Advanced high-porosity filter technologies to meet BS VI regulations Dr. Ameya Joshi, Dr. Timothy V. Johnson JoshiA@corning.com JohnsonTV@Corning.com ECT 2016: Emission Control Technology for Sustainable Growth, 9 10 November 2016, New Delhi
PM 10 or PM 2.5 (mg/m 3 ) Significant advances in past decades towards cleaner air yet challenges ahead to reduce particulates, NOx, CO 2 NO 2 concentrations in troposphere WHO Global Urban Ambient Air Pollution Database ~ 3000 cities, 2012 2015 New Delhi PM 10 = 229 mg/m 3 25 of 67 cities are in India 2005 India target WHO targets 2014 Images from NASA's Goddard Space Flight Center Environmental Technologies 2
Particulate EPA regulations Tier 2 expected to drive Tier adoption 3 (phase in) of DPFs and USA GPFs globally CARB LEV III Phase in 3mg/mi > 1mg/mi EU JP USA Korea EU China JP Korea India Russia China EPA CARB Cycle RDE Beijing Diesel Nation Gasoline 12 Nation Cities 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 EU7? 2024 2025 NEDC WLTC Tier 3 (phase in) Monitor CF 2.1 CF 1.5 CF 1.0 Diesel Gasoline Beijing EU4 Beijing 5Expected needs EU5for particulate BJ 6 (LEV III ULEV filters70) or CN6b EU6? Brazil Proconve L6 (~T2B7) Proconve L7 Proconve L8? Nation BS III (EU3) BS IV India BS VI (~EU6b) 12 Cities BS IV (~EU4) Russia Cycle RDE Diesel Gasoline Nation 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 NEDC EU4 EU6b GDI PN 6e12# /km Tier 2 WLTC Monitor CF 2.1 CF 1.5 CF 1.0 EU6b GDI PN 6e12# /km Tier 2 EU6 JP 09 LEV III Phase in Diesel China 4 (~EU4) JP 09 China 5 (~EU5) New China PNLT 6 (WLTC) (~EU6c and tighter) Gasoline Beijing 5 BJ 6 (LEV III ULEV 70) or CN6b EU6 BS III (EU3) BS IV Tier 2 Tier BS VI 3 (phase (~ EU6b) in) BS VI (~EU6b) BS IV (~EU4) China 4 (~EU4) China 5 (~EU5) China 6 (~EU6c and tighter) EU5 EU6c GDI PN 6e11# /km EU6c GDI PN 6e11# /km Tier 3 (phase in) New PNLT (WLTC) Brazil Proconve L6 (~T2B7) Proconve L7 Proconve L8? DPF DPF + GPF EU6? 3mg/mi > 1mg/mi EU7? EU7? EU7? BS VI-2 GDI PN 6e11 #/km Environmental Technologies 3
Particulate filters have been designed to meet stringent performance needs Need High filtration efficiency Low pressure drop - Coated, soot/ash loaded Maintain catalytic performance Soot management Durability & strength Implication Engineered pore size & Optimized cell design Adequate porosity for catalyst Wide operating window High strength, low CTE, chemical resistance, etc. Example* Engineered pore size to meet conflicting requirements of high FE & low DP *Results using Corning s AT filter technology AT-LP = Low porosity for high SML application AT-HP High porosity for SCR integration Environmental Technologies 4
Diesel and gasoline emissions after-treatment systems are evolving to meet Euro6-level regulations Light-Duty Diesel EU5 Gasoline EU5/6b EU6c / BSVI EU6c / BS VI LNT / passive SCR Filtration + TWC Filtration only Active SCR Environmental Technologies 5
LD Diesel Likely BS VI after-treatment solutions Potential BS VI architectures LNT / passive SCR Active SCR Considerations for integrated SCR on filters Aspect Better space utilization Less passive regeneration Lower denox @ equal SCR cat. and/or NH 3 Explanation Combines 2 components NO 2 competition Limited urea decomposition & low NO 2 System pressure drop Faster heat-up (cold start) Cost, system complexity Could be higher at high WCL Better denox PGM (LNT), Urea infrastructure, controls Choice of LNT vs. SCR dictated by engine size & system cost Environmental Technologies 6
denox Integration of SCR on DPF for enhanced denox performance SCR Temperature Challenge with zeolite SCR technology is still improving denox at low temperatures (cold start) Close-coupled application enables early catalyst light-off and urea injection Close-coupled implementation = Faster Thermal Response Translates to earlier Urea Injection & Lower Emissions Results using Corning s AT-HP filter Environmental Technologies 7
PAH Conc. (mg/m 3 ) LD Gasoline Advanced substrates and particulate filters to meet BSVI regs. In-cylinder methods are insufficient for maintaining low PN over real world conditions Variation in speed/load Ambient temperature Deposits Injectors, combustion chamber, valves Production tolerances Wear, aging Variation of fuel, lube oil quality Variability across fleet Measurement challenges Gasoline Particulate Filters offer a robust solution to minimize tailpipe PN and capture PAHs Potential BS VI Architectures Filtration + TWC Filtration only 12 PAHs from EPA list of preferentially monitoring carcinogenic pollutants Fraidl et al. (AVL, 2012) 1.5L GDI engine, w/ TWC Tsinghua & Peking Univ., Fuel, 2016 Environmental Technologies 8
Extensive vehicle fleet experiments confirm robust filtration performance of GPF with minimal Dp penalty PN Filtration studied using large Vehicle Fleet with GPF retrofits 12 GDI vehicles (EU5/6b), Engines 1.4 3.0L, various segments (C,D,E, SUVs) GPFs uncoated and some TWC coated Gray: TWC only Color: With GPF Retrofit No clear trend for impact of GPF on CO 2 emissions observed Symbols: Various Engines Environmental Technologies 9
LD Gasoline Advanced substrates enable early light-off Low thermal mass FLORA substrates Porous substrate Washcoat Porous substrate Corning SAE 2015-01-1009, Honda SAE 2015,01-1001 14% improvement 21% improvement Environmental Technologies 10
Summary Implementation of BSVI regulations is an important step towards cleaner air Emissions are typically higher under real-world driving conditions, development of RDE and monitoring of in-use compliance is important After-treatment solutions exist and have been developed to meet the stringent requirements of reduced gas and particulate tailpipe emissions Choice of diesel after-treatment solution (SCR vs. LNT) will depend on engine size, urea infrastructure, control strategy etc. In either case, filters and substrates are capable of meeting the requirements BSVI regulations or gasoline implies use of advanced substrates, catalysts and particulate filters for GDI engine (for 6x10 11 #/km limit) Extensive testing has shown robustness of GPF technology to meet regulations without significant impact on fuel economy Environmental Technologies 11