Ab Gas Nach Be Hand Lungs Strategie N

Abgasnachbehandlungsstrategien
zur Einhaltung der Euro VI- bzw.

EU-Stufe IV- Emissionsgrenzwerte
CVC-Jahrestagung
19. November 2010
Dr. Wolfgang Reuter

Geschftsfhrer Heinrich Gillet GmbH
Vice President TENNECO Emission Control Europe
Copyright Tenneco Inc. This document and the information embodied herein is the property of Tenneco Inc. and is disclosed in confidence for informational purposes only.
It may not be copied, disclosed or used for any purpose without the prior written consent of Tenneco Inc..
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Emission Control
Fabricated Manifolds
Manifolds-Converter Modules
Downpipes
Converters
Diesel Particulate Filters
Mufflers
Complete Exhaust Systems
Aftertreatment Systems for
commercial vehicles
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Shock Absorbers
Struts
Elastomers/Vibration Control
Components
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Commercial Vehicle Product Range

Largest Customers
Deutz
Daimler
International
Volvo Global Trucks
PACCAR / DAF
Scania
Caterpillar
John Deere
Non Road Product Range

Regeneration Burners
Mixer
SCR Systems
Urea Dosing & Injectionn
TRUE-Clean
SCR
Ignition
Coils & Plugs
Urea
Injector
Air/Fuel Block
Coolant Line
DPF
Air Pump
Controller
DCU Box
Urea Tank
Light Vehicle Product Range

Fabricated Manifolds
Rear Mufflers
Exhaust Heat Exchanger
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Converters
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Global Emissions Regulation Timeline
Emission Limits in Europe

for Heavy Duty Trucks - onroad
0,1
EU III
0,08
EU III
5,0
g/kWh
PM
0,1
g/kWh
PM [g/kWh]
NOx
0,04
EU V
0,02
EU IV
EU VI
0
0
2
3
NOx [g/kWh]
2000
NOx
EU IV
0,06
ESC
ESC/ETC
2005
3,5
g/kWh
PM
0,02/0,03
g/kWh
EU V
ESC/ETC
NOx
2,0
g/kWh
PM
0,02/0,03
g/kWh
EU VI
ESC/ETC
2008
2013
NOx
0,4
g/kWh
PM
0,01
g/kWh
PM# Limit is planned
Emission Limits in Europe

for Heavy Duty Vehicles - offroad
Stage III B
<8 KW
no limits defined
8 - 19
no limits defined
19 - 37
7,5 / 0,6
37 - 56
4,7 / 0,4
Stage IV
4,7 / 0,19 / 0,025
4,7 / 0,4
3,3 / 0,19 / 0,025
75 - 130
4,7 / 0,3
3,3 / 0,19 / 0,025
130 - 560
2008
NOx + NMHC / PM
NOx / NMHC / PM
4,0 / 0,2
2009
2010
2011
0,
4
56 - 75
2,0 / 0,19 / 0,025
2012
2013
/0
,0
25
Stage III A
/0
,1
9
no limits
2014
2015
2016
NRTC starting Stage III B

PM# limit is not planned
Strategies to Meet Future Limits
Particulates
Fuel
Consumption
Stage IV
DPF (>90%)
High Pressure CR (<2000bar),

improved injectors, waste gate TC,
charge air cooling, cooled EGR,
SCR (>80%)
Stage IIIB
w/o EGR
NOx
Operation mode
Engine raw emissions
Particulates
Technology Strategy Drivers

Fuel
Consumption
Fuel efficiency requirement

NOx
Local air quality requirements

(operation restrictions)
Available fuel quality (Sulfur)
System cost
Diesel Aftertreatment Strategy in Europe
ON-ROAD EU VI (2012+)
SCR &/or Cooled EGR
Wallflow DPF (>95%)
Open filters unlikely
OFF-ROAD Stage III B (2011+)

Agriculture SCR
Construction DPF
(Open filters possible)
OFF-ROAD Stage IV (2014+)

Wallflow or open DPF
Urea SCR system
DPF - Filtration
ASH
Wallflow filter
Open filter
Cordierite, SiC, AT or sintered metal
Sintered metal, foam, wire mesh
>95% filtration efficiency
<50% filtration efficiency
Soot loading control required
Self controlled soot blow-off possible
Active regeneration required
Passive regeneration
Collect ashes maintainance
Maintainance free
DPF - Regeneration
Active
regeneration
required
O2 Regeneration
with additive (FBC)
O2 Reg.
CSF
CRT
(NO2 Regeneration)
VEHICLE
OPERATION
RANGE
100
TRUCKS
PASSENGER CARS
250
450
600
T [C]
At lower temperatures active regeneration support is mandatory

Competing Regeneration Technologies

Fullsize Burner
Small Burner
Insulation
D
O
C
Intake Air Throttle

Late / Post Injection
Exhaust Throttle
CRT - Plus
DOC
DPF
Injector / Vaporizer
Diesel
Vaporizer / Injector
Diesel
Burner
yes
yes
yes
no
Engine /
throttle
Engine /
throttle
Small burner
Full size
burner
continuous
periodic
periodic
periodic
limited
unlimited
unlimited
unlimited
Sulfur tolerance
low
low
low
high
Secondary emissions
NO2
NO2
NO2
none
--
Regeneration support
Regeneration mode
Application range
Cost
TRUE-Clean for DPF Regeneration
Air supply
Air/Fuel
block
Fuel supply
DPF
Controller
Ignition
coils
Nozzle
Spark plugs
w/ ion sensing
Combustion
Chamber
Delta P
DeNOx Technologies
Liquid based SCR:
AdBlue
Denoxium (Kemira)
Guanidinium Formate (AlzChem)
Solid based SCR:
Source: Yara
Solid urea (Pierburg)

Ammonia Carbamate (FEV)
Metal Amine (Amminex)
HC - Lean NOx Catalyst

Lean NOx trap (LNT)
Source: FEV
HC LNC (Lean NOx Catalyst)
Alternative to Urea SCR technology

Uses HC (diesel fuel, E85, ) to reduce NOx
Innovative GE
Ag coating technology
Strongly demanded by rail, on-road & offroad equipment
manufacturers
Tenneco is licensee of GE
technology
DOC
HCInjection
HC-LNC
NOx + HC
Flow
CAT
Mixer
N2 + CO2 + H2O (+ N2O + NO)
Advantages of HC-LNC Versus AdBlue
Existing reductant infrastructure ULSD & E85

Improved packaging less tank volume
Reduced weight no need to carry water
Eliminate freeze issues
No deposit concern
No corrosion concern
Less complex system
integration
Lower system cost
Catalyst
Integration
OEMs
HC-LNC Development Status
CNH T2420 Tractor (2.2l / 60HP)

100
NOx conversion [%]
HC-LNC is installed in several demo

vehicles
500hrs high temperature (<650C) aging
successfully passed
Initial 13-mode testing resulted in up to
55% NOx reduction with ULSD
When using E85 as reduction, NOx
reduction ramped up to 95%
TRUE-Clean integration for thermal
management
Control strategy under development
E 85
80
60
ULSD
40
20
0
250
300
350
400
450
Exhaust Gas Temperature [C]

500
Urea Dosing & Injection System

Wire Harness
Urea Line
Coolant Line
Injector
Dosing
Control Unit
Urea Tank
NOx Sensor
Temp Sensor
SCR Box
Urea Dosing Control Unit (DCU)
Pump
Serviceable filter
Urea pressure transducer
Heat and power relays
DCU (Dosing Control Unit) with TEN
dosing algorithm
Learn pack for fast
calibration
Integrated heating
Environmentally sealed
with SAE J2044 fluid connections
Pump
Filter
DCU
SCR System Integration Objectives
Efficient catalyst usage uniform flow distribution

Efficient conversion of urea into ammonia
Efficient mixing of ammonia & exhaust gas
No ammonia slip
No deposits
Low backpressure
Compact, low cost and
low weight system
Deposits with non-optimized SCR system

SCR System Integration Parameters
Operation parameters (flow rate & gas temperature)

Injector spray quality (droplet diameter, spray angle, etc)
Injector position
Injector temperature
Mixer design
Mixer position and orientation
Pipe & cone design
SCR catalyst NH3 storage capacity (buffer effects)
Skin temperatures (insulation design)
High number of parameters requires a systematic approach

System Integration 3 Step Approach

STEP1 Simulation
Design tuning for flow uniformity
Injector & Mixer Positioning
Pressure loss analysis
STEP2 Hot Flow Bench
Steady state NOx conversion

Design adjustments
Fine tuning of injector & mixer position
Deposit evaluation
STEP3 Engine Bench

Design validation under transient testing
Focus on overall NOx conversion efficiency, ammonia
slip and deposits
w/o mixer
TENNECO
mixer
Stage IV / EU VI
The Integration Challenge
Package constraints
Challenging flow conditions
Short urea evaporation &
mixing length
Thermal management
SCR light-off
Avoidance of deposits
DPF regeneration
SCR
DOC
DPF
Urea Injector
Extreme skin temperature

requirements (200C)
Meet acoustic targets
>350C
Integrated Stage IV System

Mixer
TRUE-Clean
SCR
Ignition
Coils & Plugs
Urea
Injector
Air/Fuel Block
Coolant Line
DPF
Air Pump
Controller
DCU Box
Urea Tank
Conclusions
Upcoming EU VI and Stage IV legislation will require a combination of
DPF and SCR technologies
The challenge is the integration of all required functions into a compact,
robust and cost efficient aftertreatment unit
Tenneco owns all simulation and testing tools for effective EU VI and
Stage IV system integration
TRUE-Clean and Vaporizer Technologies are cost efficient and
reliable solutions for active DPF regeneration
Urea SCR is mainstream technology for near future limits
Tenneco offers turnkey urea dosing & injection system
Tenneco develops a HCLNC system as an alternative to urea SCR

Ab Gas Nach Be Hand Lungs Strategie N

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Ab Gas Nach Be Hand Lungs Strategie N

Enviado por

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Formatos disponíveis

Abgasnachbehandlungsstrategien

zur Einhaltung der Euro VI- bzw.

Dr. Wolfgang Reuter

Commercial Vehicle Product Range

Non Road Product Range

Diesel Particulate Filters

Light Vehicle Product Range

Complete Exhaust System

Emission Control Europe, Edenkoben, Pfalz

Edenkoben, Heinrich Gillet GmbH

Global Emissions Regulation Timeline

Emission Limits in Europe

PM# Limit is planned

Emission Limits in Europe

4,7 / 0,19 / 0,025

3,3 / 0,19 / 0,025

3,3 / 0,19 / 0,025

2,0 / 0,19 / 0,025

NRTC starting Stage III B

Strategies to Meet Future Limits

High Pressure CR (<2000bar),

Technology Strategy Drivers

Fuel efficiency requirement

Local air quality requirements

Diesel Aftertreatment Strategy in Europe

OFF-ROAD Stage III B (2011+)

OFF-ROAD Stage IV (2014+)

Cordierite, SiC, AT or sintered metal

Sintered metal, foam, wire mesh

>95% filtration efficiency

<50% filtration efficiency

Soot loading control required

Self controlled soot blow-off possible

Active regeneration required

Collect ashes maintainance

At lower temperatures active regeneration support is mandatory

Competing Regeneration Technologies

Intake Air Throttle

TRUE-Clean for DPF Regeneration

Solid based SCR:

Solid urea (Pierburg)

HC - Lean NOx Catalyst

HC LNC (Lean NOx Catalyst)

Alternative to Urea SCR technology

N2 + CO2 + H2O (+ N2O + NO)

Advantages of HC-LNC Versus AdBlue

Existing reductant infrastructure ULSD & E85

HC-LNC Development Status

CNH T2420 Tractor (2.2l / 60HP)

HC-LNC is installed in several demo

Exhaust Gas Temperature [C]

Urea Dosing & Injection System

Urea Dosing Control Unit (DCU)

SCR System Integration Objectives

Efficient catalyst usage uniform flow distribution

Deposits with non-optimized SCR system

SCR System Integration Parameters

Operation parameters (flow rate & gas temperature)

High number of parameters requires a systematic approach

System Integration 3 Step Approach

STEP2 Hot Flow Bench

Steady state NOx conversion

STEP3 Engine Bench