24Aug2006

European Experience and Case study of SCR Passenger Car Integration

JJ Van Schaftingen

Inergy Research

24Aug2006

Program

SCR system overview

Focus on some functions Storage Filling Venting Heating Injection Control

Case studies: system integration examples

24Aug2006

SCR Technology : System Overview

Urea (NH2)2CO

1

Exhaust gas

Exhaust gas + water + ammonia

2

3

4

56

7 8

9

SCR Catalyst

Engine

hydrolysis

NO NO2 NH3 N2 H2O

NOx Reduction Reaction :

1 Urea solution tank 2 Temperature sensor 3 Level sensor 4 Supply module 5 ECU 6 Injector 7 Exhaust-gas

temperature sensor 8 Exhaust-gas sensor 9 Treated exhaust gas

24Aug2006

Program

SCR system overview

Focus on some functions Storage Venting Heating Filling Injection Control

Case studies: system integration examples

24Aug2006

SCR-System : AdBlue® tank

Consumption : approximately 1 l/1000 km for a Passenger Car (depending on Engine NOx generation, injection/dosing quality, etc.)

Integration into the vehicle.

Adblue® volume

1.5 l

Filling frequency

Filling at each fuel refill

Filling every 3 fuel refills

Filling at oil service

5 l

>18l

Integration possibilities

Tank in Mudguard

Tank along filler pipe

5 000 km1 000 km 25 000 km

1.5 l

Fillingfrequency

Filling ateach fuel refill

Filling every3 fuel refills

Filling atoil service

5 l

>18l

Tank in trunk area, under chassis, …

5 000 km1 000 km 25 000 km

24Aug2006

Inergy SCR system : system integration – Filling, Storage, Venting

Inergy concept with tank in trunk Refilling at trap Poke-Yoke function

Advantage : all functions in 1 concept

Cap with integrated OPR

Venting to the outside required

Over Pressure Relief valve (200-450 mbar +/- 50 mbar)

24Aug2006

Ammonia release + AdBlue® concentration evolution

Ammonia release Tank initially filled with 10 l Adblue®

80 °C constant temperature Over Pressure Relief opening pressure : 450 mbar

Measurement over 10 days

With Over Pressure Relief, 50 % more ammonia stays in solution and can be injected in the exhaust line

2% change in concentration with OPR compared to 4% without OPR after extreme/exagerated ageing phase

0 200 400 600 800

1000 1200

0 5 10

Wei

ght l

oss

(g) without OPR (B)

with OPR (A)

0

20

40

60

80

100

0 5 10

Am

mon

iaco

ncen

tratio

n (g

/l) without OPR (B) with OPR (A)

24Aug2006

Ammonia release + AdBlue concentration evolution

Monitoring the ammonia amount

potentially released by venting and wall permeation

Tank installed in a chamberof a known volume

Sampling the chamber atmosphere

at regular time interval

Use of an ammonia reactive cartridge

(lowest sensitivity range : 0.25 – 3 ppm)to measure ammonia concentration

Example of results : Car trunk internal volume : 0.35 m³ (estimation)

After 40 hours at continuous 40°C : no detection of any trace of ammonia vapour. < 3 ppm of ammonia vapour

24Aug2006

SCR-System : Heating system

Experiments : Heater in swirl pot.

Initial temperature T = -40°C

Heater power (electrical power) P = 100 W

Heating time t = 8 minutes (for measurement equipment)

Volume molten and ready for supply 150 ml

INERGY proposes an electrical heater with a power below 200 W (to include also preheating of pump and lines)

24Aug2006

Injector : Performance factors and integration

Injector performance : Droplet size and speed

(Spray measurement 50% on-time) 5 cm

5 cm

-2 +20

5 cm

5 cm

-2 +20

Droplet size and Mean speed

0

10

20

30

40

50

60

70

80

-2,5 -2 -1,5 -1 -0,5 0 0,5 1 1,5 2 2,5 3

Radial position (cm)

SMD

(µm

)

0

1

2

3

4

5

6

7

8

9

Ave

rage

spe

ed (m

/s)

Vmean D32

Overall droplet size : 54,6 µm Overall average speed : 7,0 m/s

Spray distribution : Interaction between droplets, gas flow and pipe wall

PowerSupply

24Aug2006

Inergy Electrical Control unit

At the centre of the SCR system

CPU

Pump

Injector

Purge valve

Pressure Sensor

Level sensor

Temperature Sensor

Actuators Sensors

Heating relay 1

Heating relay 2

Heating 1 (8.5A)

Heating 2 (8.5A)

Power Supply

Vbat GND CANH CANL

Engine or exhaust sensor data

Optional

Outputs :

•Dosing control •Spray quality control •Tank/lines heating •Tank/lines purging

Inputs :

•System pressure •Tank level signal •Tank temperature signal •Exhaust system sensor data •Engine control data

24Aug2006

Program

SCR system overview

Focus on some functions Storage Filling Venting Heating Injection Control

Case studies: system integration examples

24Aug2006

Case 1: Passenger Car tested in hot conditions

Personal car equipped with Dinox system Tank inside of trunk

Purge valve, filter and pump in trunk

Injector mounted on exhaust line

PA Lines: Starting from trunk

Going below car body to injector and back to trunk

Urea flow rate: 12kg/h (controlled by flowmeter)

Urea Tank Purge valve Filter Pump

Injector

Air

Exhaust pipe

(206)

(205)(207)T T

T

T (212)

24Aug2006

Case 1: Passenger Car tested in hot conditions (Pico Veleta test drive) Warm up drive Uphill drive Downhill drive

70Critical test conditions: very small Urea temperatures

urea volume in tank (3l) 65

60

55

In tank urea temperature exceeds [°C

]

50

hardly 50°C Confirmed by test started at 50°C by

artificial heating: reached only 54°C at mountain top.

With average urea volume (10l), urea temperature in tank hardly reached 43°C (with same test protocol)

45

40

35

30 0 1000

450

400

350

300

250

205(C) Urea temperature after pump (°C)206(C) Urea temperature after injector (°C)207(C) Urea temperature in return line close to tank (°C)212(C) Urea temperature in tank - bottom (°C)

2000 3000 4000 5000 6000

time [s]

Exhaust temperatures

[°C

]

200

150

Î limited generation of ammonia inside tank

100

203(C) Exhaust wall temperature at injector (°C)50 204(C) Exhaust gasses temperature before SCR catalyst (°C)

0 0 1000 3000 5000 2000 4000

time [s] 6000

24Aug2006

Case 2: Light Duty Truck

24Aug2006

Case 2: LDT Underside

Diesel Tank

Urea Tank

SCR Catalyst

24Aug2006

Case 2: Filler Pocket (Diesel & Urea Station Filling)

Diesel Fill Cap

Urea Fill Cap (w/ integrated overpressure relief valve)

24Aug2006

Case 2: Filler Pocket (Underside) & Fill Pipes

Diesel Fill

Urea Fill Tube

24Aug2006

Case 2: Station Fill Spud Option

Urea Fill Tube

Urea Fill Spud

Urea Storage Tank

24Aug2006

Conclusion

OEMs strategies and requirements can be met, i.e. volume of SCR tanks depending upon driving range and refilling intervals

Plastics offer flexible integration solutions in view of spatial and operational constraints

Global optimization of the system is essential in tight passenger car environment

With its longtime experience of fuel systems and diesel emissions reductions, Inergy is offering complete design, development and validation of SCR systems for passenger cars and light duty vehicles, from tank to injector

24Aug2006

Contact

www.inergyautomotive.com

Thank you!

Op de Beeck, Joël

Urea-SCR project manager Inergy Automotive Systems

rue de Ransbeek 310

B-1120 Bruxelles

Belgique

tel : (+32) 2 / 264 21 09

fax : (+32) 2 / 264 30 75

E-mail : joel.opdebeeck@inergyautomotive.com