LNT Catalysis at Ford Motor Company A Case History
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1 LNT Catalysis at Ford Motor Company A Case History 2017 CLEERS Workshop Christine K. Lambert, Joseph R. Theis, Giovanni Cavataio Ford Motor Co. 10/5/ CLEERS WORKSHOP 1
2 Background Ford studied Lean NOx Traps (LNTs) for > 20 years Ford used LNTs successfully on diesel and gasoline vehicles Thermal stability of LNTs was improved Sulfur management of LNTs is critical to performance and durability LNTs generate NH 3 for downstream SCR or SDPF on diesels LNT application to gasoline is very limited Should weigh potential fuel benefit against the cost of the catalyst system, including sensors for control and onboard diagnostics 10/5/ CLEERS WORKSHOP 2
3 Examples of LNT-containing systems LNT position determines the temperature window in which it will operate TWC or DOC for CO and HC light-off during cold start, or LNT may replace the DOC if space is limited Diesel systems include a filter LNT may be either the main NOx control device or an assisting device 10/5/ CLEERS WORKSHOP 3
4 Differences in LNT requirements (1/4) Requirements Gasoline LNT Diesel LNT Operational Normally stoichiometric Naturally lean Lean operation when feasible Rich operation difficult Rich operation easy 10/5/ CLEERS WORKSHOP 4
5 Differences in LNT requirements (2/4) Requirements Gasoline LNT Diesel LNT Functional LNT provides lean NOx LNT may be main NOx control control device LNT provides additional TWC activity during stoichiometric operation to supplement the close-coupled TWC(s) LNT may replace DOC for HC, CO control and exotherm generation for downstream filter LNT may generate NH 3 for downstream SCR LNT may assist urea SCR system for cold start NOx control 10/5/ CLEERS WORKSHOP 5
6 Differences in LNT requirements (3/4) Requirements Gasoline LNT Diesel LNT Compositional Designed for higher temperature and high NOx storage capacity NOx storing materials (Ba, optional alkali metals Cs, K, Na) Precious metals (Pt, Pd, Rh) Oxygen storage component (Ce-Zr) Sulfur scavenger (Ni) Support material (Al 2 O 3 ) Designed for lower temperature NOx storage and desox temperature NOx storing materials (Ce, Ba) Precious metals (Pt, Pd, Rh) Support material (Al 2 O 3 ) 10/5/ CLEERS WORKSHOP 6
7 Differences in LNT requirements (4/4) Requirements Gasoline LNT Diesel LNT NOx Control Level Engine out NOx high Engine out NOx low NOx conversion 95-99% NOx conversion 50-60% - Europe NOx conversion 85-90% - U.S. 10/5/ CLEERS WORKSHOP 7
8 LNT Fundamentals Important characteristics of LNTs: operating window precious metal content ceria content sulfur tolerance & desulfation capability total capacity thermal stability 10/5/ CLEERS WORKSHOP 8
9 LNT Fundamentals Important characteristics of LNTs: operating window precious metal content ceria content sulfur tolerance & desulfation capability total capacity thermal stability At low temperatures, higher PGM is best At high temperatures, lower PGM is best 10/5/ CLEERS WORKSHOP 9
10 LNT Fundamentals Important characteristics of LNTs: operating window precious metal content ceria content sulfur tolerance & desulfation capability total capacity thermal stability MO: mixed oxide Higher ceria levels promote more purge NOx Release by consuming reductants during rich purge. 10/5/ CLEERS WORKSHOP 10
11 LNT Fundamentals Important characteristics of LNTs: operating window precious metal content ceria content sulfur tolerance & desulfation capability total capacity thermal stability 10/5/ CLEERS WORKSHOP 11
12 LNT Fundamentals Important characteristics of LNTs: operating window precious metal content ceria content sulfur tolerance & desulfation capability total capacity thermal stability Low temperature NOx storage limited by purging and NO oxidation. 10/5/ CLEERS WORKSHOP 12
13 LNT Fundamentals Important characteristics of LNTs: operating window precious metal content ceria content sulfur tolerance & desulfation capability total capacity thermal stability Low temperature NOx storage degraded by high temperature aging. 10/5/ CLEERS WORKSHOP 13
14 LNT + SCR = a way to use the ammonia increased zoning LNT/SCR sandwich designs LNTs make NH 3 add SCR to store and use the NH 3 for further NOx conversion. 10/5/ CLEERS WORKSHOP 14
15 Gasoline LNT Ford s research on lean burn gasoline MY 1.8L European Mondeo Close-coupled TWC, underbody TWC, and LNT Research supporting this system included: Four mode aging schedule for TWC represented high mileage on TWC+LNT system Oxygen sensor was sufficient for NOx purge control Two-step NOx purges minimized emissions and total duration Low frequency air/fuel ratio modulation during desox minimized H 2 S make 10/5/ CLEERS WORKSHOP 15
16 Gasoline LNT Passive lean NOx approaches (TWC+LNT+SCR) Ford-MTU-DOE program with 2.3L Miller cycle GTDI engine 10/5/ CLEERS WORKSHOP 16
17 Gasoline LNT Passive lean NOx approaches (TWC+SCR) Ford-MTU-DOE program with 2.3L Miller cycle GTDI engine single-zone SCR 10/5/ CLEERS WORKSHOP 17
18 Gasoline LNT Estimated lean burn fuel economy benefit (2.3L Miller cycle GTDI) 10/5/ CLEERS WORKSHOP 18
19 Gasoline LNT Estimated lean burn fuel economy benefit (2.3L Miller cycle GTDI) 10/5/ CLEERS WORKSHOP 19
20 Gasoline LNT Estimated lean burn fuel economy benefit (2.3L Miller cycle GTDI) 10/5/ CLEERS WORKSHOP 20
21 Gasoline LNT Estimated lean burn fuel economy benefit (2.3L Miller cycle GTDI) 10/5/ CLEERS WORKSHOP 21
22 Gasoline LNT Estimated lean burn fuel economy benefit (2.3L Miller cycle GTDI) Stop-start idles Stoich accelerations Fuel shutoff on decelerations Lean burn limited to cruises Fuel economy benefits were low relative to other technologies Added costs of catalysts and sensors exceeded targets 10/5/ CLEERS WORKSHOP 22
23 Diesel LNT Ford s research on diesel LNT Pd added for greater thermal stability Ce added for low temperature NOx storage (not oxygen storage) Diesel exhaust treatment also includes a soot filter Often the LNT replaces a DOC and is used to generate heat for soot oxidation LNT desulfation requires hot, rich conditions DeSOx was developed in conjunction with desoot LNT applied to diesel passenger cars in Europe 10/5/ CLEERS WORKSHOP 23
24 Diesel LNT Three-mode aging scheme for diesel LNTs Three modes used to age LNTs low temp sulfur 300 C inlet DeSOx T* 650 C bed high temp rich desox high temp lean desoot Represents high mileage DeSOx T determined by sulfur loading and TPD 10/5/ CLEERS WORKSHOP 24
25 Diesel LNT Improvements in diesel LNT desox thermal safety margin and control range Later Status Thermal safety margin improved by 190 o C Control of desox temperature on vehicle improved ±50 o C 10/5/ CLEERS WORKSHOP 25
26 Diesel LNT System trade-off example for a Tier 2 midrange diesel application 10/5/ CLEERS WORKSHOP 26
27 Diesel LNT System trade-off example for a Tier 2 midrange diesel application 10/5/ CLEERS WORKSHOP 27
28 Diesel LNT System trade-off example for a Tier 2 midrange diesel application 10/5/ CLEERS WORKSHOP 28
29 Diesel LNT System trade-off example for a Tier 2 midrange diesel application NOx conversion capability assessed at FUL (120K mi) on FTP-75 Fuel economy penalties were estimated for FTP only and metro-highway [M-H] Deployment issues were noted, as well as new sensors needed for OBD 10/5/ CLEERS WORKSHOP 29
30 LNT Outlook Lean burn gasoline emission control cost is high vs the fuel benefit, which limits the application Real world driving conditions and extended mileage requirements make it more difficult to use LNT as the main NOx control device on diesels LNT can assist cold start control of NOx for downstream urea SCR system (i.e., LTNA) LNT may be modified for lower temperature performance and multiple functions (HC trap, DOC) 10/5/ CLEERS WORKSHOP 30
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