Overview of Emissions Treatment Technologies for Heavy-duty Engines Mr. R. Brück AECC Technical Steering Committee AECC Technical Seminar on Heavy-duty Engine Emissions Brussels, 25 October 2007 1
Introduction Contents Diesel Oxidation Catalysts Particulate Filters Wall-flow particulate filters Partial-flow particulate t filters Selective Catalytic reduction SCR catalysts Sensors Applications 2
PM vs NOx (ESC test): 2002-2006 0,180 0,160 2002 0,140 PM g/k kwh 0,120 0,100 0,080 Euro III limits (<0.75dm 3 & >3000min -1 rated power speed) Euro III limits 0,060 0,040 0,020 Euro V limits Euro IV limits 0,000 0,00 1,00 2,00 3,00 4,00 5,00 6,00 NOx g/kwh Source: KBA data, June 2002, January 2006, March 2007 3
PM vs NOx (ESC test): 2002-2006 0,180 0,160 2002 2006 0,140 PM g/k kwh 0,120 0,100 0,080 Euro III limits (<0.75dm 3 & >3000min -1 rated power speed) Euro III limits 0,060 0,040 0,020 Euro V limits Euro IV limits 0,000 0,00 1,00 2,00 3,00 4,00 5,00 6,00 NOx g/kwh Source: KBA data, June 2002, January 2006, March 2007 4
PM vs NOx (ESC test): 2002-2006 0.180 0.160 2002 2006 2007 (Euro V & EEV data) 0.140 PM g/k kwh 0.120 0.100 0.080 Euro III limits (<0.75dm 3 & >3000min -1 rated power speed) Euro III limits 0.060 0.040 0.020 Euro V limits Euro IV limits 0.000 0.00 1.00 2.00 3.00 4.00 5.00 6.00 NOx g/kwh Source: KBA data, June 2002, January 2006, March 2007 5
Euro V & EEV diesels at Hanover IAA Show September 2006 6
Engine Technology (engine out emissions) Emissions Control Technologies Tailpipe Emissions 7
One view of a future engine ETC cycle demands on the engine raw emissions and on PM conversion to meet emissions i limits it (MAN) Euro Limit Value Stage NOx g/kwh / PM mg/kwh Raw ~max. EGR CR Injection emissions rate (%) pressure NOx g/kwh / (bar) PM mg/kwh Turbo PM Conversion (%) IV 35/30 3.5 30 33/50 3.3 18 20 1600 1stage 60 V 2.0 / 30 1.8 / 60 25-30 1800-2000 2 stage intercooled VI 1.0 / 20 0.9 / 60 30-35 2400-2500 2 stage intercooled 65 75 Source: MAN; 26. Internationales Wiener Motorensymposium 2005 8
Emissions i Control Technologies - Diesel Oxidation Catalyst t (DOC) => Conversion of HC and CO - Diesel Particulate Filters => Particulate Reduction (Mass / Number) - Selective Catalytic Reaction (SCR) => NOx Reduction 9
Diesel Oxidation Catalysts (DOC) Source: MAN 10
Emissions i Control Technologies - Diesel Oxidation Catalyst t (DOC) => Conversion of HC and CO - Diesel Particulate Filters => Particulate Reduction (Mass / Number) - Selective Catalytic Reaction (SCR) => NOx Reduction 11
Wall-flow particulate filters for light- duty and heavy-duty applications 12
Wall-flow particulate filters concentrat tion dn/dlog gdp[cm-3] 1,00E+07 1E+06 Engine-out 1E+05 Post-DPF number 1E+04 1400 rpm/50% load downstream of the trap 1E+03 10 100 mobility diameter [nm] 1400 rpm/50% load without trap clean room ambient air Measurement by Matter Engineering Ingenieurschule Biel 13
Partial-flow particulate filters for light- duty and heavy-duty applications 14
Partial-flow particulate filter Source: MAN, CTI Forum Abgastechnik, 2007 Source: AECC Member Company, CTI Forum Abgastechnik, 2007 15
Worldwide DPF retrofit experiences Construction equipment Mining equipment Materials Handling Refuse trucks City and School buses Stationary Diesel Engines Marine Vessels Locomotives 16
Diesel Particulate Filter (DPF) regeneration technologies Engine control to increase exhaust gas temperature Catalysed C-DPF Catalysed DPF 17
Catalysed Particulate Filter (C-DPF) Dirty Exhaust Inlet Channels Porous Filter Wall Catalyst Plug Plug Cleaned Exhaust Outlet Channels 18
Diesel Particulate Filter (DPF) regeneration technologies Engine control to increase exhaust gas temperature Catalysed C-DPF Catalysed DPF Continuously Regenerating CR-DPF Oxidation Catalyst DPF 19
Continuously Regenerating Particulate Filter (CR-DPF) 20
Diesel Particulate Filter (DPF) regeneration technologies Engine control to increase exhaust gas temperature Catalysed C-DPF Catalysed DPF Continuously Regenerating CR-DPF Oxidation Catalyst DPF DPF + Fuel Borne Additive FBC Oxidation Catalyst DPF 21
Particle Filters using fuel-borne additive Source: PSA 22
Diesel Particulate Filter (DPF) regeneration technologies Engine control to increase exhaust gas temperature Catalysed C-DPF Catalysed DPF Continuously Regenerating CR-DPF Oxidation Catalyst DPF DPF + Fuel Borne Additive FBC Oxidation Catalyst DPF (Off-line electrical / thermal regeneration) 23
Emissions i Control Technologies - Diesel Oxidation Catalyst t (DOC) => Conversion of HC and CO - Diesel Particulate Filters => Particulate Reduction (Mass / Number) - Selective Catalytic Reaction (SCR) => NOx Reduction 24
Selective-Catalytic reduction (SCR) 25
Urea SCR-system Exhaust Gas 85% NOx NOx NH 3 O 2 > 85% NOx reduced N 2 H 2 O Source: Bosch, drawing adapted 26
Chemistry of the SCR catalyst system urea (NH 2 ) 2 CO SCR catalyst (S) 4NH 3 + 4NO + O 2 4N 2 + 6H 2 O 2NH 3 + NO + NO 2 2N 2 + 3H 2 O 8NH 3 + 6NO 2 7N 2 + 12H 2 O exhaust gas V H S O Oxidation catalyst (V) 2NO + O 2 2NO 2 4HC + 3O 2 2CO 2 + 2H 2 O 2CO + O 2 2CO 2 Oxidation catalyst (O) 4NH 3 +3O 2 2N 2 +6H 2 O Hydrolysis catalyst (H) (NH 2 ) 2 CO + H 2 O 2NH 3 + CO 2 27
NOx and NH 3 sensors 28
Heavy-duty applications 29
Marine vessels SCR system Emission reduction in Baltic Sea maritime transport: Reducing the weighted overall NOx emission to levels below 2 g/kwh. Main propulsion engines: 06 0.6 resp. 0.85 085 g/kwh NOx. Auxiliary engines: 02 0.2 g/kwh NOx. (according to SJÖFS 1997:28 at 75% load) 30
Thank you for your attention 31