Low Emissions Potential ofEGR-SCR-DPF and Advanced Fuel Formulations-A Progress Report
Low Emissions Potential ofEGR-SCR-DPF and Advanced Fuel Formulations-A Progress Report
Department of Emissions ResearchAutomotive Products and Emissions
Research DivisionAugust 2002
Department of Emissions ResearchAutomotive Products and Emissions
Research DivisionAugust 2002
Southwest Research Institute
Southwest Research Institute
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AcknowledgmentsAcknowledgmentsSouthwest Research Institute wishes to acknowledge the followingSouthwest Research Institute wishes to acknowledge the following organizations, agencies,organizations, agencies,
trade associations, and companies for their support of this worktrade associations, and companies for their support of this work and their many technical and their many technical
contributions without which progress in this project would not hcontributions without which progress in this project would not have been possible:ave been possible:
nnUS DOEUS DOE--Funding Via ORNLFunding Via ORNL
nnU.S. EPAU.S. EPA
nnAPIAPI--FuelsFuels
nnNPRANPRA
nnEMAEMA
nnMECA MECA
nnBattelleBattelle--FluidsFluids
nnCARB/SCAQMD CARB/SCAQMD
nnTechnical TeamTechnical Team
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OutlineOutline
uu IntroductionIntroduction
uu ObjectivesObjectives
uu Technical ApproachTechnical Approach
uu Test Setup Test Setup
uu System ComponentsSystem Components
uu ResultsResults
uu Summary & ConclusionsSummary & Conclusions
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Introduction--APBF-DECIntroduction--APBF-DEC
Lubricants
SCR
EGR
DPF
Fuels
LNT (NOx Ads.)
EGR
DPF
Fuels
SCR
EGR
DPF
Fuels
UnregulatedEmissions
Experimental Designand Data Analysis
Fuels - Lubricantsand Urea
APBFAPBF--DECDECSteering CommitteeSteering Committee
Adapted From NREL/W. ClarkPresentation 9/26/01
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uu IntroductionIntroduction
uu ObjectivesObjectives
uu Technical ApproachTechnical Approach
uu Test Setup Test Setup
uu System ComponentsSystem Components
uu Results Results
uu Summary & ConclusionsSummary & Conclusions
OutlineOutline
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ObjectivesObjectives
uu To Demonstrate Low Emissions Performance of Advanced To Demonstrate Low Emissions Performance of Advanced Diesels+LPL EGR*+Urea SCR+DPF (2 Different Systems)Diesels+LPL EGR*+Urea SCR+DPF (2 Different Systems)
* Low Pressure Loop EGR* Low Pressure Loop EGR
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uu To Determine The Regulated And Unregulated Emissions W. To Determine The Regulated And Unregulated Emissions W. &W/O Emission Controls&W/O Emission Controls
uu To Examine The Emission Control System DurabilityTo Examine The Emission Control System Durability
uu To Sample Toxic Emissions For Analysis By Outside LabTo Sample Toxic Emissions For Analysis By Outside Lab
uu To Evaluate Sensitivities of The Control System Performance To Evaluate Sensitivities of The Control System Performance To Fuel VariablesTo Fuel Variables
uu IntroductionIntroduction
uu ObjectivesObjectives
uu Technical ApproachTechnical Approach
uu Test Setup Test Setup
uu System ComponentsSystem Components
uu ResultsResults
uu Summary & ConclusionsSummary & Conclusions
OutlineOutline
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Technical Approach--Development (φ 1)Technical Approach--Development (φ 1)
CorrelationCorrelation Characterization Characterization
EngineEngineBaselineBaseline4.0 NO4.0 NOxx
2D Fuel2D Fuel500 ppm500 ppm
SwRISwRICaterpillarCaterpillar
2D Fuel2D FuelDECSE 3DECSE 3
SteadySteady--StateState+Transient+Transient
DesignDesign DevelopmentDevelopment
EGREGRand Controland Control
2.0 NO2.0 NOxx
PartsPartsProcurementProcurement
FabricationFabrication Engine Engine InstallationInstallation
Test & Test & ControlControl
CBCB--DPFDPFAdaptationAdaptation
DesignDesign DevelopmentDevelopment
TotalTotalSystemSystem
IntegrationIntegration
EGR EGR OptimizedOptimized
UreaUreaInjectionInjection
Engine Engine InstallationInstallation
Test & Test & ControlControl
Comparison BetweenComparison BetweenBaseline & New SystemBaseline & New System
4 Fuels4 Fuels Test ProtocolTest Protocol
*DECSE3 + 8, 15*DECSE3 + 8, 15ppm & BP15ppm & BP15
[10[10--100100--200]200]--Hrs.Hrs.
C+3HsC+3Hs 2 OICAs2 OICAs
2007 System2007 SystemCharacterization Characterization
RR*30 ppm for occasional verification
A
B
uu IntroductionIntroduction
uu ObjectivesObjectives
uu Technical ApproachTechnical Approach
uu Test Setup Test Setup
uu System ComponentsSystem Components
uu ResultsResults
uu Summary & ConclusionsSummary & Conclusions
OutlineOutline
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Test SetupTest Setup
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INTAKE MANIFOLD
MANIFOLD
ATA
A
FTE
RC
OO
LER
C12 DIESEL ENGINE
EXHAUST
AIR FILTER
FLOW BALANCING
VALVES
EXHAUST
EXHAUST FLOW
SENSORS
CB-DPF AR
CB-DPF AL
SCR AL
SCR AR
UREA INJECTION
UREA INJECTION
EXHAUST DAMPER
CLEANUP CATALYST
LPL EGR PICKUP
INT
AK
E
TH
RO
TT
LE
T (IMP)
N
TPS
PRESSURE CONTROL
UREA PUMP
UREA INJECTION CONTROLUREA
EGR COOLER LPL EGR
EGR VALVE
uu IntroductionIntroduction
uu ObjectivesObjectives
uu Technical ApproachTechnical Approach
uu Test Setup Test Setup
uu System ComponentsSystem Components
uu ResultsResults
uu Summary & ConclusionsSummary & Conclusions
OutlineOutline
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Engine DescriptionEngine Description (on consignment to the project)(on consignment to the project)
nn Caterpillar C12Caterpillar C12
nn 12.0 L/12.0 L/450 hp450 hp
nn InIn--Line/6 CylindersLine/6 Cylinders
nnTurbocharged/IntercooledTurbocharged/Intercooled
nn Rated Speed: 1800 rpmRated Speed: 1800 rpm
nn Peak Torque: 1650 lbPeak Torque: 1650 lb--ftft
nn Peak Torque Speed:Peak Torque Speed:1200 rpm1200 rpm
nnEmission Calibration: MY 2000Emission Calibration: MY 2000
System Components--EngineSystem Components--Engine
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System Components--FuelsSystem Components--Fuels
Fuel EstimatesFuel Estimates
nn Phase 1: Development 25,000 To 30,000 GallonsPhase 1: Development 25,000 To 30,000 Gallons
nn Phase 2: 6.5 Gallons/OICAPhase 2: 6.5 Gallons/OICA----2 OICAs/Hr.2 OICAs/Hr.----13 Gallons/Hr. or 78,000 Gallons13 Gallons/Hr. or 78,000 Gallons
Per 6,000 HoursPer 6,000 Hours
uu Fuel 1: Fuel 1: Baseline Baseline ----3 ppm S 3 ppm S
uu Fuel 2: Fuel 2: Durability/Emission Durability/Emission EvalEval. . ----8 ppm S8 ppm S
uu Fuel 3: Fuel 3: Research/Emission Research/Emission EvalEval..----15 ppm S15 ppm S
uu Fuel 4: Fuel 4: BP 15BP 15
uu Fuel 5: 30 ppm (Excursions)Fuel 5: 30 ppm (Excursions)
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Engine Installation -- EGR SystemEngine Installation -- EGR System
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Exhaust Treatment Arrangement--CB-DPF and SCRExhaust Treatment Arrangement--CB-DPF and SCR
EGR Pickup
Flow Control
Valves
SCR Catalysts
Urea InjectionControl Units
Urea Injectors
CB-DPF
CB-DPF
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uu IntroductionIntroduction
uu ObjectivesObjectives
uu Technical ApproachTechnical Approach
uu Test Setup Test Setup
uu System ComponentsSystem Components
uu Results Results
uu Summary & ConclusionsSummary & Conclusions
OutlineOutline
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Engine PerformanceEngine Performance
0
200
400
600
800
1000
1200
1400
1600
1800
500 700 900 1100 1300 1500 1700 1900 2100
Engine Speed, rpm
Tor
que,
lb-f
t
0
50
100
150
200
250
300
350
400
450
500
Pow
er, h
p
Peak PowerPeak Power
451 hp @ 1800 rpm451 hp @ 1800 rpm
Peak TorquePeak Torque
1641 lb1641 lb--ft @ 1200 rpmft @ 1200 rpm
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Transient Emissions--350ppm Cert. 2D FuelTransient Emissions--350ppm Cert. 2D Fuel2D Fuel
0.09 0.07
0.84 0.85
3.54 3.55
0.064 0.067
0.381 0.370
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
g/b
hp
-hr
BSHC BSCO BSNOx BSPM BSFC
092001-H1 092001-H2
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Steady-State Emissions--350ppm Cert. 2D FuelSteady-State Emissions--350ppm Cert. 2D Fuel2D Fuel
0.01
0.39
4.82
0.0310.336
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
g/b
hp
-hr
BSHC BSCO BSNOx BSPM BSFC
092001-H1
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EGR* CalibrationEGR* CalibrationEGR Calibration Iteration
0
20
40
60
80
100
120
140
160
0 200 400 600 800 1000 1200
Time, sec
NO
x, p
pmProduction Calibration EGR Map1 EGR Map2 EGR Map3
EGR* : Low Pressure Loop EGR With CBEGR* : Low Pressure Loop EGR With CB--DPFDPF
As-Received
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Transient Emissions--EGR* and DECSE 3ppm FuelTransient Emissions--EGR* and DECSE 3ppm FuelFuel
EGR* : Low Pressure Loop EGR With CBEGR* : Low Pressure Loop EGR With CB--DPFDPF
0.02 0.02
0.11 0.09
1.46 1.46
0.007 0.007
0.366 0.368
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
g/b
hp
-hr
BSHC BSCO BSNOx BSPM BSFC
010802-H2 010802-H3
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Steady-State Emissions Comparison--As-Received W. Cert. Fuel 350ppm S and W.EGR*--DECSE 3ppm Fuel
Steady-State Emissions Comparison--As-Received W. Cert. Fuel 350ppm S and W.EGR*--DECSE 3ppm FuelFuel
0.00 0.01 0.01
0.39
2.32
4.82
0.005 0.0310.342 0.336
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
g/b
hp
-hr
BSHC BSCO BSNOx BSPM BSFC
W. EGR As-Received
EGR* : Low Pressure Loop EGR With CBEGR* : Low Pressure Loop EGR With CB--DPFDPFRR
Transient Emissions--EGR*/SCR/DPF/DECSE 3ppm FuelTransient Emissions--EGR*/SCR/DPF/DECSE 3ppm FuelFuel
0
50
100
150
200
250
300
350
400
450
500
550
600
650
700
0 100 200 300 400 500 600 700 800 900 1000 1100 1200
Time, sec
Raw
NO
x, p
pm
0
5
10
15
20
25
Raw
Am
mon
ia, p
pm
NOx B4 SCR NOx After SCR Ammonia
Emissions, g/bhp-hrHC: 0.039 (0.14)**CO: 0.099 (15.5)**NOx: 0.38 (0.20)**PM: 0.006 (0.01)**
* *HD Standards For 2007
EGR* : Low Pressure Loop EGR With CBEGR* : Low Pressure Loop EGR With CB--DPFDPF
Preliminary-Without Cleanup Catalyst
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Steady-State Emissions Emissions Comparison--As Received vs. EGR*/CB-DPF/SCR--DECSE 3ppm FuelSteady-State Emissions Emissions Comparison--As Received vs. EGR*/CB-DPF/SCR--DECSE 3ppm FuelFuel
0.00 0.01 0.05
0.390.17
4.82
0.003 0.0310.342 0.336
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
g/b
hp
-hr
BSHC BSCO BSNOx BSPM BSFC
EGR+CB-DPF+SCR As-Received
EGR* : Low Pressure Loop EGR With CBEGR* : Low Pressure Loop EGR With CB--DPFDPF
Preliminary-Without Cleanup Catalyst
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Steady-State Emissions--DEVELOPMENT & PROGRESSSteady-State Emissions--DEVELOPMENT & PROGRESS
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0.1
0.2
0.3
0.4
0.5H
C, C
O, &
PM
Em
issi
ons,
g/b
hp-h
r
0
1
2
3
4
5
NO
x E
mis
sion
s, g
/bhp
-hr
2007 Stds. As Received EGR/CB-DPF EGR/CB-DPF/SCR
Development Sequence
0.14
0.010 00
0.39
0.01
0.05
0.010.031
0.005 0.0030.2
4.82
2.32
0.17
HC CO PM NOx
15.5
uu IntroductionIntroduction
uu ObjectivesObjectives
uu Technical ApproachTechnical Approach
uu Test Setup Test Setup
uu System ComponentsSystem Components
uu Results Results
uu Summary & ConclusionsSummary & Conclusions
OutlineOutline
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Some Conclusions Were Based on Preliminary Results
Summary and ConclusionsSummary and Conclusions
uThe C-12 Caterpillar test engine had an EPA Transient NOx/PM emissions of 3.5/0.07 g/bhp-hr.
uThe LPL EGR system was installed and calibrated to yield:
−over 50% NOx reduction and,
− about 90%PM reduction
uSystem A SCR was installed and urea injection was optimized for the OICA cycle.
uSystem A (including LPL EGR) yielded NOx/PM of 0.17/0.003 g/bhp-hr in the OICA test.
uSystem A calibration for the EPA transient test cycle is in progress and nearing completion.
uSystem B calibration will follow the completion of System A calibration.
uPreparation for the durability phase of the program is complete.
uBoth durability engines have been broken in.
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