Fueling the Future TM Diesel Reformers for On-board Hydrogen Applications in Exhaust Aftertreatment Systems. Mark Mauss and Wayne Wnuck

Transcription

1 Fueling the Future TM Diesel Reformers for On-board Hydrogen Applications in Exhaust Aftertreatment Systems Mark Mauss and Wayne Wnuck Mining Diesel Emissions Conference 4-6 November 3 Overview Presentation Outline Background Results of using hydrogen to regenerate NOx Adsorbers Diesel reformer development Present activity and future work Terminology NOx Adsorber = Lean NOx Trap = LNT Diesel Reformer => Hydrogen-rich gas = Hydrogen reformate = Syngas = H 2 + CO mixture Catalytic Partial Oxidation = CPOx 4-6 Nov 3 3 MDEC - Toronto, Canada 2 S7P3-1

2 HydrogenSource Background Created in 1 Develop, manufacture and sell Fuel Processors 4-6 Nov 3 3 MDEC - Toronto, Canada 3 HyS On-Board CPOx Reformer System Fuel tank Diesel engine NO x adsorber Exhaust CPOx Reformer Diesel + Engine Exhaust => H 2 + CO + H 2 O, CO 2, N 2, HC Ultra Low Sulfur Diesel (15 ppm sulfur) O 2 and H 2 O from exhaust 4-6 Nov 3 3 MDEC - Toronto, Canada 4 S7P3-2

3 Initial LNT Regeneration Test Test Objective Determine feasibility of using hydrogen-rich gas from an existing CPOx reformer for LNT regeneration Demonstration Test Configuration Naphtha used for reformer fuel rather than diesel Air used as oxidant rather than engine exhaust Steady state engine & reformer operation One leg of dual leg LNT exhaust system Fixed NOx trapping & regeneration cycle times 4-6 Nov 3 3 MDEC - Toronto, Canada 5 LNT Regeneration Test Configuration Test Configuration DOC DOC LNT LNT 5.9L engine 14L LNT Reformate comp.: % H 2 16% CO 5% CO 2 38% N 2 % H 2 O <1% THC 4-6 Nov 3 3 MDEC - Toronto, Canada 6 S7P3-3

4 LNT Regeneration Test Results % NOx Reduction at 1 o C LNT Temperature 83 g/hr NOx out of Engine Adsorber Flow (g/s) => NOx (g/hr) <= NOx Out (g/hr) Ads Flow (g/s) Regeneration % NOx reduction 13: 13:22 13:24 13:26 13:28 13: 4-6 Nov 3 3 MDEC - Toronto, Canada 7 LNT Regeneration Test Results 99 % NOx Reduction at o C LNT Temperature g/hr NOx out of Engine 1 Adsorber Flow (g/s) => 1 NOx (g/hr) ~1.5% Fuel Penalty <= NOx Out (g/hr) Ads Flow (g/s) 99 % NOx reduction Regen 11:31 11:33 11:35 11:37 11:39 11:41 11:43 11:45 11: Nov 3 3 MDEC - Toronto, Canada 8 S7P3-4

5 LNT Regeneration Test Results 99 % NOx Reduction at 4 o C LNT Temperature 8 g/hr NOx out of Engine 2 Adsorber Flow (g/s) => 2 NOx (g/hr) <= NOx Out (g/hr) Ads Flow (g/s) Regeneration 99 % NOx reduction 14:55 14:57 14:59 15:1 4-6 Nov 3 3 MDEC - Toronto, Canada 9 Challenges for CPOx Reformer Durability Operation on engine exhaust Thermal cycling for operating temperatures > o C Long-term durability Total System Cost CPOx catalyst cost not expected to be an issue Exhaust system configuration needs better definition to estimate CPOx cost impact (e.g. LNT size and precious metals loading, regeneration time & frequency, integration with engine operation) 4-6 Nov 3 3 MDEC - Toronto, Canada S7P3-5

6 Diesel CPOx Reforming Durability 15 ppm Sulfur Diesel Reformed using Air as Oxidant 1 H2 + CO Yield (%) Original Diesel Catalyst Current Diesel Catalyst 1 Run Time in Hours 4-6 Nov 3 3 MDEC - Toronto, Canada 11 Diesel CPOx Reforming Durability 15ppm S Diesel Reformed using Simulated Exhaust as Oxidant H2 + CO Yield (%) Simulated Exhaust Engine A/F=34 11% O 2 5.7% H 2 O H 2 O/C=.3 Run Time in Hours 4-6 Nov 3 3 MDEC - Toronto, Canada 12 S7P3-6

7 CPOx Thermal Cycling Data o C Thermal Shock Cycling 1% % % Natural gas catalyst Naphtha catalyst % Thermal Shock Cycle H2 + CO Yield (%) % % % % Temp > C % % % < minutes time % No. of cycles 4-6 Nov 3 3 MDEC - Toronto, Canada 13 Benefits of Hydrogen for LNT Regeneration Demonstrated Benefits Low Temperature Regeneration >% NOx Conversion from 1 o C to 4 o C Expected Benefits Rapid exhaust catalyst light-off & thermal control High temperature of reformer exhaust (~ o C) H 2 combustion on low temp noble metal catalysts Faster or lower temperature desulfation Lower fuel penalty Smaller, more durable LNT system 4-6 Nov 3 3 MDEC - Toronto, Canada 14 S7P3-7

8 Present Activity Light Duty Truck Demonstration Use diesel reformer to regenerate LNTequipped aftertreatment system Drive cycle testing planned in Q Nov 3 3 MDEC - Toronto, Canada 15 Next Steps Aftertreatment System with CPOx Reformer Demonstrate benefit for desulfation Demonstrate rapid exhaust light-off Cyclic & steady state durability testing Optimize configuration for cost and performance CPOx Reformer Longer term cyclic & steady state durability testing 4-6 Nov 3 3 MDEC - Toronto, Canada 16 S7P3-8

9 Summary and Conclusions Hydrogen-rich gas from a CPOx reformer is highly effective for regenerating NOx adsorbers >% NOx conversion demonstrated at 1 C >99% NOx conversion demonstrated at 4 C A CPOx reformer has been developed to: Operate on ULSD fuel and engine exhaust Integrate into a diesel powered vehicle equipped with a LNT aftertreatment system Future development is focused on: Demonstrating durability Optimizing system with respect to performance and cost 4-6 Nov 3 3 MDEC - Toronto, Canada 17 Thank you Fueling the Future TM 4-6 Nov 3 3 MDEC - Toronto, Canada 18 S7P3-9