Advanced Petroleum Based Fuels- Diesel Emission Control (ABPF-DEC) Update Shawn D. Whitacre June 1, 2005 Presented at 4 th Japan Clean Air Program Conference Tokyo, Japan
Advanced Petroleum Based Fuels Diesel Emission Control Study Government/Industry Sponsorship
Participating Companies/Organizations Automobile: DaimlerChrysler Ford GM Toyota Engines: Caterpillar Cummins Detroit Diesel EMA International Truck & Engine John Deere Mack Trucks Government: CARB/SCAQMD DOE EPA NREL ORNL Technology: Battelle Emission Control: Argillon ArvinMeritor Benteler Clean Diesel Tech. Corning Delphi Donaldson Co. Engelhard Johnson Matthey MECA NGK Rhodia Robert Bosch Corp. STT Emtec AB Tenneco Automotive 3M Umicore Energy/ Additives: American Chemistry Council API BP Castrol Chevron Oronite ChevronTexaco Ciba Conoco-Phillips Crompton Ergon Ethyl ExxonMobil Infineum Lubrizol Marathon Ashland Motiva NPRA Pennzoil-Quaker State Shell Global Solutions Valvoline
APBF-DEC Projects NOx Adsorber/DPF SCR/DPF Lubes FEV SwRI Ricardo SwRI AEI 1.9L TDI 6.6L Isuzu Duramax 15L Cummins ISX Caterpillar C12 Cummins ISB Audi A4 Avant Chevrolet Silverado No vehicle
Project Summaries
NO x Adsorber/DPF Passenger Car Platform FEV Engine Technologies Vehicle: Audi A4 Avant Engine: 1.9L TDI Catalyst aging study completed 2200 hour aging Final report: Summer 2005 Evaluation of criteria and unregulated pollutants and air toxins
Project Objective TIER 1: after 100,000 miles 4 NOx 1.25 g/miles 4 PM 0.1 g/mile TIER 2 BIN 5: after 120,000 miles 4 NOx 0.07 g/miles 4 PM 0.01 g/mile PM [g/mile] 0.10 0.08 0.06 0.04 0.02 Diesel Future II: Advanced Engine Control & Advanced Aftertreatment (NAC + DPF) TIER 2 BIN 5 TIER 2 BIN 8 EU 4 EU 3 Audi A4 1.9 l TDI Station Wagon European Certification TIER 1 0.00 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 NOx [g/mile]
Emission Control System Development Catalyst Configuration and Specifications Engine ECS-A: DOC + NAC ECS-B: NAC Cell Density: 400 cpsi Volume: 1.34 L Diameter: 4.16 inch Length: 6 inch Wall Thickness: 4.5 mil Pre- Catalyst Substrate Material: Cordierite Cell Geometry: Square Underbody NAC All ECS: NAC Cell Density: 350 cpsi Wall Thickness: 5.5 mil Volume: 2.5 L Diameter: 5.66 inch Length: 6 inch CDPF Exhaust All ECS: CDPF Cell Density: 200 cpsi Wall Thickness: 14 mil Substrate Material: SiC Volume: 2.5 L Diameter: 5.66 inch Length: 6 inch Cell Geometry: Square
Test Cell Emission Performance FTP Cycle (Un-aged System) CO [g/mi] PM [g/mi] Euro 4 0.8 0.040 Euro 4 0.7 0.035 System A CO at 4.2 g/mi 0.6 0.030 System B Tier 2 Bin 8 * 0.5 0.025 0.4 0.020 Tier 2 Bin 8 * Tier 2 Bin 5 * 0.3 0.015 0.2 0.010 Tier 2 Bin 5 * 0.1 0.005 0.125 0.1 0.075 0.05 0.025 HC [g/mi] * EMISSION LIMITS AFTER 120,000 MILES 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 NOx [g/mi]
Passenger Car Platform Aging Results (LA4 Composite) NOx Conversion 100% 90% 80% 70% 60% 50% 40% 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 Age (hours) Desulfation LA4 Composite(D15) LA4 Composite(BP15) More details: SAE 2005-01-1755
NO x Adsorber/DPF SUV Platform Southwest Research Institute Vehicle: 2002 Chevrolet Silverado Engine: 2002 Isuzu Duramax 6.6L Catalyst aging study completed 2000 hours Final Report: Summer 2005 Evaluation of criteria and unregulated pollutants and air toxics
6 Project Objective FTP Drive Cycle Only -99% Stock (with EGR) Emissions (g/mile) 5 4 3 2 Stock (no EGR) Target (Tier 2, Bin 5) 1-88% 0 THC NOx CO PM
Emissions Control System Diesel Burner SFI2 NAC1 Oxi-Cats 1,2,3 DPF Duramax SFI1 NAC2 NAC1 Volume (2nd Generation System): 3.5L x 2 + 7L x 2 + 3.5L + 12.5L = 37.0L Front Oxi NAC Rear Oxi DPF ECS : Eng = 5.6:1 NAC : Eng = 2.1:1
Measured Exhaust Temperature - On-Vehicle 400 350 300 Targeted Temperature Window for >90% NAC NO X Reduction Efficiency Temperature ( C) 250 200 150 100 Downpipe Location (Average = 162 C) 50 0 0 200 400 600 800 1000 1200 1400 Time, seconds
Supplemental Energy-Diesel Burner Approach 2: Supplemental Energy-Diesel Burner
Diesel Burner Details Engine Exhaust In Burner Head Combustion Chamber Location
Diesel Burner Management 400 Gas Temperature at Catalyst, C 300 200 100 0 0 200 400 600 800 1000 1200 1400 More details: SAE 2004-01-0584 Time, seconds
Program Achievements Low Hours, <1ppmS DECSE Fuel 5 Baseline EO EO with EGR Integrated ECS NOx Mass Emission, g/mile 4 3 2 1-98% -97% -83% 0 HLA HFET US06
100% 95% 90% 85% 80% SUV Platform Aging Results (LA4 Composite) 0 50 100 150 1800 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650 1700 1750 1850 1900 1950 2000 2050 Desulfation Age (hours) LA4 Composite (D15) LA4 Composite (BP15) Standard-D 15 NOx Conversion
NO x Adsorber/DPF Heavy-Duty Platform Ricardo, Inc (Chicago) Vehicle: None Engine: 2002 Cummins ISX 15L Catalyst aging study completed 2000 hours Final report in progress
Project Scope Develop system capable of meeting 2010 emissions standards: - 0.20 g/bhp.h NO x and 0.01 g/bhp.h PM Develop sulfur management strategy Conduct 2000 hour catalyst aging test - Transient and steady-state evaluations of: - Regulated emissions - Currently unregulated emissions
Test Engine Cummins ISX 15L 475 hp Rating DOHC 4V central EUI Cooled EGR, VGT Advanced electronic controls 2002/2004 Base engine out emissions (pre-production)
Emission Control System DPF NAC NO x Sensor DOC NO x Sensors DOC Cummins ISX DPF NAC1 Full Flow System (no bypass) Device Dimensions Volume (Diameter x Length) Upstream DOC 12 x 6 11.1 L DPF (x2) 12 x 14 25.9 L (51.8 L total) NO x Adsorber 12 x 12 22.2 L (44.4 L total) Catalyst (x2) Clean-up DOC 12 x 6 11.1 L Total Volume: 118 L
Aging Results - NO x NOx (g/bhp-hr) 2.5 2.0 1.5 1.0 0.5 0.0 FTP Composite NOx Engine-out Level 0 250 500 750 1000 1250 1500 1750 2000 Age (hours) NOx Mean Desulfation More details: SAE 2005-01-1760
Trends Analysis - NO x 1.2 1 NOx (g/bhp-hr) 0.8 0.6 0.4 0.2 0 EPA 2010 standard 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Aging Hours Fresh Pre-Des ulfation A verage Post- Des ulfation
Heavy-duty SCR/DPF (Southwest Research Institute) Vehicle: none Engine: Caterpillar C12 w/ LPL EGR Two systems evaluated: System A: 6000 out of 6000 hours System B: 6000 out of 6000 hours Also testing NO x sensor durability
SCR - System Design AIR FILTER EGR COOLER LPL EGR T (IMP) UREA INJECTION INTAKE THROTTLE EGR VALVE N TPS EXHAUST CB-DPF AR EXHAUST FLOW SENSORS CB-DPF AL SCR AR FLOW BALANCING VALVES SCR AL CLEANUP CATALYST LPL EGR PICKUP EXHAUST DAMPER ATA AFTERCOOLER EXHAUST MANIFOLD C12 DIESEL ENGINE UREA PRESSURE CONTROL UREA INJECTION UREA INJECTION CONTROL INTAKE MANIFOLD UREA PUMP
Heavy-duty SCR/DPF Aging Study (HD FTP Composite NO x 8-ppm S fuel) Effects of Aging on NO x (Composite) (Mean and 95% Prediction Interval) 1.6 1.4 1.2 NOx (g/bhp-hr) 1 0.8 0.6 0.4 0.2 0 A B A B A B A B A B 0 200 2000 4000 6000 Unit / Age (Hours)
Lubricants Project Phase I Determine the impact of lubricant properties and composition on engine-out/catalyst-in emissions Phase II Determine if lubricant formulation impacts the performance and durability of NO x adsorber catalysts
Lubricants Project Status Phase I Completed in 2003 Final Report available Phase II Testing completed Aug 2004 Final reporting underway Detailed results to be presented in later session
Future Direction APBF-DEC projects to wrap up in 2005 At present time, no formal plans to continue the activity Anticipate future collaborative activities in fuels and lubricants research: Fuels for advanced combustion Non-petroleum based fuels Lubricant impact on PM