Value Analysis of Alternative Diesel Particulate Filter ... · August 4, 2009 DEER Conference, S....

August 4, 2009 DEER Conference, S. Majkowski 1

Value Analysis of Alternative Diesel Particulate Filter (DPF) Substrates for Future

Diesel Aftertreatment Systems

DEER ConferenceAugust 4, 2009

Steve MajkowskiGlobal Marketing Director -

Powertrain and Emissions

August 4, 2009 DEER Conference, S. Majkowski2

Outline

•

Regulations Driving New and Optimized Systems Architectures•

Aerify™

Acicular Mullite Diesel Particulate Filter •

Case 1 –

Heavy-Duty Engine•

Case 2 –

Light-Duty Engine


Tightening Emissions Regulations Drive Engine Management and Aftertreatment

Euro III – 2008.01

Euro IV – 2010.01?Euro V – 2012.01?

Euro VI – ?

Euro III – 2008.01

Euro IV – 2010.01?Euro V – 2012.01?

Euro VI – ?Euro VI – ?

Increasing Fuel Economy 3-6%

SCR

Higher EGR

DPF

Euro III – 2008.01

Euro IV – 2010.01?Euro V – 2012.01?

Euro VI – ?

Euro III – 2008.01

Euro IV – 2010.01?Euro V – 2012.01?



SCR

Higher EGR

DPF

Euro III – 2008.01

Euro IV – 2010.01?Euro V – 2012.01?

Euro VI – ?

Euro III – 2008.01

Euro IV – 2010.01?Euro V – 2012.01?



SCR

Higher EGR

DPF

Euro III – 2008.01

Euro IV – 2010.01?Euro V – 2012.01?

Euro VI – ?

Euro III – 2008.01

Euro IV – 2010.01?Euro V – 2012.01?



SCR

Higher EGR

DPF

Euro III – 2008.01

Euro IV – 2010.01?Euro V – 2012.01?

Euro VI – ?

Euro III – 2008.01

Euro IV – 2010.01?Euro V – 2012.01?

Euro VI – ?

• Engine Technology– Fuel Injection– Combustion and Control Strategy– Air Delivery / Boosting / EGR

Engine Out Trade-Off Curves

Increasing Fuel Economy

Higher EGR

But Lower Standards Push Strategies From

PM or

NOx

PM and NOx

Engine Controls Move the Trade-Off Curve


Aerify™ Diesel Particulate Filter (DPF)•

Wall Flow Ceramic Filter -

High porosity substrate with excellent strength

•

Mass production begins 2011

•

Additional chemical process performed in manufacturing to create the acicular mullite unique microstructure

•

Product families include monolith and segmented parts, depending on customer requirement

•

Enables flexible value proposition

–

High Filtration Efficiency –

Both mass and particle number

–

Reduced fuel consumption

–

Reduced package size

–

Reduction of total systems cost

–

Improved systems integration

•

i.e. SCR on filter

Acicular Mullite -

Unique High porosity microstructure

Monolith & Segmented Constructions

Before Mullite Process After Mullite Process


•

“Soot-in-the-wall”

is the cause for pressure drop hysteresis•

The high porosity and permeability protects AERIFY DPF from being vulnerable in regards to “soot-in-the-wall”

•

Soot lay down on unique needle structure provides high contact area between soot and needle structure

Cordierite AERIFY

Soot Deposition In AERIFY DPF


Case 1 –

Heavy –

Duty Diesel


Heavy Duty Needs

HD Market Attribute

Engine Design Goals Ways to Improve

•

Fuel is a large variable cost for the end user

• Reduced fuel consumption •

Reduce post injection occurrences • More passive regeneration•

Reduced DPF backpressure for lower pumping losses

•

Aftertreatment is a large system expense

• Reduced system cost •

Downsize the aftertreatment system• Reduce PGM usage• Integrated solutions

•

Long life –

minimize downtime due to reliability

• Reduce in-field warranty •

Reduce post injection occurrences –

less chance of uncontrolled regeneration•

Improve control system and soot mass measurement•

Improve DPF material robustness


HD Diesel Aftertreatment -

System Architecture Trends

Euro IV / V HD On-road trucks

US 2007 On-road trucks

Engine DOC SCR

Urea dosing

Engine DOC SCR

Urea dosing

Engine DOC DPFEngine DOC DPF

Engine DOC DPFPost fuel injection

Engine DOC DPFPost fuel injection

Engine DOC DPF SCRUrea dosingPost fuel injection


Post 2013 US / EU Trend

New systems to take advantage of engine out NOx to increase passive regeneration

Engine DOC DPF/SCR

Post fuel injection Urea dosing

Engine DOC DPF/SCR

Post fuel injection Urea dosing


•

High porosity and permeability of AERIFY DPF makes the wall contribution small compared to the channel contribution

•

Optimal filter length is shorter for AERIFY DPF than for other commercially available DPF

Porous wall & soot cake flow loss

Inlet & outlet channel flow frictional lossExpansion

loss

Contractionloss

AERIFY DPF Can Be Downsized!

exitentranceflowchannelsootwalltotal PPPPP /

small strong


Back Pressure Advantage -

CDPF -

Significant Length Downsizing (>25%)

-

Low back pressure compared to competitive materials

-

Segmented Acicular Mullite filter versus Monolith cordierite

-

Linear backpressure profile for improved soot load predictions and OBD control

-Results in improved fuel economy on the engine dyno

0102030405060708090

100

0 10 20 30 40 50 60 70 80 90 100 110Total soot (grams)

Bac

kpre

ssur

e (m

bar)

Baseline Cordierite 12"x12"

Thin Wall Cordierite 12"x12"

DOW AERIFY 12"x12"

DOW AERIFY 12"x8.5"

12”x 12” 110g soot = 4.9 g/L 12” x 8.5” 110g soot = 7.0 g/L

0102030405060708090

100

0 10 20 30 40 50 60 70 80 90 100 110Total soot (grams)

Bac

kpre

ssur

e (m

bar)

Baseline Cordierite 12"x12"

Thin Wall Cordierite 12"x12"

DOW AERIFY 12"x12"

DOW AERIFY 12"x8.5"

12”x 12” 110g soot = 4.9 g/L 12” x 8.5” 110g soot = 7.0 g/L

0

0.5

1

1.5

2

2.5

A Speed B Speed C Speed

25% Load50% Load75% Load

%

Fuel savings for AERIFY over Cordierite at 65 g,

0

0.5

1

1.5

2

2.5

A Speed B Speed C Speed

25% Load50% Load75% Load

%

Fuel savings for AERIFY over Cordierite at 65 g,


Improved Strength Of High-Porosity Mullite DPF

Honeycomb Comparison

010

20

30

40

50

60

70

80

30 40 50 60 70 80 90

Porosity (%)Fl

exur

al S

treng

th (M

Pa)

High-porosity Mullite exhibits higher flexural and isostatic strength compared

to Cordierite

Cordierite*

Acicular MulliteCordierite

0123456

40 50 60 70Porosity (%)

Iso.

Stre

ngth

(MP

a)


Tmax Isotherms for Coated 12x8.5

30

40

50

60

7080

90

100

110

120

550 560 570 580 590 600 610 620

Tinlet, °C

Soot

mas

s, g

Tmax = 650CTmax = 700CTmax = 800CTmax = 900CTmax = 1000CObserved

Excellent Soot Mass Limit DTI Tests For Coated 12x8.5 Mullite DPF

•

High robustness by segmentation and downsizing

Temperature Isotherms -

100 °C/min ramp, drop-to-idle

DPF thermocouples

120 grams~ 5.5 g/L 12x12”~7.5 g/L 12x 8.5”


DPF (Cd) PGM Coating Canning Dow DPF PGM Coating Canning System CostSavings

Cd 12 in x 12 in (22.2L) Dow ACM 12 in x 8.5 in (15.7L)

Process Step

Cos

t ($/

filte

r)C

ost t

o O

E ($

)

Value Analysis –

HD (Downsized DPF)12x8.5”12x12”

AERIFY Value CreationLower Total Systems CostsDownsized package sizeLess Sensitivity to PGM price variationsBackpressure (fuel efficiency) advantagesWeight savings






Heavy-Duty System

•

Conclusions–

Heavy duty trucks have some unmet needs•

Reduced fuel consumption•

Reduced the system cost•

Improved the system reliability–

System architectures are evolving to help meet those needs•

Aftertreatment design•

More passive regeneration•

Improved controls–

New DPF products like Acicular Mullite offer multiple improvements•

Have a higher SML and strength than cordierite –

improved robustness•

Enable system downsizing–

Lower system cost–

Less exposure to PGM pricing–

Smaller package•

Reduced system backpressure for reduced fuel consumption


Case 2 –

Light-Duty Vehicle


Light Duty Needs

LD Market Attribute

Engine Design Goals Ways to Improve

•

Aftertreatment is a large system expense for diesel –

competing against gasoline engines

• Reduced system cost • Reduce PGM usage•

Downsize the aftertreatment system• Integration of aftertreatment

• Emission regulation • Improved efficiency• Reduce light-off time

• Improved catalyst technology• Lower thermal mass substrates

• CO2 regulation • Reduced fuel consumption •

Reduce post injection occurrences –

more passive regeneration•Reduced DPF backpressure for lower pumping losses

• Customer satisfaction •

Maintain / reduce warranty while implementing new substrate materials

•

Find appropriate high porosity substrate materials


LD Diesel Aftertreatment -

System Architecture Trends

Euro IV / V LD

Euro 6 / US Tier 2 Bin 5

Integrated Solutions

Engine DOC DPF

(U/F Location)

Engine DOC DPF

(U/F Location)


SCR / LNTUrea dosing

Engine DOC DPF SCR / LNTUrea dosing


Engine DOC SCR (Heavy veh)

/ LNT (Lighter veh) DPFUrea dosing

Engine DOC SCR (Heavy veh)

/ LNT (Lighter veh) DPFUrea dosing

SCR / LNTUrea dosing

Engine DPF / DOC SCR / LNTUrea dosing

Engine DPF / DOC

DPFEngine DOC / LNT DPFEngine DOC / LNT

Engine DOC DPF/SCRUrea dosing

Engine DOC DPF/SCRUrea dosingIntegration critical to

reduce aftertreatment costs to maintain diesel engine competitiveness


Superior Coatability and Strength at High Porosity-

Enables Multi-function Substrates without FE penalty

0

5

10

15

20

25

0 50 100 150 200 250Washcoat Concentration (g/L)

Rel

ativ

e Pr

essu

re D

rop

0

5

10

15

20

25

0 50 100 150 200 250Washcoat Concentration (g/L)

Rel

ativ

e Pr

essu

re D

rop

Standard AERIFY Product

Optimized AERIFY(Optimized Pore Size and Distribution)

Advanced AERIFY(Optimized Porosity & Pores)

(CDPF & Lower Loadings) (SCR & Multi-Functional Loadings)

Standard AERIFY : Low backpressure at low & moderate coating concentrationsAdv AERIFY: Add’l backpressure advantages at high coating concentrations

AERIFYMicrostructureOptimization

Stan

dard

CD

PF C

oatin

g R

ange

sSt

anda

rd C

DPF

Coa

ting

Ran

ges

Curves are a combination of modeling and test data

Coatability Strength


010

20

30

40

50

60

70

80

30 40 50 60 70 80 90

Porosity (%)

Flex

ural

Stre

ngth

(MP

a)


010

20

30

40

50

60

70

80

30 40 50 60 70 80 90

Porosity (%)

Flex

ural

Stre

ngth

(MP

a)


SCR (Cd) DPF (SiC) PGM Coating (2) Canning (2) IntegratedDPF/SCR

PGM Coating (1) Canning (1) System CostSavings

Cd 5.66 in x 6 in (2.5L) & SiC 5.66 in x 6 in (2.5L) Dow ACM 5.66 in x 6 in (2.5L)

Process Step

Cos

t ($/

filte

r)

Value Analysis –

LD (Integrated DPF/SCR)

Value CreationDownsized package sizeLower Total Systems CostLess Sensitivity to PGM variationsBackpressure (fuel efficiency) advantagesWeight savingsLower thermal mass (faster light-off)



Cos

t to

OE

($)

Engine DOC SCR DPFUrea dosing

Engine DOC SCR DPFUrea dosing


Light-Duty System

•

Conclusions–

Light-duty vehicles have some unmet needs•

Reducing the system cost•

Reducing CO2 / fuel consumption due to regulation•

Maintain durability performance–

System architectures are evolving to help meet those needs•

Integrated solutions are the trend•

Improved controls enable high porosity solutions–

New DPF products like Acicular Mullite meet multiple needs•

Enable high washcoat loadings while minimizing backpressure on DPF•

Eliminate separate substrates and cans to enable system cost savings•

Provide higher soot mass limits and durability than other materials at the same porosity


Thank You

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