Highly efficient SCR Solution for Large Engine Application by modular System Set-up - universal and cost efficient

Highly efficient SCR Solution for Large Engine Application by modular System Set-up - universal and cost efficient Klaus Müller-Haas Rolf Brück Andreas Scheeder EMITEC Gesellschaft für Emissionstechnologie mbh 5 TH AVL LARGE ENGINE TECHDAYS 09 th & 10 th May 2012

Introduction Requirements and Demands for Large Engine SCR- Technology Components for DeNOx Technology Multi-Pipe Decomposition System for Large Engines SCR catalyst technology and optimization Outlook Content

PM [g/kwh] 0,2 PM [g/kwh] 0,2 NOx [g/kwh] 6 C&I currently no EU limits under consideration 0,1 Stationary currently no EU limits regulated by TA-Luft 8 C&I 2011 Tier 4i 2011 Tier 4i < 900 kw 2016 Stage IV (CCNR) NOx 2015 2015 [g/kwh] Tier 4 Tier 4 2012 4 4 8 Stage IIIB 2016 Stage IV NOx (Euromot) [g/kwh] 0,1 2011 Tier 4i > 900 kw Stationary 4 2015 2012 4 8 Tier 4 Tier 4 NOx [g/kwh] 0,1 2012 Stage IIIB (Euromot) 2012 Stage IIIB (CCNR) 2011 Tier 4i 0,1 2012 Tier 3 Rail (Switch) Marine Rail (Switch) Marine 0,2 PM [g/kwh] 0,2 PM [g/kwh] (CCNR) Central Commission for Navigation on the Rhine EU and US Emission Legislation for Different Applications EU : S < 15ppm (2014) IMO: S < 5000ppm (2020) Emission Control Area: S < 1000ppm (2015)

relative torque nonroad vehicles and industrial equipment 0 0 0.2 0.4 0.6 0.8 1 relative speed marine engines 1.2 less than 24m; except tug/push boats HD, constant speed for marine propulsion 1 0.8 0.6 0.4 1 0.8 0.6 0.4 0.2 C1 E1 E2 0.15 0.32 0.19 0.1 0.1 280..350 C 200..250 C 0.08 0.11 280..350 C 0.2 200..250 C 0 0.3 0 0.2 0.4 0.6 0.8 1 high 0.1 0.15 > 500 C 1 0.15 0.15 0.1 0.2 0.15 0.15 0.5 constant speed 1.2gensets, pumps 0.8 0.6 0.4 0.2 0 Marine: 1.2 for test cycles based on propeller curve 1 0.8 0.6 0.4 0.2 0.15 0.02 0.05 0.15 0.1 0.3 0 0.2 0.4 0.6 0.8 1 0.3 C2 E4 E5 200..250 C 200..250 C 0.32 280..350 C 0.13 0.13 0.15 0 0 0.2 0.4 0.6 0.8 1 0.06 0.08 high 0.2 > 500 C 0.17 280..350 C 0.5 constant speed 1.2 Genset, units with intermitted load 1 0.8 0.6 0.4 0.2 rail engines 1.2 1 0.8 0.6 0.4 0.2 0 0.6 D1 D2 high 0.3 0.05 > 500 C 0.5 280..350 C 0.2 0 0 0.2 0.4 0.6 0.8 1 F 200..250 C 200..250 C 0.25 280..350 C high 0.2 > 500 C 0 0.2 0.4 0.6 0.8 1 0.1 0.25 0.3 0.3 Classification of Test Cycles according to ISO 8178 and Exhaust Gas Boundary Conditions

Low Temperature Mid range High Injection of reduction agent 200..250 C 280..350 C decomposition of reduction agent high > 500 C Uniformity Substrate/ Catalyst optimization Thermodynamic Challenges for DeNOx-Systems

EMITEC Technology Air Assisted Dosing System Airless Dosing Systems Air Supply Exhaust Pipe Diameter Injection of Reduction Agent Needed easy in pipe installation of nozzle Droplet size Small droplets << 50µm Droplet penetration /- distribution Variation based on p, gasflow > 200 mm 400mm Emitec AdBlue-Dosing Systems

low gas velocity bigger droplets small droplets Principle Droplet Penetration/ Evaporation of Air-Assisted System as Function of Gas Speed

low gas velocity high gas velocity bigger droplets droplet penetration smaller droplets fast evaporation Principle Droplet Penetration/ Evaporation of Air-Assisted System as Function of Gas Speed

Air Assisted Dosing System Airless Dosing Systems Air Supply Needed Not needed (Motivation) Exhaust Pipe Diameter Injection of Reduction Agent Nozzle in gas stream e.g. Ø400 mm Nozzle outside in pipe Droplet size < 50 SMD 50.. 100 SMD Droplet penetration /- distribution Variation based on p, flow defined spray angle, p, Scope of development for large engines Goal: optimal ammonia distribution at LARGE Ø Pipes at all operation conditions Development Scope for AL-AdBlue-Dosing Systems for Large Engines

Injectors (Airless, Watercooled) Inlet Modular Arrangement of Multi Dosing Pipe Outlet Multi-Pipe Decomposition System (e.g. 3000 kw)

Introduction Requirements and Demands for Large Engine SCR Technology Components for DeNOx Technology Multi-Pipe Decomposition System for Large Engines System Layout Universal Dosing Pipe Design Function and Characterization Performance results SCR catalyst technology and optimization Outlook Content

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

Overview of Multi-Pipe Decomposition System

Key features: usage of 6- hole injector to increase droplet uniformity penetration of droplets in flow direction towards a hot surface at low cell density MX-Metalit Substrate Design of Decomposition Pipe and Components

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 Fundamantal Steps for AdBlue Decomposition and Technology for System Optimization

Droplet Efficiency [-] 50,8 mm 74,5 mm MX 40 cpsi no droplets 0 50 100 150 200 Substrate Length [mm] MX-Metalit design Criteria: Influence of Matrix Length on Droplet Efficiency Temperature =300 C, Channel Velocity 10 m/s

potential improvement wall enthalpy ~ Characterization of Decomposition Pipe

to be avoided Design of Decomposition System Source: AVL

wetted MX-front face as function of injector distance 1,0 10 0,8 0,6 0,4 0.2 9 8 7 6 5 4 3 2 1 0 ~ 0 100 200 300 400 500 600 Distance Injector-Tip to MX-Front Face [mm] l Relative Spray Load at MX-Metalit Front Face depending on Injector Distance

Injection on MX-Front Face Basic Investigations without Hydrolysis Catalyst Investigations of Deposit Formation

Installation of AdBlue-Injector Flow Straightener Burner MX- Substrate Decomposition Pipe U-Pipe to simulate inlet flow condition Parameter: AdBlue-Dosing Rate Gas Flow Rate Gas Temperature Characterization of Decomposition Pipe MX- Substrate

start of deposition dosing rate to high dosing rate reduced after 2 hrs after 8 hrs after 6 hrs no deposition Deposition Test at Dosing Pipe

increase of dosing rate long medium short robust to remove more than 7 g/kwh NO x increase of AdBlue-Loading Capacity of Dosing Pipe as Function of Temperature and Injector Distance

Key features: usage of 6- hole injector to increase droplet uniformity penetration of droplets in flow direction on hot surface usage of a low cell density MX-Substrate with hydrolysis coating excellent heat transfer reduction of droplet surface tension inlet flow support droplet break up accelerate evaporation start hydrolysis process high degree for NH 3 -NO x -mixing downstram very good heat transfer coefficient at blade TiO 2 -Coating supports droplet break up and hydrolysis process Design of Decomposition Pipe: MX-Metalit with Hydrolysis Catalyst

Low Temperature Mid range High Injection of reduction agent 200..250 C 300..350 C decomposition of reduction agent high > 500 C Uniformity to be perfect (goal = UI.NH 3 = 1,0) Substrate/ Catalyst optimization Robust System performance over lifetime (degradation) Thermodynamic Challenges for high Efficient DeNOx-Systems

92% 90% 88% 86% 84% 82% 80% 78% 76% 74% 72% 70% 0.9 0.85 0.8 UI = 1,0 UI = 1,0 UI = 1,0 ALPHA = 0,8 ALPHA = 0,85 ALPHA = 0,9 DeNO x -Function depending on NH 3 -Uniformity and Catalyst Stage (Assumption homogeneous flow distribution)

catalyst divided in slices Inlet Outlet eta.nox Alpha = 0,9 UI.NH 3 = 1,0-20% -20% -20% -20% -20% -20% -20% -20% -20% -7% (NH 3 consumed) 90,0% Inlet eta.nox Alpha = 0,9 UI.NH 3 = 0,935 85,2% 4,8% NH 3 Slip Modell to predict System DeNOx Performance as Function of Uniformity and Catalyst Activity

92% 90% 88% 86% 84% 82% 80% 78% 76% 74% 72% 70% UI = 1,0 UI = 0,935 UI = 1,0 UI = 0,935 UI = 1,0 UI = 0,935 ALPHA = 0,8 ALPHA = 0,85 ALPHA = 0,9 DeNO x -Function depending on NH 3 -Uniformity and catalyst stage (Assumption homogeneous flow distribution)

92% 90% 88% 86% 84% 82% 80% 78% 76% 74% 72% 70% UI = 1,0 UI = 0,935-2,5% UI = 1,0 ALPHA = 0,8 ALPHA = 0,85 ALPHA = 0,9 UI = 0,935-5,0% UI = 1,0 UI = 0,935-8,0% aged with DF = 0,8 NH 3 -uniformity is the key for robust DeNOx Function DeNO x -Function depending on NH 3 -Uniformity and Catalyst Stage (Assumption homogeneous flow distribution)

Low Temperature 200..250 C Mid range 300..350 C High high > 500 C Injection of reduction agent decomposition of reduction agent Uniformity to be perfect (goal = UI.NH3 = 1,0) Substrate Catalyst formulation Substrate surface area (GSA) Vandium CU- Zeolithe mass transfer and GSA Vanadium Fe-Zheolithe Thermodynamic Challenges for high efficient DeNO x -Systems

18 [mm] LS/PE-Foil Flow Position A Position H Concentration Tracer gas [%] 100 80 60 40 20 Radial Mixing after a substrate length of 18 mm LSPE Tracer Gas injected into a single Channel; 200kg/h; 300 C 0

Conversion 100 90 80 70 60 50 40 30 20 10 reaction limited by mass transfer significant boost at higher where overall reaction is controlled by mass transfer 0 200 300 400 500 600 Temperature [ C] NO x -Conversion as Function of Substrate Technology Standard Foil and LS-Foil

0,25 0,20 Stufe IIIA PM in g/kwh 0,15 0,10 0,05 0,00 Stage IV Stage IIIB SCR > 94% 0 1 2 3 4 5 6 7 8 9 NO X in g/kwh? Outlook: SCR-only with highest Efficiencies

NH 3 -Distribution at SCR Catalyst Inlet

PM in g/kwh 0,25 0,20 0,15 0,10 0,05 0,00 Stage IV Stage IIIB T [ C] 600 400 200 0 cold Stufe IIIA SCR engine speed engine load T SCR in T SCR out NOx emissions engine out NOx emissions tail pipe 0 0 120 240 360 480 600 720 840 960 108012001320 t [s] 0 1 2 3 4 5 6 7 8 9 NO X in g/kwh NRTC (α = 1,05) warm 8 7 6 5 4 3 2 1 T [ C] 600 400 200 0 engine speed engine load T SCR in T SCR out NOx emissions engine out NOx emissions tail pipe 0 0 120 240 360 480 600 720 840 960 108012001320 t [s] - SCR-only (Va-Typ, w/o EGR, w/o DOC, w/o Slip-Kat - Tailpipe: cold 0,7 g/kwh (>90%) / warm 0,18 g/kwh (>97,5%) break specific NOx [g/kwh]? 8 7 6 5 4 3 2 1 break specific NOx [g/kwh] Outlook: SCR-only with highest Efficiencies

Modular Arrangement of Multi Dosing Pipe Thank you for your attention Dosing Unit with Hydrolysis Catalyst Simulation of the Dosing Unit Injectors (Airless, Watercooled) Dosing Pumps

Please contact: Klaus.Mueller-Haas@emitec.com Adreas.Scheeder@emitec.com Rolf.Brueck@emitec.com