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SINOx Emissions Control®
Review on SCR Catalysts Dr.- Ing. Bernd Amon
3rd Aaqius & Aaqius Paris’ Forum28 Sep 2004, Paris
&Strategies SolutionsControl of diesel emissions:
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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
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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
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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
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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
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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
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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
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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
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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
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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]
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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
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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
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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
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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
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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.)
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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
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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
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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