Fuel Reformer, LNT and SCR Aftertreatment System Meeting ... · End-of-Life Emissions Requirements...

© 2008 Eaton Corporation. All rights reserved.

Fuel Reformer, LNT and SCR Aftertreatment System Meeting Emissions Useful Life Requirements

James McCarthy, Jr.Eaton Corporation

2009 DOE DEER ConferenceDearborn, MIAugust 5, 2009

2 22009 DOE DEER Conference – Dearborn, MI

Topics

• Introduction to Eaton Aftertreatment• Vehicle and Dyno Test Results• Durability Test Results• System Packaging• Summary


IntroductionEaton Aftertreatment System

How it Works:How it Works:

•• Engine NOx is reduced by Engine NOx is reduced by the Lean NOx Trap (LNT) and the Lean NOx Trap (LNT) and Selective Catalytic Reduction Selective Catalytic Reduction (SCR) catalysts. (SCR) catalysts.

••The LNT stores NOx and The LNT stores NOx and undergoes controlled undergoes controlled periodic regeneration, periodic regeneration, releasing the NOx as releasing the NOx as nitrogen and ammonia. nitrogen and ammonia.

••The SCR collects the The SCR collects the released ammonia and uses released ammonia and uses it to continuously treat the it to continuously treat the remaining NOx. remaining NOx.

••A Diesel Particulate Filter A Diesel Particulate Filter (DPF) traps Particulate (DPF) traps Particulate Matter (PM) and undergoes Matter (PM) and undergoes periodic regeneration.periodic regeneration.

LNT – Lean NOx Trap

SCR – Selective Catalyst Reduction

DPF – Diesel Particulate Filter

Controller ModuleDiesel

Pipe/mixer assembly sensors

fuel pressure control & shut-off

Reformer

• Hydrogen/CO Production

LNT

• 1st Stage NOx Control

• Ammonia Production

DPF

• PM Control

SCR

• 2nd Stage NOx Control

• NH3 Storage and Usage

fuel doser


IntroductionValue Proposition

Controller Module

fuel doser

Pipe/mixer assembly

Diesel

sensors

fuel pressure control & shut-off

Reformer LNT DPF SCR

LNT – Lean NOx Trap

SCR – Selective Catalyst Reduction

DPF – Diesel Particulate Filter

Customer Values & Product Differentiation

• Compliance with strict diesel emission standards• Single fluid system (one dosing system needed)• Independent of urea solution & infrastructure

• Eliminates urea sensors and compliance-related penalties

• Reliable aftertreatment system

• Flexible, customized and smaller packaging

• Scalable with engine power (size)


Topics



Vehicle Testing

• Accumulated ~ 26,000 miles operation• Variety of Ambient Conditions

• Temperature from -40 to 51 C• Altitude to 11,158 feet

• Achieving 80%+ NOx reduction under majority of driving conditions

• Automatic aftertreatment operation (transparent to driver)• No drivability issues


Vehicle Testing – Cold Weather (-20 F)

0 500 1000 1500 2000 2500 3000 3500 40000

200

400

600

800

Time [s]

NO

x [p

pm] \

RE

F Te

mp.

[ ^o

C ]

NOx Engine Out [ppm] NOx SCR Out [ppm] REF Inlet Temp. [ oC ]

Total DeNOx Efficiency = 85.2 [%]Fuel Penalty = 5.74 [%] BSNOx Engine Out = 1.3979 [g/hp-hr]

BSNOx System Out = 0.2671 [g/hp-hr]

0 200 400 600 800 10000

200

400

600

800

Time [s]

NO

x [p

pm] \

REF

Tem

p. [

^oC

]

NOx Engine Out [ppm] NOx SCR Out [ppm] REF Inlet Temp. [ oC ]

Fuel Penalty = 5.01 [%] BSNOx Engine Out = 1.5370 [g/hp-hr]

City NOx Conversion of 84.1%

Highway NOx Conversion of 86.6%

Meets in use requirements for cold weather testingHighway = 55mph two lane road

Low

sys

tem

inle

t tem

pera

ture


FTP Test Results – Combined CycleInitial Results

Hot Cycle

Cold Cycle

Engine Out (1.81 g/bhp-hr) System Out (0.15 g/bhp-hr)System NOx Efficiency = 92% (Combined)

(Removed ~1.7 g/bhp-hr NOx)


Topics



DurabilityAftertreatment Durability Aging

• Application• Aged on an Off-Highway Engine at an OEM test

facility to end-of-emissions life conditions

• Sulfur Loading Assumptions• Total Sulfur in exhaust: 12 ppm on a fuel basis

• 7 ppm from diesel fuel• 5 ppm from oil

• Triggered DeSOx Event: 0.5 g/L Sulfur on LNT• LNT Sizing: 1.5 times engine displacement


DurabilityEnd-of-Life Emissions Requirements

• Off-Highway Analysis• 500 DeSOx events required – 8000 hour useful emissions life

• One DeSOx event every 16 hours

• On-Highway Analysis – Medium Duty Vehicles• 225 DeSOx events required – 185,000 miles useful emissions life

• One DeSOx event every 822 miles

• On-Highway Analysis – Heavy Duty Vehicles• 500 DeSOx events required – 435,000 miles useful emissions life

• One DeSOx event every 870 miles


DurabilityNOx System Efficiency


DurabilityPerformance Summary

• Demonstrated NOx Margin (<0.4 g/kW-hr)• ¼ of NOx standard @ 50% load• ½ of NOx standard @ 75% load• Slightly below NOx standard @ 100% load (safely within NTE zone)

EAS performance results following 500 DeSOx CyclesMeets Off-Road Final Tier 4 and HD On-road Emission Standards

1800 rpm - 50% load 93% 0.10 0.10

1800 rpm - 75% load 87% 0.20 0.19

1800 rpm - 100% load 79% 0.36 0.20

Tailpipe HC (g/kW-hr)

Tailpipe NOx (g/kW-hr)

System NOx Conversion


Topics



System PackagingFlexible Options to Meet OEM Applications

Beta On-Highway

Compact Option

ReformerLNTLNT

DPFDPF

SCRSCREFVEFV

Doser

FlexFlex

Reformer

LNTDPFDPF

SCR

EFVDoser

FlexFlex

Alpha On-Highway

ReformerReformer

LNTLNT

DPFDPF

SCRSCR Doser

FlexFlex

SCR

DPF

DoserEFV

Reformer

LNT

Beta On-Highway


Topics



Summary

• Vehicle Testing• Demonstrated 80%+ NOx reduction (cold temperature & high altitude)

• Dyno Testing• Demonstrated Viability for FTP testing

• Durability Testing• Met stringent durability requirements (Off-Highway & HD On-Highway)

• System Packaging• Flexible packaging options to meet OEM needs

• Targeted launch dates• 2012 targeted for On-Highway• 2013 targeted for Off-Highway• Joint Development with global engine OEM’s


Acknowledgements

• Eaton Aftertreatment Team• Southfield, MI• Galesburg, MI• Santa Clara, CA• Pune, India

• OEM Partners & Suppliers

Fuel Reformer, LNT and SCR Aftertreatment System Meeting ... · End-of-Life Emissions Requirements...

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