engine(no EGR) + DPF + SINOx®-SCR-Catalyst

NOx

0

1

2

3

4

5

6

EngineOut

SCR DPF +SCR

NO

x [g

r/bhp

-hr]

82%

76%

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.1

EngineOut

SCR DPF +SCR

PM [

gr/b

hp-h

r]

22%

90%

& PM

18

SINOx® Emissions Control

Automotive Applications / BA / 2004-09-28

Conclusions

SCR is a feasible and well-proven technology to reduceDiesel emissions and make to use of fuel optimized engines

European HDV manufacturers have decided to use SCR to comply with Euro 4 (2005) and Euro 5 (2008) emissionregulations and reduce fuel consumption

For future emissions regulation in Europe, but also in US and Japan SCR in combination with filter technology offersa solution even for the most stringent emission limits

Use of NOx/Ammonia sensors will further improve NOx reduction efficiency of SCR technology


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