Improved System Performance and Reduced Cost of a Fuel ...Damodara Poojary,Jacques Nicole, James...

© 2008 Eaton Corporation. All rights reserved.

Improved System Performance and Reduced Cost of a Fuel Reformer, LNT, and SCR Aftertreatment System Meeting Emissions Useful Life Requirement

Damodara Poojary, Jacques Nicole, James McCarthy, Jr., & Hanlong YangEaton Corporation

2010 DOE DEER ConferenceDetroit, MISeptember 30, 2010

2 22010 DOE DEER Conference – Detroit, MI

Agenda

• Introduction to Eaton Aftertreatment

• System cost reduction

• Durability demonstration of cost reduced system

• Fuel doser and system packaging

• Summary


Agenda





• Summary


IntroductionEaton Aftertreatment System

How it Works:

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

• The LNT stores NOx and undergoes controlled periodic regeneration, releasing the NOx as nitrogen and NH3.

• The SCR collects the released NH3 and uses it to continuously treat the remaining NOx.

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

LNT – Lean NOx Trap

SCR – Selective Catalytic 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

• NH3Production

DPF

• PM Control

SCR

• 2nd Stage NOx Control

• NH3 Storage and Usage

fuel doser


IntroductionTypical Performance

• Proven Vehicle Performance• Tens of thousands of miles of EAS operation on MD and HD vehicles• Fuel consumption as low as 1.3% • Consistent NOx reduction performance meeting EPA 2010 standards• No vehicle drivability issues

Engine Out NOx

LNT Out NOx

SCR Out NOx

NO

x C

once

ntra

tion

[ppm

]

SAE 2009-01-2835

Time, sec


Agenda





• Summary


PGM reduction in the Reformer, LNT and DPFPGM cost of the 2010 system is 36% lower than previous publication

System Cost ReductionRelative PGM Cost vs Time

0%

20%

40%

60%

80%

100%

120%

2005 2006 2007 2008 2009 2010

Rel

ativ

e sy

stem

PG

M (%

of 2

005

leve

l)

SAE 2009-01-2835


Agenda





• Summary


System Configuration• Fuel doser, Fuel reformer, LNT, DPF, SCR

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

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

DurabilityAftertreatment Durability Aging


ECU accurately controls reformer/LNT temperatures

System Control - DesulfationReformer and LNT Temperature Control

0

100

200

300

400

500

600

700Te

mpe

ratu

re (C

)

0

100

200

300

400

500

600

700

Fuel

inje

cted

(g/m

in)

300

400

500

600

700

0 100 200 300 400

Ref. inlet gas Temp.

Ref. model Temp.Ref. Outlet gas Temp.

Reformer Fueling

SCR outlet gas Temp.

LNT Outlet gas Temp.LNT brick center

DPF outlet gas Temp.LNT brick edge

Time, sec


Durability – 500 Desulfation EventsPrevious End of Life Aging

0

10

20

30

40

50

60

70

80

90

100

0 100 200 300 400 500After DeSOx #

Effic

ienc

y [%

]

Sulfur Loading 50% Load 75% Load 100% Load

Final Performance (Optimized)1800-50: 93.5%

1800-75: 87.2%

1800-100: 78.7%

100% LoadSCR Cont.

50% Load

Sulfur Loading

75% Load

Constant Control Settings

Stable SCR Contribution

Reference: SAE 2009-01-2835


0

10

20

30

40

50

60

70

80

90

100

0 100 200 300 400 500After DeSOx #

Effic

ienc

y [%

]Durability – Comparison with Cost Reduced SystemNOX Reduction Efficiency

Final Performance (Optimized)1800-50: 93.5%1800-75: 87.2%1800-100: 78.7%

100% Load

SCR Cont.

50% Load

Sulfur Loading

75% Load

Constant Control Settings

Performance of cost reduced system is stable and meets end of life EPA 2010 emission standards

Reference: SAE 2009-01-2835Added EATON-2010 Data

Durability of cost reduced system @ B75


0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

2.2

B25 A50 B50 C50 A75 B75 C75 A100 B100 C100 13mode

NO

x, g

/hp-

hr

Engine Out NOx (g/hp-hr)System Out NOx (g/hp-hr)

System out NOx meets EPA 2010 emissions standards

Cost Reduced System – Emission ResultsPerformance Under Various Modes

NTE limit


Agenda





• Summary


Fuel DoserImproved Spray Quality

Early injector(poor atomization with

larger droplets)

Optimized injector(improved atomization

& smaller droplets)

• Early injectors showed a small cone angle with large drop diameters

• Improved injector shows larger cone angles having smaller drop sizes

• Smaller droplets yields better mixing in a smaller volume


System PackagingEfficient Packaging

SCR

DPF

LNT

REFSCR

DPF LNT

REF

REF – Reformer



SCR – Selective Catalytic ReductionREF

LNT

DPF

SCR Doser

Flex

DPFREFLNT

SCR

2010 MinNOx Conference

2010 MinNOx Conference

Improved mixing for compact

packaging


System PackagingApplication Examples

Inlet Cone

Tran

sitio

n to

SC

R

LNTDPF REF

SCRSCR

Tran

sitio

n to

SC

R

HD On-Highway TruckHD On-Highway Truck

REF DPFLNT SCR

MD On-Highway TruckMD On-Highway Truck

Off-Road Construction VehicleOff-Road Construction Vehicle

REFREF LNTLNT DPFDPF

SCRSCR

REF – Reformer



SCR – Selective Catalytic Reduction


Agenda





• Summary


Summary

• Demonstrated durable system performance that meets EPA 2010 on-highway emission standards

• System PGM cost 36% lower than previously published durability results

• Flexible and compact packaging options to meet OEM needs


Acknowledgements

• Eaton Aftertreatment Team

• OEM Partners & Suppliers

• Portions of this section is based on work funded by the State of Texas through a grant from the Texas Environmental Research Consortium (TERC) with funding provided by the Texas Commission on Environmental Quality (TCEQ)

Improved System Performance and Reduced Cost of a Fuel ...Damodara Poojary,Jacques Nicole, James...

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