High Performance SCR Technology with Ultra-Low-NOx Emissions for Future Regulations Emitec Gesellschaft für Emissionstechnologie mbh Klaus Müller-Haas Oswald Holz CTI, Emission Reduction for Off Highway Applications 26.-27.9 2012, Lindau am Bodensee (Germany)
Introduction Challenges to achieve high efficient SCR SCR Dosing System Evaporation and Mixing Pipe Close coupled compact SCR-System Conclusion Agenda
Engine Technology EU VI; NRMM >130 kw Stage 3 B 60 PM [mg/kwh] 30 EU V EU VI NRMM EU Stage IV NRMM EU IIIB SCR 80 % EU IV SCR 80 % NRMM Stage IIIB (2012) 0 1 2 3 4 NO x [g/kwh] 6 Heavy Duty /NRMM Emission Standards (ETC) & - Technology Shift of Priorities
Engine Technology EU VI; NRMM >130 kw Stage 3 B 60 PM [mg/kwh] 30 EU V EU VI NRMM EU Stage IV NRMM EU IIIB EU IV SCR 80 % NRMM Stage IIIB (2012) 0 1 2 3 4 NO x [g/kwh] 6 Heavy Duty /NRMM Emission Standards (ETC) & - Technology Shift of Priorities
Engine Technology EU VI; NRMM >130 kw Stage 3 B 60 PM [mg/kwh] 30 EU V NRMM EU Stage IV NRMM EU IIIB EU IV EU VI SCR >92-95 % 0 1 2 3 4 NO x [g/kwh] 6 Heavy Duty /NRMM Emission Standards (ETC) & - Technology Shift of Priorities
Introduction Challenges to achieve high efficient SCR SCR Dosing System Evaporation and Mixing Pipe Close coupled compact SCR-System Conclusion Agenda
Thermodynamic Challenges PC / LD / MD Non-Road NRMM NEDC RDE /(NTE) ++ +++ Priorities + ++ + ++ >80 FTP ++ + ++ + ++ >80 US06 ++ + >80 JC08 ++ + ++ + ++ >80 NRSC ++ >95 NRTC cold + ++ ++ ++ ++ > 80 NRTC.Warm + ++ + > 95 HD On-Road Steady State + >93 ETC + ++ ++ >93 WHTC cold ++ ++ ++ ++ ++ >70 WHTC warm ++ ++ ++ ++ >80 FTP + + ++ ++ ++ >80 JE05 ++ + ++ ++ ++ >80 Heat up during cold start low temperature condition Start of AdBlue Injection AdBlue-Decomposition NH 3 / NO x Uniformity SCR Light-Off SCR Conversion Limitation SCR Kinetic Limitation of NH 3 / NO x Limitation NH 3 storage Duty Cycle goals with lowest bsf and lowest cooling requirements Challenges and demands for SCR- Emission control technologies across various applications
AdBlue droplet interaction on surface Adblue droplet penetration on surface evaporation & thermolysis 1. + 2. reaction steps steps from AdBlue towards Ammonia: 1. Step: evaporation of Water: {(NH 2 ) 2 CO 7H 2 O} fl {(NH 2 ) 2 CO} fl + 7 H 2 O 2. Step: thermolysis of Urea: {(NH 2 ) 2 CO} fl HNCO + NH 3 3. Step: hydrolysis of isocyanic acid: HNCO + H 2 O CO 2 + NH 3 Emitec-Technology for Optimization: Optimize Hydrolysis: Usage of Hydrolysis Catalyst / Mixer Optimize NH 3 Distribution: Optimization of Mixing pipe and mixing design Fundamental Steps for AdBlue Decomposition and Technology for System Optimization
Reaktionen bei der NO X Reduktion durch SCR: Standard SCR- Reaction with NO: 4 NO + O 2 + 4 NH 3 4 N 2 + 6 H 2 O fast SCR-Reaction with NO+NO 2 : 2 NO 2 + 2 NO + 4 NH 3 4 N 2 + 6 H 2 O Emissions during ETC 100 6 NOx Conversion Rate [%] 90 80 70 60 50 40 30 20 10 0 NO 2 / NO 50% / 50% Temperature Range at low load operation NO 2 / NO 0% / 100% 0 100 200 300 400 NO, NO 2 [g/kwh] 5 4 3 2 1 0 NO NO2 NO NO 2 NO 2 NO 2 Engine Out behind DOC behind SCR - 30% Temperature [ C] NO x - SCR-Efficiency as Function of NO-NO 2 -Ratio
100 95 90 NO x -Reduction Alpha = 1.00 Alpha = 0.95 Alpha = 0.90 Alpha = 0.80 85 80 75 70 0,88 0,9 0,92 0,94 0,96 0,98 1 NH 3 -Uniformity Calculated NO x -Reduction and NH 3 Slip as Function of NH 3 -Uniformity and AdBlue-Dosing Rate
100 NO x -Reduction 60 NH 3 - Slip Alpha = 1.00 95 50 Alpha = 0.95 Alpha = 0.90 90 40 Alpha = 0.80 85 30 80 20 75 10 70 0,88 0,9 0,92 0,94 0,96 0,98 1 NH 3 -Uniformity 0 0,88 0,9 0,92 0,94 0,96 0,98 NH 3 -Uniformity Calculated NO x -Reduction and NH 3 Slip as Function of NH 3 -Uniformity and AdBlue-Dosing Rate
100 Long tube short tube DOC NOx-Conversion [%] 95 90 85 short tube NOx = 200ppm Short tube long tube SCR DOC AdBlue long tube 80 0 5 10 15 20 25 30 AdBlue NH3-Slip SCR DeNOx Performance as Function of NH 3 - Uniformity
NO x -Conversion [%] 105 100 95 90 85 80 straight tube S-tube straight tube 75 T= 410 C 70 NOx = 350 ppm SV.SCR = 58.000 1/hr 0 10 20 30 40 50 60 70 80 90 100 110 120 NH 3 -slip [ppm] Influence of System Design on NH 3 -Uniformity and DeNOx- Performance S-tube
400 380 High dosing frequency Low dosing frequency 800 400 0 Actual_Dosing_Rate [ml/h Dosing Rate n = 1800 min -1 TQ = 700 Nm NO x UP = 450 ppm Alpha NOx = 0,9 NOx down SCR [ppm] 360 NOx Tailpipe 340 320 300 High efficiency SCR system has to have a continuous flow of Adblue At high conversion rate targets is a high dosing frequency mandatory NO x tailpipe +- 14% Delta_peak = 80 ppm NO x tailpipe +- < 1% Delta_peak = 5 ppm 280 260 Time 0 5 10 15 20 time [s] Influence of Dosing Frequency on the NO x Conversion Rate
Introduction Challenges to achieve high efficient SCR SCR Dosing System Evaporation and Mixing Pipe Close coupled compact SCR-System Conclusion Agenda
Customized Tank for the application In Tank SCR-Dosing system Gen III Emitec SCR-Dosing System Gen III
Suction lance Temperature sensor Urea filter Level sensor Tank heater Heated suction line External DCU Quality sensor Emitec Gen III System Description All in One Integration Installation cost: Electrical harness Fixing devices Lines connections
Ringfilter Connector to Injector Electrical Connector Emitec Dosing System Gen III; Outside View
PTC Heater Pressure Control Valve Pump Level-/Quality Sensor Pressure Sensor Electronic Emitec Dosing System Gen III; Inside View
Manifold with SAE-Connectors Large Engine Dosing Control Unit LE- DCU.... Dosing Pumps with Urea Pumphead (60 ltr/h and 150 ltr/h)) Injectors (Airless, Watercooled) Large Engine Airless Dosing System
Introduction Challenges to achieve high efficient SCR SCR Dosing System Evaporation and Mixing Pipe Close coupled compact SCR-System Conclusion Agenda
NO x -Efficiency with Optimized Airless Dosing Layout Evaporation and Mixing Pipe
Motor Torque Drehmoment engine torque fast start of dosing excellent evaporation of droplets low risk for depositions + static mixer + Hydrolysis Catalyst low temperature area Engine Speed Motor Drehzahl engine speed Thermal Challenges for AdBlue Injection within Engine Map
100 98 96 NOx Efficiency 94 92 90 Test conditions: constant speed / torque constant temperature and massflow and exhaust gas condition exhaust gas 714 kg/h, T = 420 C, NO x = 543 ppm; NO 2 /NO x = 0,27 theoretical AdBlue demand for (alpha = 1) = 1100 ml / h setup with Fe-Zeolithe catalyst [Ø242 x (110 + 110)] 10,1 ltr dosing rate 1000 ml / h 1200 ml/h (alpha = 0,9... 1,1) 88 86 0,85 0,9 0,95 1 1,05 Alpha (-) NO x -Efficiency with Optimized Airless Dosing Layout Sweep Test
Introduction Challenges to achieve high efficient SCR SCR Dosing System Evaporation and Mixing Pipe Close coupled compact SCR-System Conclusion Agenda
DOC LS/PE-Metalit Compact SCR System for Heavy Duty and Non Road Mobile Machineries
DOC LS/PE-Metalit AdBlue-Injector Compact SCR System for Heavy Duty and Non Road Mobile Machineries
- Robust design based on mass production - gasoline injector - Spray charactristic optimized Water Cooling for robust Off Road demands Reductant Delivery Unit (Urea Injector)
DOC LS/PE-Metalit AdBlue-Injector Mixing Element / Hydrolysis Catalyst Compact SCR System for Heavy Duty and Non Road Mobile Machineries
Variant 1 with Mixing Element Variant 2 with Hydrolysis Catalyst N= 1200 1/min; Md = 215 Nm Exhaust Mass: 326 kg/h; T = 230 C AdBlue-Dosage = 560 g/h, α = 0.8 Comparison of a Mixer / Hydrolysis Catalyst regarding Deposits at Low Temperature AdBlue Injection
SCR- Catalyst LS-Metalit DOC LS/PE-Metalit AdBlue-Injector Mixing Element / Hydrolysis Catalyst Compact SCR System for Heavy Duty and Non Road Mobile Machineries
close coupled DOC + 1. stage SCR 2.Stage SCR Compact SCR System for Heavy Duty and Non Road Mobile Machineries, Demonstrator
1. Stage 2. Stage Engine DOC (2,2 ltr) static mixer SCR 1 (6,5 ltr) SCR 2 (4,0 ltr) close coupled NOx T T NOx NOx SCR only System Layout
UI = 0,96 0 Total velocity [m/s] 10 Flow / NH 3 Distribution @ Close Coupled SCR Catalyst
AdBlue Flow at constant Exhaust Flow m= 550 kg/h T = 430 C m.adblue = 1,29 kg/h (12 shots/sec)
90 300 NOx after 1. Stage Accumulated NOx [g] 60 30 Accumulated AdBlue [g] 200 100 NOx after 1. Stage 0 0 SCALE Accumulated NOx [g] 5 0 0 200 400 600 800 1000 1200 1400 time [sec] Accumulated NOx Emissions pre and post 1.Stage at Alpha = 1 during NRTC
90.0 300 Acumulated NOx [g] 60.0 30.0 Acumulated AdBlue [g] 200 100 NOx engine out AdBlue-Mass 0.0 Acumulated NOx [g] 0 5 0 0 200 400 600 800 1000 1200 1400 NOx after 1. Stage NOx Tailpipe time [s] Accumulated NOx Emissions at Alpha = 1 during NRTC
90 Acumulated NOx [g] Acumulated NOx [g] 60 30 0 3 0 0 200 400 600 800 1000 1200 1400 1. SCR Stage 91,1 % 94,6 % post SCR 2 2.SCR Stage time [s] Accumulated NOx Emissionen after 1 st and 2 nd SCR Stage during NRTC Test
90 NH 3 [ppm] Acumulated Nox [g] 60 30 0 100 94,6 % SCRa 0 0 200 400 600 800 1000 1200 1400 time [s] Tailpipe NH 3 concentration (no NH 3 slip catalyst) Total NO x Reduction and NH 3 Slip during NRTC Test
Introduction Challenges to achieve high efficient SCR SCR Dosing System Evaporation and Mixing Pipe Close coupled compact SCR-System Conclusion Agenda
η.nh 3 > 94 % High Efficient SCRTechnolgy η.nh 3 > 94 % Optimized NH 3 Slip Catalyst Advanced DOC Technology η.hc > 90 % NO 2 /NO x < 0,5 SCR Catalyst Technoloy 10110100 10110100 10110100 01010101 01001010 01001010 01010100 01001010 Advanced Dosing Strategy Robust AdBlue-Injection UI.NH 3 > 0,98 Perfect Mixing of NH 3 with Exhaust Gas Excellent Decompostion of Reduction Agent Minimum HNCO concentration
High Performance SCR Technology with Ultra-Low-NOx Emissions for Future Regulations Emitec Gesellschaft für Emissionstechnologie mbh Klaus Müller-Haas Oswald Holz CTI, Emission Reduction for Off Highway Applications 26.-27.9 2012, Lindau am Bodensee (Germany)