Advanced Petroleum Based Fuels- Diesel Emission Control (ABPF-DEC) Update

Transcription

1 Advanced Petroleum Based Fuels- Diesel Emission Control (ABPF-DEC) Update Shawn D. Whitacre June 1, 2005 Presented at 4 th Japan Clean Air Program Conference Tokyo, Japan

2 Advanced Petroleum Based Fuels Diesel Emission Control Study Government/Industry Sponsorship

3 Participating Companies/Organizations Automobile: DaimlerChrysler Ford GM Toyota Engines: Caterpillar Cummins Detroit Diesel EMA International Truck & Engine John Deere Mack Trucks Government: CARB/SCAQMD DOE EPA NREL ORNL Technology: Battelle Emission Control: Argillon ArvinMeritor Benteler Clean Diesel Tech. Corning Delphi Donaldson Co. Engelhard Johnson Matthey MECA NGK Rhodia Robert Bosch Corp. STT Emtec AB Tenneco Automotive 3M Umicore Energy/ Additives: American Chemistry Council API BP Castrol Chevron Oronite ChevronTexaco Ciba Conoco-Phillips Crompton Ergon Ethyl ExxonMobil Infineum Lubrizol Marathon Ashland Motiva NPRA Pennzoil-Quaker State Shell Global Solutions Valvoline

4 APBF-DEC Projects NOx Adsorber/DPF SCR/DPF Lubes FEV SwRI Ricardo SwRI AEI 1.9L TDI 6.6L Isuzu Duramax 15L Cummins ISX Caterpillar C12 Cummins ISB Audi A4 Avant Chevrolet Silverado No vehicle

5 Project Summaries

6 NO x Adsorber/DPF Passenger Car Platform FEV Engine Technologies Vehicle: Audi A4 Avant Engine: 1.9L TDI Catalyst aging study completed 2200 hour aging Final report: Summer 2005 Evaluation of criteria and unregulated pollutants and air toxins

7 Project Objective TIER 1: after 100,000 miles 4 NOx 1.25 g/miles 4 PM 0.1 g/mile TIER 2 BIN 5: after 120,000 miles 4 NOx 0.07 g/miles 4 PM 0.01 g/mile PM [g/mile] Diesel Future II: Advanced Engine Control & Advanced Aftertreatment (NAC + DPF) TIER 2 BIN 5 TIER 2 BIN 8 EU 4 EU 3 Audi A4 1.9 l TDI Station Wagon European Certification TIER NOx [g/mile]

8 Emission Control System Development Catalyst Configuration and Specifications Engine ECS-A: DOC + NAC ECS-B: NAC Cell Density: 400 cpsi Volume: 1.34 L Diameter: 4.16 inch Length: 6 inch Wall Thickness: 4.5 mil Pre- Catalyst Substrate Material: Cordierite Cell Geometry: Square Underbody NAC All ECS: NAC Cell Density: 350 cpsi Wall Thickness: 5.5 mil Volume: 2.5 L Diameter: 5.66 inch Length: 6 inch CDPF Exhaust All ECS: CDPF Cell Density: 200 cpsi Wall Thickness: 14 mil Substrate Material: SiC Volume: 2.5 L Diameter: 5.66 inch Length: 6 inch Cell Geometry: Square

9 Test Cell Emission Performance FTP Cycle (Un-aged System) CO [g/mi] PM [g/mi] Euro Euro System A CO at 4.2 g/mi System B Tier 2 Bin 8 * Tier 2 Bin 8 * Tier 2 Bin 5 * Tier 2 Bin 5 * HC [g/mi] * EMISSION LIMITS AFTER 120,000 MILES NOx [g/mi]

10 Passenger Car Platform Aging Results (LA4 Composite) NOx Conversion 100% 90% 80% 70% 60% 50% 40% Age (hours) Desulfation LA4 Composite(D15) LA4 Composite(BP15) More details: SAE

11 NO x Adsorber/DPF SUV Platform Southwest Research Institute Vehicle: 2002 Chevrolet Silverado Engine: 2002 Isuzu Duramax 6.6L Catalyst aging study completed 2000 hours Final Report: Summer 2005 Evaluation of criteria and unregulated pollutants and air toxics

12 6 Project Objective FTP Drive Cycle Only -99% Stock (with EGR) Emissions (g/mile) Stock (no EGR) Target (Tier 2, Bin 5) 1-88% 0 THC NOx CO PM

13 Emissions Control System Diesel Burner SFI2 NAC1 Oxi-Cats 1,2,3 DPF Duramax SFI1 NAC2 NAC1 Volume (2nd Generation System): 3.5L x 2 + 7L x L L = 37.0L Front Oxi NAC Rear Oxi DPF ECS : Eng = 5.6:1 NAC : Eng = 2.1:1

14 Measured Exhaust Temperature - On-Vehicle Targeted Temperature Window for >90% NAC NO X Reduction Efficiency Temperature ( C) Downpipe Location (Average = 162 C) Time, seconds

15 Supplemental Energy-Diesel Burner Approach 2: Supplemental Energy-Diesel Burner

16 Diesel Burner Details Engine Exhaust In Burner Head Combustion Chamber Location

17 Diesel Burner Management 400 Gas Temperature at Catalyst, C More details: SAE Time, seconds

18 Program Achievements Low Hours, <1ppmS DECSE Fuel 5 Baseline EO EO with EGR Integrated ECS NOx Mass Emission, g/mile % -97% -83% 0 HLA HFET US06

19 100% 95% 90% 85% 80% SUV Platform Aging Results (LA4 Composite) Desulfation Age (hours) LA4 Composite (D15) LA4 Composite (BP15) Standard-D 15 NOx Conversion

20 NO x Adsorber/DPF Heavy-Duty Platform Ricardo, Inc (Chicago) Vehicle: None Engine: 2002 Cummins ISX 15L Catalyst aging study completed 2000 hours Final report in progress

21 Project Scope Develop system capable of meeting 2010 emissions standards: g/bhp.h NO x and 0.01 g/bhp.h PM Develop sulfur management strategy Conduct 2000 hour catalyst aging test - Transient and steady-state evaluations of: - Regulated emissions - Currently unregulated emissions

22 Test Engine Cummins ISX 15L 475 hp Rating DOHC 4V central EUI Cooled EGR, VGT Advanced electronic controls 2002/2004 Base engine out emissions (pre-production)

23 Emission Control System DPF NAC NO x Sensor DOC NO x Sensors DOC Cummins ISX DPF NAC1 Full Flow System (no bypass) Device Dimensions Volume (Diameter x Length) Upstream DOC 12 x L DPF (x2) 12 x L (51.8 L total) NO x Adsorber 12 x L (44.4 L total) Catalyst (x2) Clean-up DOC 12 x L Total Volume: 118 L

24 Aging Results - NO x NOx (g/bhp-hr) FTP Composite NOx Engine-out Level Age (hours) NOx Mean Desulfation More details: SAE

25 Trends Analysis - NO x NOx (g/bhp-hr) EPA 2010 standard Aging Hours Fresh Pre-Des ulfation A verage Post- Des ulfation

26 Heavy-duty SCR/DPF (Southwest Research Institute) Vehicle: none Engine: Caterpillar C12 w/ LPL EGR Two systems evaluated: System A: 6000 out of 6000 hours System B: 6000 out of 6000 hours Also testing NO x sensor durability

27 SCR - System Design AIR FILTER EGR COOLER LPL EGR T (IMP) UREA INJECTION INTAKE THROTTLE EGR VALVE N TPS EXHAUST CB-DPF AR EXHAUST FLOW SENSORS CB-DPF AL SCR AR FLOW BALANCING VALVES SCR AL CLEANUP CATALYST LPL EGR PICKUP EXHAUST DAMPER ATA AFTERCOOLER EXHAUST MANIFOLD C12 DIESEL ENGINE UREA PRESSURE CONTROL UREA INJECTION UREA INJECTION CONTROL INTAKE MANIFOLD UREA PUMP

28 Heavy-duty SCR/DPF Aging Study (HD FTP Composite NO x 8-ppm S fuel) Effects of Aging on NO x (Composite) (Mean and 95% Prediction Interval) NOx (g/bhp-hr) A B A B A B A B A B Unit / Age (Hours)

29 Lubricants Project Phase I Determine the impact of lubricant properties and composition on engine-out/catalyst-in emissions Phase II Determine if lubricant formulation impacts the performance and durability of NO x adsorber catalysts

30 Lubricants Project Status Phase I Completed in 2003 Final Report available Phase II Testing completed Aug 2004 Final reporting underway Detailed results to be presented in later session

31 Future Direction APBF-DEC projects to wrap up in 2005 At present time, no formal plans to continue the activity Anticipate future collaborative activities in fuels and lubricants research: Fuels for advanced combustion Non-petroleum based fuels Lubricant impact on PM