High Performance SCR Technology with Ultra-Low-NOx Emissions … · 2015-03-11 · High Performance...
Transcript of High Performance SCR Technology with Ultra-Low-NOx Emissions … · 2015-03-11 · High Performance...
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High Performance SCR Technology with Ultra-Low-NOxEmissions for Future Regulations
Emitec Gesellschaft für Emissionstechnologie mbH
Klaus Müller-HaasOswald Holz
CTI, Emission Reduction for Off Highway Applications26.-27.9 2012, Lindau am Bodensee (Germany)
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Agenda
Introduction
Challenges to achieve high efficient SCR
SCR Dosing System
Evaporation and Mixing Pipe
Close coupled compact SCR-System
Conclusion
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Heavy Duty /NRMM – Emission Standards (ETC) & -Technology Shift of Priorities
PM
[m
g/k
Wh
]
NOx [g/kWh]1
60
30
42 6
EU V EU IV
03
Engine TechnologyEU VI; NRMM >130 kW Stage 3 B
NRMM EUStage IV
SCR 80 % NRMMStage IIIB(2012)
NRMM EU IIIB
SCR 80 % EU VI
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Heavy Duty /NRMM – Emission Standards (ETC) & -Technology Shift of Priorities
PM
[m
g/k
Wh
]
NOx [g/kWh]1
60
30
42 6
EU V EU IV
03
Engine TechnologyEU VI; NRMM >130 kW Stage 3 B
NRMM EUStage IV
SCR 80 % NRMMStage IIIB(2012)
NRMM EU IIIB
EU VI
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Heavy Duty /NRMM – Emission Standards (ETC) & -Technology Shift of Priorities
PM
[m
g/k
Wh
]
NOx [g/kWh]1
60
30
42 6
EU V EU IV
EU VI
03
Engine TechnologyEU VI; NRMM >130 kW Stage 3 B
NRMM EUStage IV
NRMM EU IIIB
SCR >92 -95 %
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Agenda
Introduction
Challenges to achieve high efficient SCR
SCR Dosing System
Evaporation and Mixing Pipe
Close coupled compact SCR-System
Conclusion
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Priorities
PC / LD / MD NEDC
RDE /(NTE)
++
+++
+ ++ + ++ >80
FTP ++ + ++ + ++ >80
US06 ++ + >80
JC08 ++ + ++ + ++ >80
Non-Road
NRMM
NRSC ++ >95
NRTC cold + ++ ++ ++ ++ > 80
NRTC.Warm + ++ + > 95
HD On-Road Steady State + >93
ETC + ++ ++ >93
WHTC cold ++ ++ ++ ++ ++ >70
WHTC warm ++ ++ ++ ++ >80
FTP + + ++ ++ ++ >80
JE05 ++ + ++ ++ ++ >80
Thermodynamic Challenges
Heat up during cold start
low temperature condition
Start of AdBlue Injection
AdBlue-Decomposition
NH3/ NOx Uniformity
SCR “Light-Off”
SCR Conversion
Limitation SCR Kinetic
Limitation of NH3/ NOx
Limitation NH3 storage
Challenges and demands for SCR- Emission control technologies across various applications
Duty Cycle goals with lowestbsf and lowest coolingrequirements
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Fundamental Steps for AdBlue Decompositionand Technology for System Optimization
1. Step: evaporation of Water: {(NH2)2CO •7H2O}fl {(NH2)2CO}fl + 7 H2O
2. Step: thermolysis of Urea: {(NH2)2CO}fl HNCO + NH3
3. Step: hydrolysis of isocyanic acid: HNCO + H2O CO2 + NH3
steps from AdBlue towards Ammonia:
Adblue® droplet penetration on surface evaporation & thermolysis1. + 2. reaction steps
AdBlue droplet interaction on surface
Emitec-Technology for Optimization:
� Optimize Hydrolysis: Usage of Hydrolysis Catalyst / Mixer
� Optimize NH3 – Distribution: Optimization of Mixing pipe and mixing design
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0
10
20
30
40
50
60
70
80
90
100
0 100 200 300 400
NO
x C
on
ve
rsio
n R
ate
[%
]
Temperature [°C]
NO2 / NO50% / 50%
NO2 / NO0% / 100%
TemperatureRange at low
load operation
0
1
2
3
4
5
6
Engine Out behind DOC behind SCRN
O,
NO
2[g
/kW
h]
NO
NO2
NOx- SCR-Efficiency as Function of NO-NO2-Ratio
Standard SCR- Reaction with NO: 4 NO + O2 + 4 NH3 4 N2 + 6 H2O
“fast“ SCR-Reaction with NO+NO2: 2 NO2 + 2 NO + 4 NH3 4 N2 + 6 H2O
Reaktionen bei der NOX – Reduktion durch SCR:
Emissions during ETC
- 30%
NO2
NO2
NO2
NO
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Calculated NOx-Reduction and NH3 Slip as Function of NH3-Uniformity and AdBlue-Dosing Rate
70
75
80
85
90
95
100
0,88 0,9 0,92 0,94 0,96 0,98 1
NOx-Reduction
NH3-Uniformity
Alpha = 1.00
Alpha = 0.95
Alpha = 0.90
Alpha = 0.80
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0
10
20
30
40
50
60
0,88 0,9 0,92 0,94 0,96 0,98
NH3- Slip
NH3-Uniformity
Calculated NOx-Reduction and NH3 Slip as Function of NH3-Uniformity and AdBlue-Dosing Rate
70
75
80
85
90
95
100
0,88 0,9 0,92 0,94 0,96 0,98 1
NOx-Reduction
NH3-Uniformity
Alpha = 1.00
Alpha = 0.95
Alpha = 0.90
Alpha = 0.80
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80
85
90
95
100
0 5 10 15 20 25 30
NH3-Slip
NO
x-C
on
vers
ion
[%
]
short tube
long tube
NOx = 200ppm
DeNOx Performance as Function of NH3- Uniformity
SCR
AdBlue
DOC
SCRAdBlue
DOCshort tube
long tube
Short tube
Long tube
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Influence of System Design on NH3-Uniformity and DeNOx- Performance
70
75
80
85
90
95
100
105
0 10 20 30 40 50 60 70 80 90 100 110 120
NO
x-C
on
vers
ion
[%
]
NH3-slip [ppm]
T= 410°C
NOx = 350 ppm
SV.SCR = 58.000 1/hrS-tube
straight tube
S-tube
straight tube
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Influence of Dosing Frequency on the NOx Conversion Rate
NOx tailpipe +- 14%Delta_peak = 80 ppm
NOx tailpipe +- < 1%Delta_peak = 5 ppm
n = 1800 min-1
TQ = 700 NmNOxUP = 450 ppmAlpha NOx = 0,9
time [s]
0 5 10 15 20
NO
x d
ow
n S
CR
[ppm
]
260
280
300
320
340
360
380
400
High dosing frequency Low dosing frequency
Actu
al_
Dosin
g_R
ate
[m
l/h
0
400
800
Time
NO
x T
ail
pip
e
Do
sin
g R
ate
High efficiency SCR system has to have a continuous flow of Adblue At high conversion rate targets is a high dosing frequency mandatory
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Agenda
Introduction
Challenges to achieve high efficient SCR
SCR Dosing System
Evaporation and Mixing Pipe
Close coupled compact SCR-System
Conclusion
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Emitec SCR-Dosing System Gen III
In Tank SCR-DosingsystemGen III
Customized Tank for the application
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Emitec Gen III System DescriptionAll in One Integration
Suction lance
Temperature sensor
Urea filter
Level sensor
Tank heater
Heated suction line
External DCU
Installation cost:
Electrical harness
Fixing devices
Lines connections
Quality sensor
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Ringfilter
Electrical ConnectorConnector to
Injector
Emitec Dosing System Gen III; Outside View
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Pump
PTC Heater
Level-/Quality Sensor
Pressure Sensor
Pressure ControlValve
Electronic
Emitec Dosing System Gen III; Inside View
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Large Engine Airless Dosing System
LE-DCU
Injectors(Airless, Watercooled)
. . . .
Dosing Pumpswith Urea Pumphead (60 ltr/h and 150 ltr/h))
Large EngineDosing Control Unit
Manifoldwith SAE-Connectors
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Agenda
Introduction
Challenges to achieve high efficient SCR
SCR Dosing System
Evaporation and Mixing Pipe
Close coupled compact SCR-System
Conclusion
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NOx -Efficiency with Optimized Airless Dosing Layout Evaporation and Mixing Pipe
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Mo
tor
Dre
hm
om
en
te
ng
ine
to
rqu
e
Motor Drehzahlengine speed
low temperature area
• fast start of dosing
• excellent evaporation of droplets
• low risk for depositions
+ static mixer
+ Hydrolysis Catalyst
Thermal Challenges for AdBlue Injection within Engine Map
Engine Speed
To
rqu
e
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NOx -Efficiency with Optimized Airless Dosing Layout Sweep Test
86
88
90
92
94
96
98
100
0,85 0,9 0,95 1 1,05
NO
xE
ffic
ien
cy
Alpha (-)
Test conditions:� constant speed / torque• constant temperature and massflow and exhaust gas condition• exhaust gas 714 kg/h, T = 420 °C, NOx = 543 ppm; NO2/NOx = 0,27theoretical AdBlue® demand for (alpha = 1) = 1100 ml / h
� setup with Fe-Zeolithe catalyst [Ø242 x (110 + 110)] ���� 10,1 ltr� dosing rate 1000 ml / h ���� 1200 ml/h (alpha = 0,9 ... 1,1)
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Agenda
Introduction
Challenges to achieve high efficient SCR
SCR Dosing System
Evaporation and Mixing Pipe
Close coupled compact SCR-System
Conclusion
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Compact SCR System for Heavy Duty and Non Road Mobile Machineries
DOC
LS/PE-Metalit®
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Compact SCR System for Heavy Duty and Non Road Mobile Machineries
AdBlue-Injector
DOC
LS/PE-Metalit®
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- Robust design based on mass production
- gasoline injector- Spray charactristic optimized
Reductant Delivery Unit (Urea Injector)
Water Cooling for robustOff Road demands
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Compact SCR System for Heavy Duty and Non Road Mobile Machineries
AdBlue-Injector
Mixing Element /Hydrolysis CatalystDOC
LS/PE-Metalit®
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Comparison of a Mixer / Hydrolysis Catalyst regardingDeposits at Low Temperature AdBlue Injection
Variant 1 withMixing Element
Variant 2 withHydrolysis Catalyst
N= 1200 1/min; Md = 215 Nm
Exhaust Mass: 326 kg/h; T = 230°CAdBlue-Dosage = 560 g/h, α = 0.8
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Compact SCR System for Heavy Duty and Non Road Mobile Machineries
AdBlue-Injector
Mixing Element /Hydrolysis CatalystDOC
LS/PE-Metalit®
SCR- Catalyst
LS-Metalit®
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Compact SCR System for Heavy Duty and Non Road Mobile Machineries, Demonstrator
close coupledDOC + 1. stage SCR
2.Stage SCR
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SCR only System Layout
Engine
DOC(2,2 ltr) static mixer
SCR 1(6,5 ltr)
SCR 2(4,0 ltr)
close coupled
NOx T NOxT
NOx
1. Stage 2. Stage
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0 Total velocity [m/s] 10
Flow / NH3 Distribution @ Close Coupled SCR Catalyst
UI = 0,96
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m= 550 kg/hT = 430 °Cm.AdBlue = 1,29 kg/h(12 shots/sec)
AdBlue Flow at constant Exhaust Flow
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Accumulated NOx Emissions pre and post 1.Stageat Alpha = 1 during NRTC
time [sec]
0 200 400 600 800 1000 1200 1400
Accu
mula
ted A
dB
lue [
g]
0
100
200
300
Accum
ula
ted N
Ox [
g]
0
5
Accum
ula
ted
NO
x [
g]
0
30
60
90
NOx after 1. Stage
SC
AL
E
NOx after 1. Stage
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Accumulated NOx Emissions at Alpha = 1 during NRTC
0 200 400 600 800 1000 1200 1400
0
100
200
300
0
5
0.0
30.0
60.0
90.0
time [s]
Acu
mu
late
dN
Ox [
g]
Acu
mu
late
dN
Ox [
g]
Acu
mu
late
dA
dB
lue [
g]
AdBlue-Mass
NOx Tailpipe
NOx after 1. Stage
NOx engine out
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Accumulated NOx Emissionen after 1st and 2nd SCR Stage during NRTC Test
1. SCR Stage
2.SCR Stage
post SCR 2
94,6 %
91,1 %
0 200 400 600 800 1000 1200 1400
0
30
60
90
0
3
time [s]
Acu
mu
late
dN
Ox [
g]
Acu
mu
late
dN
Ox [
g]
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Total NOx Reduction and NH3 Slip during NRTC Test
TailpipeNH3 concentration(no NH3 slip catalyst)
SCRa
94,6 %
time [s]
0 200 400 600 800 1000 1200 1400
0
30
60
90
0
100
NH
3[p
pm
]A
cu
mu
late
dN
ox
[g]
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Agenda
Introduction
Challenges to achieve high efficient SCR
SCR Dosing System
Evaporation and Mixing Pipe
Close coupled compact SCR-System
Conclusion
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η.NH3 > 94 %High Efficient SCRTechnolgyη.NH3 > 94 %
Advanced DOC Technology
Robust AdBlue-Injection
Excellent Decompostion of Reduction Agent
Perfect Mixing of NH3 with Exhaust Gas
OptimizedNH3 Slip Catalyst
UI.NH3 > 0,98
Minimum HNCO concentration
SCR Catalyst Technoloy
η.HC > 90 %NO2/NOx < 0,5
10110100 10110100
10110100 01010101
01001010 01001010
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AdvancedDosing Strategy
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High Performance SCR Technology with Ultra-Low-NOxEmissions for Future Regulations
Emitec Gesellschaft für Emissionstechnologie mbH
Klaus Müller-HaasOswald Holz
CTI, Emission Reduction for Off Highway Applications26.-27.9 2012, Lindau am Bodensee (Germany)