Overview of HD Diesel Emission Control. Tim Johnson May 22, 2008

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1 Overview of HD Diesel Emission Control Tim Johnson May 22, 2008

2 Regulatory and engine technology framework 0.14 PM, g/kw-hr; ESC test US2010+ US2010 DPF+NOx Japan 2009 DPF+NOx Euro VI US2007 DPF US2007 Japan 2005 DPF or SCR US2004 (2002) DOC Euro V 2008 SCR Euro IV 2005 SCR ? DPF+NOx NOx, g/kw-hr; ESC test Euro III 2000 nothing 2

3 Engine Developments

4 Heavy-duty engine technologies are compared for >300 kw class. US2007 US2010 Euro VI Tier 4A Non- Road w/ DPF Turbocharging 1- and 2- stage; up to 4.5 bar 2-stage; 2-stage 2-stage Full load EGR 25% up to 35% 25% ~15% Peak cylinder pressure bar bar Fuel injection 2200 bar UI 2500 bar CR 220 bar bar >2200 bar CR 2000 bar CR Daimler, Vienna, 5-07 AVL June 2007 Iveco, Integer Conf, June 2007 Cummins, SAE Daimler, AVL emissions conf

5 Incremental technologies shown to obtain 47% BTE and <0.4 g/bhp-hr NOx. BTE dropped with introduction of EGR. New developments for 2010 are ahead of plan and could deliver 47% BTE (-10% FC vs. 2007) Increased injection pressure drops PM Improved combustion recipe has multiple injections and better EGR control Hydroground nozzles improve FIE Electric turbo Advanced controls Cummins, DEER 8/07 5

6 SCR

7 State-of-the Art SCR system has NO 2 generation and oxidation catalyst to eliminate ammonia slip SCR Catalyst (S) Urea (NH 2 ) 2 CO 4NH 3 + 4NO + O 2 4N 2 + 6H 2 O 2NH 3 + NO + NO 2 2N 2 + 3H 2 O 8NH 3 + 6NO 2 7N H 2 O Exhaust Gas V H S O Oxidation Catalyst (V) 2NO + O 2 2NO 2 4HC + 3O 2 2CO 2 + 2H 2 O 2CO + O 2 2CO 2 Hydrolysis Catalyst (H) Oxidation Catalyst (O) 4NH 3 + 3O 2 2N 2 + 6H 2 O (NH 2 ) 2 CO + H 2 O 2NH 3 + CO 2 7

8 Layout of a PM/NOx urea-based system Key features: airless urea injection urea temperature control closed-loop aftertreatment control Bosch, Euro V/VI conference

9 Nissan Diesel used a comprehensive approach to implement HD SCR Zeolite catalysts are preferred due to higher efficiency over the temperature range, and due to smaller size. Nissan Diesel SAE

10 Urea decomposition catalysts are a possibility for aid zeolite LT SCR performance. Drops decomposition temperature by ~50C. ZrO 2 TiO 2 (anat.) PSI, CTI conf. 6/07 10

11 Zeolite SCR catalysts perform well at LT for short periods of time. T<200C: NH 4 NO 3 formation LT: Rate controlling step is NO NO 2 kinetics PSI, MinNOx conf

12 PM Control

13 Diesel particulate filters use porous ceramics and catalyst to collect and burn the soot Trapped soot on inlet wall surface Cell Plugs Place a catalyst in front of or within filter to oxidize NO to NO 2 Exhaust (CO 2, H 2 O) Out Exhaust (Soot, CO, HC) Enter Ceramic Honeycomb Wall with Supported Catalyst 13

14 HDD is moving toward auxiliary heating of DPFs in the exhaust system. Interest is increasing in LD also. Donaldson, DEER

15 An algorithm is developed to safely control DPF regeneration. Soot morphology change observed for increased injection pressure. Combustion rate constant and inlet temperature are used to detect threshold between normal and abnormal regeneration. Hino, SAE

16 DPFs exhaust is cleaner than ambient highway air for particles. Particle Number, dn/dlogdp, (particles/cm 3 ) 1.0E E E E+03 CRT, CS, DGN = 33.5, Mode 8 CRT, CS, DGN = 19.1, Mode 7 CRT, CS, DGN = 21.2, Mode 6 CRT, CS, DGN = 30.1, Mode 5 CRT, CS, DGN = 25.7, Mode 2 CRT, CS, DGN = 19.2, Mode 1 Number concentration 10 m from highway Number concentration 700 m from the highway Average on-road number 1.0E Midpoint diameter, nm Univ of MN

17 Soot charging sensor shows promise for post-dpf soot sensing for OBD. Soot charging sensor measures post-dpf soot (0.05 mg/m 3 ) by looking at charge transfer to electrodes from soot. Soot picks up charge from top plate, is then repelled by same polarity to measuring plate. EAST Solutions, CTI DPF Forum 7-07 Charge sensor signal follows instrument signal very well in transient testing with a partially damaged DPF. 17

18 Summary Regulations HD regulations are getting very tight worldwide. Technologies are addressing. Engine strategies are making impressive progress HD heading very clean and very high BTE NOx solutions are available for ultra-low emissions SCR is addressing cold temperature and secondary emission issues DPF systems show continuous improvement Very sophisticated regeneration control strategies. Tailpipe PM levels below ambient highway levels. 18

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