Emission Control Technology Highlights for Gasoline and Diesel Engines

Transcription

1 Emission Control Technology Highlights for Gasoline and Diesel Engines Manufacturers of Emission Controls Association July

2 Emission Control Systems for Spark-Ignited Vehicles & Engines The Potential for Achieving Ultra Low Emissions from Large Light-Duty Gasoline Vehicles 38 different 2007 model PZEVs currently available 4, 5, and 6 cylinder engines Heavier weight class LDTs currently limited to LEV II LEV or Tier 2, Bin 4 compliant models Quick light-off UHEGO linear sensor Perforated metal substrate with Integrated lambda sensor ivvt Gas mixing (but less heat) cam sensor (fast synch) 3rd brick Ce 400/4 HEGO binary lambda sensor 2nd brick Ce 600/3 L-Ocatalyst Me600PE/0.04 SAE Paper No

3 Advanced Emission Technology Demonstration MECA Test Program: (SAE Paper ) 1261) Goal Ultra-low HC and NOx exhaust emissions on 2 large light-duty trucks: 2004 Ford F150, 5.4L Triton V GMC Yukon Denali, 6.0L Vortec V8 Integration of advanced TWC systems with modified engine calibrations FTP/SFTP Evaluations on de-greened and engine aged advanced emission systems

4 GMC Denali Advanced Catalyst System Design Total TWC Catalyst Volume: 4.46 L (0.74 SVR) 0.67 L 1.56 L 6.0L V8 Engine 900 cpsi ceramic; 150 g/ft3, Pt/Pd/Rh=1/16/2 600 cpsi ceramic; 60 g/ft3 Pd/Rh=4/ L 1.56 L CC UF

5 Baseline FTP Emissions (4K mi, stock) and Program Emission Targets LEV-I ULEV (100k) LEV II ULEV (120k) LEV-I ULEV (50k) NOx (g/mile) SULEV (120k) PZEV (150k) K stock Denali NMOG (g/mile) CO (g/mile) 4K stock F150 Denali & F-150 F with 4K advanced catalyst system: mg/mi NMOG; mg/mi NOx

6 GMC Denali & Ford F-150 F Fully Aged Advanced Emission Systems FTP Performance - Below 50K ULEV2 Limits FTP Emissions, mg/mi NMOG/NMHC NOx 70 SULEV ULEV2-50K Denali - adv. TWCs, fully aged F adv. TWCs, fully aged ULEV2-120K Denali Results Include Modified Calibration Strategy; F-150 Results Using Stock Engine Calibration 220 hrs. of accelerated fuel-cut aging

7 GMC Denali Fully Aged Advanced Emission System SFTP Performance - Below Current ARB 4K Limits NMHC + NOx, g/mi US06 SC03 (A/C) ARB 4K PC/LDT1 ARB 4K LDT2 Denali - adv. TWCs, fully aged

8 SAE Paper No Summary and Conclusions Advanced emission control technologies can be combined with advanced engine controls to achieve ultra-low HC and NOx exhaust emissions on heavy, light-duty gasoline vehicles Tight air/fuel control is an important enabler to maintaining ultra-low exhaust emissions on gasoline vehicles Emission performance would benefit from further improvements to thermal management and engine controls available to OEMs A Tier 3 or LEV 3 program could limit available certification bins to ULEV and SULEV

9 Light-Duty Vehicle Emission Technology Developments Beneficial to Full Range of Stoichiometric Engine Applications High Performance Aftermarket Converters CARB OBD-Compliant Aftermarket Converters Medium & Heavy-Duty Engines Cummins-Westport 2010-compliant CNG HD Engine Motorcycles/Mopeds Closed-Loop TWC Systems for California/U.S.; ARB may tighten further Recreational Vehicles & Engines ATVs, Off-road Motorcycles, Marine engines; ARB likely to tighten > 25 hp Off-Road Applications Advanced Closed-Loop TWCs to Achieve 2010 ARB Standards on Fork Lifts, GSE, Generator Sets Closed Loop TWC Retrofit Systems Handheld Equipment & Non-Handheld Equipment Blowers, String Cutters, Chain Saws, Lawn Mowers, Riding Mowers Alternative Fuels E-85, CNG, Propane

10 2007 On-Road Diesel Roll-out On-Track Operators report no significant shift in fuel economy relative to 2006 engines

11 Diesel Emission Control Technology Is Making Significant Progress Filter technology US/Canada 2007 launch successfully underway > 4 million filter-equipped diesel passenger cars in Europe Retrofit experience and options expanding NOx solutions SCR is commercial in Europe (> 100,000 trucks) NOx adsorber commercial on Mercedes E320, Med-duty Dodge Ram pick-up, Toyota DPNR Integrated solutions continuing to develop SCR/DPF are on vehicles LNT/DPF is commercial with applications expanding LNT/SCR combinations under development Retrofit options available for combined PM/NOx reductions

12 Developments Continue to Improve PM Filters Pressure Drop (kpa) at 4 g/l soot /19 Optimized Porosity 200/19 Optimized Cell/Web 275/14 Coated Bare Variety of materials: Cordierite, SiC, Al 2 TiO 5, Mullite, Sintered metal Porosity (%) Pore connectivity Good catalyzed backpressure characteristics Extended maintenance intervals possible with proper filter designs, low ash oils, low lube consumption engines

13 NOx Adsorber Catalyst Development Continues to Show Progress at Low Temperatures Note: first baseline LNT and advanced LNT are Ba-based; Second baseline LNT is K-based Reference: SAE Paper No

14 Zeolite-Based SCR Catalysts Emerging with Good Thermal Durability NOx Conversion over Cu, Fe, and Vanadium based SCR formulation as a function of temp. 120 NOx Conversion (%) Cu/Zeolite SCR 40 Fe/Zeolite SCR Vanadium SCR Inlet Gas Temperature (C) NOx Conversion (%) Comparison of time at temp for hydrothermal aging of a Fe/zeolite SCR catalyst 64 hrs/670c 2000 hrs/550c 10 Reference: SAE Paper No Inlet Gas Temperature (C)

15 Experience Growing in On-Road SCR Applications Filter Module

16 Urea Injection Systems Moving from Air Assist to Airless Designs

17 2010 Heavy-duty SCR Systems Will Include Sophisticated Controls and Diagnostics Combined O 2 /NOx Sensor Ammonia Sensor Heated Urea Tanks Urea Quality Sensor Diagnostic Systems

18 Advanced System Designs Emerging that Combine LNTs and SCR Catalysts: Mercedes E320 CDI Reference: Mercedes Benz press release

19 Advanced System Designs Emerging that Combine LNTs and SCR Catalysts Conventional HDD DPF/SCR Design Advanced HDD LNT+ SCR Design (no urea addition) Reference: DEER 2006

20 Honda s Advanced Clean Diesel Strategy Layers LNT and SCR Catalyst Functions on a Single Substrate Reference:

21 DPFs with Passive and Active Soot Regeneration Strategies Available for Retrofits Passive systems rely on exhaust temperature and catalyst for regeneration Active systems suited for onand off-road applications with low exhaust temperatures including locomotives & marine engines Uncatalyzed wall-flow filter with electrical or fuel burner regeneration

22 Integrated Solutions for Combined PM/NOx Reductions Available for Retrofit HC-SCR + DPF 25-40% NOx reduction Low Pressure EGR + DPF 40-50% NOx reduction Catalyst-based Filter + Urea- SCR Catalyst 70+% NOx reduction

23 Retrofit Experience is Expanding to Off-Road Vehicle Applications

24 Off-Road Retrofit Installations of NOx Catalysts + Filter Systems SCR Catalysts DPF Filter

25 Urea-SCR System Retrofit Applied to NYC Ferry 90+% NOx efficiency under normal cruise conditions

26 Challenges for Off-Road Retrofits More diverse engine/equipment application space than on-road Skewed toward older equipment Proper engineering judgment applied to heat shielding and mounting locations Maintaining driver visibility Can require extensive use of high grade vibration isolators especially in track drive equipment Lack of preventative equipment maintenance Especially air filters, injectors and turbochargers Basic inspection and maintenance of installations User interference with the installation process Taking short cuts to get machines done now Both ARB and EPA need more effective retrofit verification resources

27 Conclusions All Major Regulations Moving to Tight PM and NOx Emission Standards for Diesel Engines Technology Forcing Standards are an Important Driver for Continued Emission Control Innovations and Investments Continued Development of Advanced Diesel Engine Combustion Strategies will have a Significant Impact on the Overall Emission System Designs Required to Meet Future Regulatory Standards A Variety of Technologies Are Available and Emerging for PM, NOx, and Toxic HC Emission Control for Both Light-Duty and Heavy-Duty Diesel Vehicles On-Road Diesel Technologies Will Migrate into Nonroad Diesel Applications including Locomotive and Marine diesels. Retrofit NOx Technologies Expected to Expand in the Near Term to Include HC- and urea-scr options for on-road and off-road applications