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Institute for Powertrains
& Automotive Technology
Institute for Powertrains & Automotive Technology
Urea Injection and Preparation in
Diesel ApplicationsMultiphase Multicomponent Modeling using Star-CD
STAR European Conference 2010, London
Dipl.-Phys. Simon Fischer
Dr. Thomas Lauer
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 2
Contents
The SCR-Process: Problem Introduction
Methodology and Analysis Setup
Thermodynamic Multicomponent Model of a Urea-Water-Solution
Droplet-Wall-Interaction and Liquid Film Dynamics
Conjugate Heat Transfer and Liquid Film Boiling
Ammonia Homogenization
Conclusion and Outlook
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 3
Contents
The SCR-Process: Problem Introduction
Methodology and Analysis Setup
Thermodynamic Multicomponent Model of a Urea-Water-Solution
Droplet-Wall-Interaction and Liquid Film Dynamics
Conjugate Heat Transfer and Liquid Film Boiling
Ammonia Homogenization
Conclusion and Outlook
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 4
Problem Introduction: Future Diesel Emission Limits
exhaust aftertreatment of NOx is a major requirement for future Diesel engines
[1]
NOx- Emissions [g/km]
Pa
rtic
leE
mis
sio
ns
[g/k
m]
SC
R
source: Auto News
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 5
Principle of Selective Catalytic Reduction (SCR)
exhaust gas flow (NOx)
injection of a
water-urea mixture
32.5 mass-% urea
67.5 mass-% water
timescales of ammonia preparation
ammonia uniformity at catalyst frontal area
exhaust pipe
impingement film transport
heat transfer
ammonia (NH3) vapour
homogenization
preparation process
1) water evaporation
2) chemo-physical urea
decomposition to ammonia
(thermo-/hydrolysis)
CFD-simulation for efficient SCR-system designSCR-catalyst:„NOx+NH3 →N2 + H2O“
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 6
Contents
The SCR-Process: Problem Introduction
Methodology and Analysis Setup
Thermodynamic Multicomponent Model of a Urea-Water-Solution
Droplet-Wall-Interaction and Liquid Film Dynamics
Conjugate Heat Transfer and Liquid Film Boiling
Ammonia Homogenization
Conclusion and Outlook
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 7
Methodology and Validation Setup
straight exhaust pipe
urea-water-
solution-injection
from engine
exhaust gas flow
SC
R-C
ata
lyst
CFD mesh according to
experimental setup
OP 3 - high temperature / mass flow / NOx raw emission
OP2 - intermediate temperature / mass flow / NOx raw emission
OP1 - low temperature / mass flow / NOx raw emission
Analysis of Representative Operating Points (OP):
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 8
Contents
The SCR-Process: Problem Introduction
Methodology and Analysis Setup
Thermodynamic Multicomponent Model of a Urea-Water-Solution
Droplet-Wall-Interaction and Liquid Film Dynamics
Conjugate Heat Transfer and Liquid Film Boiling
Ammonia Homogenization
Conclusion and Outlook
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 9
Thermodynamic Multicomponent Model (Liquid Film, Droplets)
TBoil(Yurea)
Partial Pressures
(Raoult`s law):
AdBlue:
32.5 Mass.-% Urea,
67.5 Mass.-% Water
pure water:
Antoine
equation
implemented in
dropro.f, lqfpro.f
pure urea:
saturation
pressure curve
implemented in
dropro.f, lqfpro.f
)()( , TpxTp ipure
si
i
s
i
i
stot TpTp )()(
Total Pressure
(Dalton`s law):
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 10
Decomposition of a Single Urea-Water-Solution-Droplet
water evaporation urea thermolysis
two-step preparation process modeled
[1]
[1] Wang, Baek,Lee: Experimental Investigation on Evaporation of Urea-Water-Solution Droplet for SCR Applications, AICE 2009
heat flux
through fibre,
fine tuning of
urea-psat-curve
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 11
Contents
The SCR-Process: Problem Introduction
Methodology and Analysis Setup
Thermodynamic Multicomponent Model of a Urea-Water-Solution
Droplet-Wall-Interaction and Liquid Film Dynamics
Conjugate Heat Transfer and Liquid Film Boiling
Ammonia Homogenization
Conclusion and Outlook
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 12
Multiphase Modeling: Challenge Of Timescales
Small Time Scales:
turbulent flow field
droplet dynamics
species (ammonia) transport
Steady-State Calculation (PISO)
fluid flow field
temperature field
no spray injection (liquid phase)
Large Time Scales:
liquid film formation and -dynamics
ammonia formation from film
wall cooling (CHT)
Transient Calculation (Simple)
thermodynamics (enthalpy)
droplets and liquid film
species (ammonia, water vap.)
time steps: 0.1 ms (droplets present)
1 ms (otherwise)
Solution Strategy:
Restart with
flow field
solvers
switched off
simulated interval of several minutes incl. spray dynamics and species transport
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 13
Droplet Dynamics: Injection
three hole nozzle
diameter
distribution
from
measurement
timescale miliseconds
droico.f
no primary break-up modelled
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 14
Droplet Impingement Regimes
depending on liquid properties, droplet dynamics, wall temperature,…
OP 3 – high temp.
OP2- medium temp.
OP1 - low temp
…complex behaviour
Bai-M
odel (S
w30)
Sp
rea
d-M
ode
l
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 15
Liquid Film Formation: Validation
Experiment
(Videoanalysis)
Simulation Spread-
Model
Simulation Bai-
Model- Switch 30
OP 1
(„cold“)
extensive liquid
film, flow to pipe
bottom x
OP 2
(„medium“)
thin film after
some delay, no
remarkable flowx
OP 3
(„hot“) no permanent film x
impingement model not yet predictive across whole temperature range
not observed
in simulation
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 16
Simulated Liquid Film Formation
OP3-Bai-Sw30
OP2-BaiSw30
OP1- Spread
…
OP1-BaiSw30massive liquid film with spread model in OP1
small extent liquid film with Bai model in OP1
no permanent film in OP3
transient behaviour in OP2
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 17
Droplet Impingement and Liquid Film Dynamics
timescale millisecondstimescale minutesliquid film spread after 120 s
high
Droplet
Diameter
low
Film
Thickness
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 18
Liquid Film Dynamics Validation
180°
90°
180°
90°
Expe
rim
ent
Sim
ula
tio
nV
ideo-A
naly
sis
[2]
Sim
ula
tion
Distribution of Liquid Film after 120 Seconds
OP1- Spread
exce
llen
td
escri
ptio
no
f film
dyn
am
ics
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 19
Contents
The SCR-Process: Problem Introduction
Methodology and Analysis Setup
Thermodynamic Multicomponent Model of a Urea-Water-Solution
Droplet-Wall-Interaction and Liquid Film Dynamics
Conjugate Heat Transfer and Liquid Film Boiling
Ammonia Homogenization
Conclusion and Outlook
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 20
Thermal Wall Boundary Conditions In Star-CD
Adia
batic
Fix
ed
Tem
pera
ture
Fix
ed
with
Resis
tance
Conju
gate
Heat T
ransfe
r
Rele
vance
in
SC
R-M
odelin
g
wall as a heat source !!!cooling of wall due to
evaporation !!!
thermal inertia of wall !!
wall parallel heat conduction !!
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 21
Meshing For Conjugate Heat Transfer Approach
boundary Layer
extruded solid cells for CHT
single layer approach
fluid cells
trimmed from custom-grid
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 22
The Nukiyama Film Boiling Model (Star-CD 4.10)
OP 3
OP2
OP1
regime positions
from experiment
(IR-thermography)
Burnout Point
Leidenfrost Point
Film-boilingTransition-
Nucleate-Convection
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 23
Local Wall Spray CoolingOP 1-Spread
Temperature T[ C]
primary
impingement
position (water
evaporation)
Flow direction
IR-Thermography
Star-CD 4.10good qualitative representation
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 24
Wall Spray Cooling
OP3-Bai Sw30OP2-BaiSw30
Steady State Wall CoolingDynamics of Cooling Process
OP1-Spread
IR-Themography
Star-CD 4.06
Star-CD 4.10
numerical instability
in v4.10 Bai model
for thermal break-
up-regime
(currently fixed by
Switch 30 and
NOTHBREAK
in *.prob)
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 25
Contents
The SCR-Process: Problem Introduction
Methodology and Analysis Setup
Thermodynamic Multicomponent Model of a Urea-Water-Solution
Droplet-Wall-Interaction and Liquid Film Dynamics
Conjugate Heat Transfer and Liquid Film Boiling
Ammonia Homogenization
Conclusion and Outlook
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 26
Film
Thickness
OP 1
Ammonia Vapour Homogenization
Ammonia-
Concentration
high
low
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 27
Ammonia Vapour Homogenization: Validation
FTIR- measurement [2]
Ammonia-
Concentration
OP 1
Simulation
high
low
concentrations
scaled by
mean value
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STAR European Conference 2010
Urea Injection and Preparation in Diesel Applications
March 23rd 2010 | London | Simon Fischer | Slide 28
Contents
The SCR-Process: Problem Introduction
Methodology and Analysis Setup
Thermodynamic Multicomponent Model of a Urea-Water-Solution
Droplet-Wall-Interaction and Liquid Film Dynamics
Conjugate Heat Transfer and Liquid Film Boiling
Ammonia Homogenization
Conclusion and Outlook
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STAR European Conference 2010
Urea-injection and -preparation in Diesel applications
March 23rd 2010 | London | Simon Fischer | Slide 29
Conclusion
validated Star-CD-Model of the urea-water-solution preparation process:
simulation of several injection events and long time liquid film behaviour
via separated (steady) flow field and liquid-phase/thermodynamic calc.
two step ammonia preparation process modeled properly with Raoults` law
predictive impingement model for whole temperature range missing
→ massive film formation (OP1) currently forced by spread-model
→ break-up model in v4.10 (for high temp. impingement) not stable
liquid film dynamics well represented in simulation
implementation of Conjugate Heat Transfer for a correct prediction of liquid
film formation and preparation timescales (validated by IR-themography)
promising liquid film boiling model improvements from v4.06 to v4.10
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STAR European Conference 2010
Urea-injection and -preparation in Diesel applications
March 23rd 2010 | London | Simon Fischer | Slide 30
Outlook
check and adaption of improved Star-CDs` physical models (4.10/4.12)
NIST approach (internal calculation) for multicomp. thermodynamics properties
fix of Break-Up regime numerical instabilities of extended Bai-model (v4.10)
(currently NOTHBREAK in *.prob and Switch 30 → support)
underestimation of liquid film at low temperatures (OP1): tuning of critical
Regime Weber-Numbers to realize „one-fits-all“ Bai-impingement-model
adaption of liquid film boiling model (Nukiyama-curve) for urea-water solution
(currently standard Star-CD parameter set for pure water)
(thermography data available)
evaluation of post impingement droplet properties (e.g. size distribution)
laser-diffraction data available
towards a fully predictive SCR-process Star-CD-model
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Institute for Powertrains
& Automotive Technology
Institute for Powertrains & Automotive Technology
Thank you for your attention!
Dipl.-Phys. Simon Fischer