SCR-Solutions for BS IV and BS V Regulations Lakshminarayanan Govindaraj Commercial Vehicle Megatrends India 2012 25-27 April 2012, Chennai, India
Albonair 2007 2008 2009 2010 2012»Albonair is founded as part of Hinduja Automotive Sector»100% privately owned by Hinduja Group»Albonair delivers first prototypes of SCR- Systems to customers»albonair India is founded to set up a production facility for a local customer»sop of exhaust aftertreatment solutions for the Indian market»albonair moves into a new headquarter in Dortmund, Germany»SOP of EURO VI- UDS for an European OEM 1 CVM 2012 1
Agenda 1 India Emission Standard & SCR 2 3 Albonair s SCR Solution for India Summary 4 2 CVM 2012 2
Development of Emission Standards and the Need of SCR Stronger Emission Standards require SCR-Systems EURO norms BS norms 3 CVM 2012 3
Basics of SCR Technology» SCR is the abbreviation for Selective Catalytic Reduction»Principles of SCR is known and used for reduction of nitrogen oxides in the exhaust gas of power plants since the 1970 s»scr is a method to reduce nitrogen oxides (NOx) in oxygen rich exhaust gases»nitrogen oxides are converted to nitrogen and water on the surface of a catalyst by adding ammonia to the exhaust gas»to transfer SCR to the automotive sector ammonia has to be replaced by urea 4 CVM 2012 4
Basics of SCR Technology Conversion of Nitrogen Oxide (NO x ) into Nitrogen (N 2 ) and Water (H 2 0) NH 3 SCR-Catalyst NO 2 NO N 2 O 2 CO 2 H 2 O O 2 CO 2 5 CVM 2012 5
Basics of SCR Technology Conversion of Nitrogen Oxide (NO x ) into Nitrogen (N 2 ) and Water (H 2 0) AdBlue Ammonia NO + NO 2 + 2 NH 3 2 N 2 + 3 H 2 O 4 NO + O 2 + 4 NH 3 4 N 2 + 6 H 2 O 2 NO 2 + O 2 + 4 NH 3 3 N 2 + 6 H 2 O 6 CVM 2012 6
1 India Emission Standard & SCR 2 3 Albonair s SCR solution for India Summary 4 7 CVM 2012 7
Integration of SCR-Systems in commercial vehicles 8 CVM 2012 8
Concept of Albonair sscr System for BS IV and BS V Schematics Urea level Urea temperature Engine AdBlue Tank Air pressure Urea pressure Urea temperature Dosing System Coolant Engine Coolant Actuators CAN Electronics (ACU) Engine ECU Urea Air Air Engine Coolant Urea Sensors Air Supply (vehicle air or electrical air pump) Exhaust stream SCR Muffler with Injection Nozzle Temp. Sensor Nozzle NOx sensor Temp. Sensor 9 CVM 2012 9
Mechanisms of Droplet Evaporation Primary Droplet Breakup Secondary Droplet Breakup initiated by AdBlue -Injector initiated by reciprocal effect of exhaust flow and droplets 10 CVM 2012 10
Spray Formation of Different AdBlue Injection Systems System Spray Formation Characteristics Pressure Atomizer (Airless)» Energy for atomization from the liquid pressure» Increase of pressure leads to improved spray quality Twin Fluid Atomizer with internal mixing (Air Assisted)» Energy for atomization from air pressure» Typically high air consumption Albonair s Concept is based on: Twin Fluid Atomizer with external mixing(air Assisted)» Energy for atomization mainly from air pressure» Low air consumption» No contact between AdBlueand air in the dosing system / nozzle to avoid crystallization and deposits 11 CVM 2012 11
Albonair SCR-Tank Assembly with Dosing and Control Unit Specification» Integrated Urea Dosing System» Aftertreatment Control Unit (ACU)»Urea filter mesh» Urea Level Sensor» Wiring-Harness»Urea-and Coolant-Water (heated tank) tubes» Vented filler cap» Tank brackets 12 CVM 2012 12
Albonair SCR-Exhaust System Specification»No moving parts» Two temperature sensors (preand post cat)»no mixer»no ammonia slip cat» Alumninized steel for outer shell and clean side components» Circular and elliptical designs»engine power rating 90 kw 165 kw, higher power ratings possible 13 CVM 2012 13
Small and Heat Resistant Injection Nozzle Specification 3D Drawing» No mechanical parts» No electrical parts» High temperature resistant (up to 800 o C)» Small & flexible to mount» Droplet Size < 20 µm SMD 14 CVM 2012 14
Different Nozzle Designs Small and Flexible to mount Connectors for AdBlueand Air hose have to be routed out of hot areas (>120 C) 15 CVM 2012 15
CFD-Analysis of the Spray Evaporation with the ALBONAIR Doser AdBlue is homogenously distributed and evaporates fast due to small droplet size Conditions: Exhaust Gas Mass Flow: 170kg/h Frequency: 2.1 Hz Exhaust Gas Temperature: 260 C 16 CVM 2012 16
Catalyst Efficiency improved at low Exhaust Mass Flow 100 Low Exhaust Mass Flow 200-250 kg/h 100 High Exhaust Mass Flow 600-1000 kg/h 90 90 80 80 NOx-Conversion Rate (%) 70 60 50 NOx-Conversion Rate (%) 70 60 50 40 Albonair 40 Albonair Airless 30 175 195 215 235 255 275 Airless 30 175 195 215 235 255 275 Temperature ( C) Temperature ( C) 17 CVM 2012 17
Improved Spray Quality avoids Deposition of Urea within the Exhaust System Benchmark System Albonair s System» high amount of deposits» no significant amount of deposits 18 CVM 2012 18
1 India Emission Standard & SCR 2 3 Albonair s SCR Solution for India Summary 4 19 CVM 2012 19
Key Takeaways Technical Aspects» Optimized Distribution & Evaporation of AdBlue» Fast evaporation of AdBlue droplets» Improved catalyst efficiency especially at low temperatures 100% Airless: NH 3 Airless: HNCO 80% 60% 40%» No significant urea deposition in the 20% system 0% Albonair: NH 3 Albonair: HNCO 20 CVM 2012 20
Key Takeaways Design Aspects» Maintenance free no service filters in the system,» Nozzle» Compact design» No mechanical parts» No electrical parts» High temperature resistant» No possibility of congestion» Modular Design for BS IV and BS V» Autonomous Control Unit» Just two components to attach to vehicle» Tank assembly» Muffler 21 CVM 2012 21
Albonair: One-stop solution for SCR-Solutions Selective Catalytic Reduction System Urea Tank ACU & UDS SCR-Muffler & Nozzle» Albonair offers complete SCR-Solutions 22 CVM 2012 22
Summary»The Bharat Stage -4 Norm was introduced in April 2010 and currently applied in 20 major cities in India»The government of India aims to include as many as 50 major cities of the country in the BS IV emission norms category by year 2015»SCR is the mostly used solution to fulfill BS 4» Emerging markets, as India, have special demands on SCR-Systems:» Modular Systems» Easy, preferably no maintenance» Robustness to bad environmental conditions as e.g. dusty AdBlue»Bharat Stage 5 alreadyin discussions. Preferably no change on BS IV Systems to meet next stage requirements. 23 CVM 2012 23
German Engineering for Clean Air info@albonair.com 24 CVM 2012 24
Backup 25 CVM 2012 25
Emission Standards for diesel trucks & buses in India % Change in the Emission Year Norm CO HC Nox PM 1996 20 31 20 2000 BS I 60 54 44 2005 BS II 11 0 13 58 2005 BS III 48 40 29 33 2010 BS IV 29 30 30 80 26 CVM 2012 26