FRAUNHOFER INSTITUTE MDEC 2017 S6P4-1

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1 FRAUNHOFER INSTITUTE Elimination of Particulate Filters and SCR Equipment using a novel Catalytic Evaporation (CatVap ) Device to reduce Soot and NO x emissions in Internal Combustion Engines Robert Szolak, Dr. Achim Schaadt, Florian Rümmele, Fraunhofer ISE Michael Mazzuca, T.F. Hudgins Inc. Dr. Steven Gedeon, Behr Associates 23rd Annual MDEC Conference, Toronto Canada October Fraunhofer ISE Fraunhofer-Gesellschaft One of the largest organizations for applied research in Europe 69 institutes and research units 24,5 staff $2.5 billion total annual research budget. 2,+ patent families (e.g. MP3 ) CatVap Team from ISE, Freiburg Funded by Fraunhofer Venture and Innovator Programs in HQ Fraunhofer ISE Seite 2 S6P4-1

2 Engines Wide Range of Non- and Off Road Applications 5 75 HP Advantages of Engines: High Efficiency Good Engine Characteristic high torque and low speed Best solution for Non-road applications Disadvantages: Production of Harmful Emissions like NO x - and Soot Complex Exhaust Aftertreatment Systems to meet Tier 4 / Stage IV 173 HP 75 HP > 173 HP Fraunhofer ISE Seite 3 Challenges for Engines Emissions Reduction to meet Tier 4 / Stage IV Soot and NO x -reduction based on Tier 1 / Stage I HP NOx: 96 97% PM: 96 % (Particle Number under discussion) 5 75 HP, only NOx and HC regulation 5 74 HP NOx/% HP US Tier 1 Stage I US Tier 4 final Stage IV PM: 96 % Complex Exhaust Aftertreatment Systems 173 HP PM/% HP Fraunhofer ISE Seite 4 S6P4-2

3 Tier 4 final Engine Complex Exhaust Aftertreatment Air Engine Oxidation Catalyst (DOC) Particulate Filter (DPF) Adblue Selective Catalytic Reduction (SCR) Ammonia Oxidation Catalyst (AOC) Exhaust Gas Fuel Consumption ( CO 2 -Emissions) Lower Performance NOx removal from diesel exhaust gas Adblue injection required (2 nd lubricant) Low exhaust temperature polymerization Fraunhofer ISE Seite 5 Volume Engine with Exhaust Aftertreatment for Non-road applications Tier 4 final Volume Engine incl. Exhaust Aftertreatment (EAT) System EAT Engine Caterpillar C4.4 ACERT Tier 4 for 173 bhp (13 kw) EAT > 4% of the engine Major Part EAT NO x -removal (SCR- System, Adblue Tank not included) Fraunhofer ISE S6P4-3

4 Cost of Emission Reduction Technologies Exhaust Aftertreatment System for Non-road Applications Estimated costs for added emissions controls equipment approx. 1-3% of total equipment price Nett Technologies INC.: BlueMAX PLUS SCR system (Retrofit) Approx. 1-3% of total equipment price, e.g. total price bulldozer 175 hp: $23, $6,9 for emissions control equipment + Aftertreatment systems (DOC, DPF, SCR) incl. sensors, Adblue tank, etc.): approx. $7, # Picture: Fraunhofer ISE # F. Posada et. al, Cost of Emission Reduction Technolgies for Heavy-Duty Vehicles, icct (the internationl council on cleam transportation), Feb CATVAP -Catalytic Evporation Process New Approach for Low Emissions reduces Exhaust Aftertreatment System Air CATVAP SYSTEM Motor Oxidation Catalyst (DOC) Exhaust Gas Fuel Vapor in the intake manifold (homogeneous mixing with air) In-cylinder NOx and Soot Reduction in Engines No SCR, DPF required Fraunhofer ISE Seite 8 S6P4-4

5 Volume Engine with CatVap Tier 4 final CatVap reduces EAT volume by 73% CatVap DOC Engine Only DOC required Volume CatVap for 173 HP approx. 2 Liters Caterpillar C4.4 ACERT (173 bhp, 13 kw) Fraunhofer ISE Seite 9 CatVap New Fuel Vapourization Technology for ICE Usable for a wide range of different fuels (diesel, kerosene, gasoline, biodiesel, PtL-fuels and blends ) Use in diesel engines: in-cylinder emissions reductions Use in gasoline engines: boost the octane number to increase efficiency/performance Photo: CatVap in Stack Design Fraunhofer ISE Seite 1 S6P4-5

6 CatVap Technology Compact Design and scalable for different applications Fuel modification by catalytic and cracking reactions Fuel tailoring (change of ignition properties) Compact design Approx. 2 Liter reactor volume for 173 HP Scalable for small to large engines Foto: CATVAP im Stack Design Fraunhofer ISE Seite 11 fuel DIN 59 Fuel Composition.1 Oxygenated HCs 14% wt Aromatics 31% wt Unknowns 1% wt Alkanes 53 % wt Mass Fraction.8.6.4,3 bar.2 Alkenes 1 % wt C1-C5 C6-C1 C11-C15 C16-C2 Fraunhofer ISE Seite 12 S6P4-6

7 Fuel Tailoring by Catalytic Evaporation Process Comparison of Alkanes in Fuel and CatVap Fuel Vapor.1 Strong reduction of heavy alkanes Significant increase of gaseous alkanes (CH 4, C 2 H 6, C 3 H 8 ) Further shift of fuel composition, not shown in the diagram: Production of gaseous alkenes (C 2 H 4, C 3 H 6 ) Shift of aromatics (from the heavy aromatics to the lighter ones) Mass Fraction Fuel Vapor,3 bar C1-C5 C6-C1 C11-C15 C16-C2 Fraunhofer ISE Seite 13 Ignition Properties of Gasoline and Ignition Delay Time depends on Ignition Temperature Ignition Delay Time / ms 1 1 Initial pressure: 3 bar Air number: 1 Gasoline Ignition Temperature / /K Fraunhofer ISE Seite 14 S6P4-7

8 CatVap Variable Adjustment of the Ignition Properties possible Ignition Delay Time / ms 1 1 Initial pressure: 3 bar Air number: 1 Modified Fuel 4 Gasoline Modified Fuel 3 Modified Fuel 2 Modified Fuel Ignition Temperature / /K Fraunhofer ISE Seite 15 CatVap Engine Test Test Platform at Fraunhofer Engine Tested 1 Cyl. Heavy Duty Engine Displaced Volume 18 ccm Compression ratio 15.5:1 EGR (external) Common-Rail System 3% 22 bar Rated Engine Speed 2 rpm Turbocharging (external) max. 2.2 bar (abs.) Photo: Engine Test Bench Fraunhofer ISE Seite 16 S6P4-8

9 CatVap Engine Tests Dramatic Emissions Reduction in Engines with Fraunhofer CatVap Technology without Exhaust After-Treatment System NO x -Emissions Soot Emissions NO x -Emissions / g/kwh Standard Fraunhofer CatVap Soot -Emissions / FSN Standard Fraunhofer CatVap <.6 g/kwh Fraunhofer ISE Seite 17 Influence of CatVap Operating Parameters on Combustion Phasing Engine Tests without Exhaust Recirculation Operation with fuel vapor only Charge air pressure = 15 mbar flow rate constant Shift of the Combustion Phase by changing the air flow (Air Number) Shift from -5.3 CA to +3.8 CA Increase of Efficiency IMEP: 6 bar 6.8 bar Cylinder Pressure / bar Air Number:.8 Air Number:.1 Air Number:.12 Compression stroke Expansion stroke Crank Angle / CA Fraunhofer ISE Seite 18 S6P4-9

10 Fuel Consumption CatVap Engine Test: Indicated Specific Fuel Consumption 24 Operation with fuel vapor only Fuel Consumption with IMEP Fuel Consumption at best point 18 g/kwh Ultra low NOx-emissions and low fuel consumption Further increase of efficiency possible Indicated Specific Fuel Consumption / g/kwh IMEP / bar Fraunhofer ISE Seite 19 Thank you for your attention! Fraunhofer Institute for Solar Energy ISE Robert Szolak robert.szolak@ise.fraunhofer.de Fraunhofer ISE Seite 2 S6P4-1