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Introduction
Challenges to achieve high efficient SCR
SCR Dosing System
Evaporation and Mixing Pipe
Close coupled compact SCR-System
Conclusion
Agenda
Heavy Duty /NRMM – Emission Standards (ETC) & -
Technology Shift of Priorities P
M [
mg
/kW
h]
NOx [g/kWh] 1
60
30
4 2 6
EU V EU IV
0 3
Engine Technology
EU VI; NRMM >130 kW Stage 3 B
NRMM EU Stage IV
SCR 80 % NRMM Stage IIIB (2012)
NRMM EU IIIB
SCR 80 % EU VI
Heavy Duty /NRMM – Emission Standards (ETC) & -
Technology Shift of Priorities P
M [
mg
/kW
h]
NOx [g/kWh] 1
60
30
4 2 6
EU V EU IV
0 3
Engine Technology
EU VI; NRMM >130 kW Stage 3 B
NRMM EU Stage IV
SCR 80 % NRMM Stage IIIB (2012)
NRMM EU IIIB
EU VI
Heavy Duty /NRMM – Emission Standards (ETC) & -
Technology Shift of Priorities P
M [
mg
/kW
h]
NOx [g/kWh] 1
60
30
4 2 6
EU V EU IV
EU VI
0 3
Engine Technology
EU VI; NRMM >130 kW Stage 3 B
NRMM EU Stage IV
NRMM EU IIIB
SCR >92 -95 %
Introduction
Challenges to achieve high efficient SCR
SCR Dosing System
Evaporation and Mixing Pipe
Close coupled compact SCR-System
Conclusion
High Efficient SCR for SCR only Applications for NRMM
Challenges and demands for SCR- Emission control
technologies across various applications
Thermodynamic Challenges
Heat up during cold start low temperature condition
Start of AdBlue Injection
AdBlue-Decomposition
Challenges and demands for SCR- Emission control
technologies across various applications
Thermodynamic Challenges
Heat up during cold start low temperature condition
Start of AdBlue Injection
AdBlue-Decomposition
NH3/ NOx Uniformity
SCR “Light-Off”
SCR Conversion Limitation SCR Kinetic Limitation NH3/ NOx
Limitation NH3 storage
Challenges and demands for SCR- Emission control
technologies across various applications
Priorities
PC / LD / MD NEDC RDE /(NTE)
FTP
US06
JC08
Non-Road NRMM
NRSC
NRTC cold
NRTC.Warm
HD On-Road Steady State
ETC
WHTC cold
WHTC warm
FTP
JE05
Thermodynamic Challenges
Heat up during cold start low temperature condition
Start of AdBlue Injection
AdBlue-Decomposition
NH3/ NOx Uniformity
SCR “Light-Off”
SCR Conversion Limitation SCR Kinetic Limitation NH3/ NOx
Limitation NH3 storage
Priorities
PC / LD / MD NEDC RDE /(NTE)
++ +++
+ ++ + ++ >80
FTP ++ + ++ + ++ >80
US06 ++ + >80
JC08 ++ + ++ + ++ >80
Non-Road NRMM
NRSC ++ >95
NRTC cold + ++ ++ ++ ++ > 80
NRTC.Warm + ++ + > 95
HD On-Road Steady State + >93
ETC + ++ ++ >93
WHTC cold ++ ++ ++ ++ ++ >70
WHTC warm ++ ++ ++ ++ >80
FTP + + ++ ++ ++ >80
JE05 ++ + ++ ++ ++ >80
Thermodynamic Challenges
Heat up during cold start low temperature condition
Start of AdBlue Injection
AdBlue-Decomposition
NH3/ NOx Uniformity
SCR “Light-Off”
SCR Conversion Limitation SCR Kinetic Limitation of NH3/ NOx
Limitation NH3 storage
Challenges and demands for SCR- Emission control
technologies across various applications
Fundamantal Steps for AdBlue Decomposition
and Technology for System Optimization
1. Step: evaporation of Water: {(NH2)2CO •7H2O}fl {(NH2)2CO}fl + 7 H2O
2. Step: thermolysis of Urea: {(NH2)2CO}fl HNCO + NH3
3. Step: hydrolysis of isocyanic acid: HNCO + H2O CO2 + NH3
11
steps from AdBlue towards ammonia:
Adblue® droplet penetration on surface evaporation & thermolysis
1. + 2. reaction steps
AdBlue droplet interaction on surface
Technologies for Optimization: Hydrolysis: Usage of Hydrolysis Catalyst / Mixer NH3 – Distribution: Optimization of Mixing pipe and mixing
design
0
10
20
30
40
50
60
70
80
90
100
0 100 200 300 400
NO
x C
on
ve
rsio
n R
ate
[%
]
Temperature [°C]
NO2 / NO
50% / 50%
NO2 / NO
0% / 100%
Temperature
Range at low
load operation
0
1
2
3
4
5
6
Engine Out behind DOC behind SCRN
O,
NO
2 [
g/k
Wh
]
NO
NO2
NOx- SCR-Efficiency as Function of NO2-Ratio
12
Standard SCR- Reaction with NO: 4 NO + O2 + 4 NH3 4 N2 + 6 H2O
“fast“ SCR-Reaction with NO+NO2: 2 NO2 + 2 NO + 4 NH3 4 N2 + 6 H2O
Reaktionen bei der NOX – Reduktion durch SCR:
Emissions during ETC
- 30%
NO2
NO2
NO2
NO
Calculated NOx-Reduction and NH3 Slip as Function of
NH3-Uniformity and AdBlue-Dosing Rate
70
75
80
85
90
95
100
0,88 0,9 0,92 0,94 0,96 0,98 1
NOx-Reduction
NH3-Uniformity
Alpha = 1.00
Alpha = 0.95
Alpha = 0.90
Alpha = 0.80
0
10
20
30
40
50
60
0,88 0,9 0,92 0,94 0,96 0,98
NH3- Slip
NH3-Uniformity
Calculated NOx-Reduction and NH3 Slip as Function of
NH3-Uniformity and AdBlue-Dosing Rate
70
75
80
85
90
95
100
0,88 0,9 0,92 0,94 0,96 0,98 1
NOx-Reduction
NH3-Uniformity
Alpha = 1.00
Alpha = 0.95
Alpha = 0.90
Alpha = 0.80
80
85
90
95
100
0 5 10 15 20 25 30
NH3-Slip
NO
x-C
on
vers
ion
[%
]
short tube
long tube
NOx = 200ppm
DeNOx Performance as Function of NH3- Uniformity
SCR
AdBlue
DOC
SCR AdBlue
DOC short tube
long tube
Short tube
Long tube
Influence of System Design on NH3-Uniformity
and DeNOx- Performance
0
20
40
60
80
100
120
70 80 90 100
NH
3-s
lip
[p
pm
]
NOx-conversion [%] T= 410°C
NOx = 350 ppm
SV.SCR = 58.000 1/hr S-tube
straight tube
S-tube
straight tube
Introduction
Challenges to achieve high efficient SCR
SCR Dosing System
Evaporation and Mixing Pipe
Close coupled compact SCR-System
Conclusion
High Efficient SCR for SCR only Applications for NRMM
Emitec SCR-Dosing system Gen III
In Tank SCR-Dosing system
Gen III
Customized Tank for the application
Emitec Gen III System Description
All in One Integration
Suction lance
Temperature sensor
Urea filter
Level sensor
Tank heater
Heated suction line
External DCU
Installation cost:
Electrical harness
Fixing devices
Lines connections Quality sensor
Pump
PTC Heater
Level-/Quality Sensor
Pressure Sensor
Pressure Control Valve
Electronic
Emitec Dosing System Gen III; InsideView
Introduction
Challenges to achieve high efficient SCR
SCR Dosing System
Evaporation and Mixing Pipe
Close coupled compact SCR-System
Conclusion
High Efficient SCR for SCR only Applications for NRMM
Mo
tor
Dre
hm
om
en
te
ng
ine
to
rqu
e
Motor Drehzahlengine speed
low temperature area
• fast start of dosing
• excellent evaporation of droplets
• low risk for depositions
+ static mixer
UDP + MX Metalit
+ Hydrolysis Catalyst
Thermal Challenges for AdBlue Injection within Engine Map
Engine Speed
Torq
ue
NOx Efficiency with Optimised Airless Dosing Layout
Summary of Sweep Test
86
88
90
92
94
96
98
100
0,85 0,9 0,95 1 1,05
NO
x E
ffic
ien
cy
Alpha (-) Test conditions: constant speed / torque
• constant temperature and massflow and exhaust gas
condition
• exhaust gas 714 kg/h, T = 420 °C, NOx = 543 ppm;
NO2/NOx = 0,27
theoretical AdBlue® demand for (alpha = 1) = 1100 ml / h
setup with Fe-Zeolithe catalyst [Ø242 x (110 + 110)] 10,1 ltr
dosing rate 1000 ml / h 1200 ml/h (alpha = 0,9 ... 1,1)
Introduction
Challenges to achieve high efficient SCR
SCR Dosing System
Evaporation and Mixing Pipe
Close coupled compact SCR-System
Conclusion
High Efficient SCR for SCR only Applications for NRMM
Compact SCR System for Heavy Duty and Non Road
Mobile Machineries
AdBlue-Injector
DOC LS/PE-Metalit®
- Robust design
based on mass production
- gasoline injector
- Spray pattern can
adapted to application
Reductant Delivery Unit (Urea Injector)
Water Cooling for highest
Off Road demands
Compact SCR System for Heavy Duty and Non Road
Mobile Machineries
AdBlue-Injector
Mixing Element / Hydrolysis Catalyst DOC
LS/PE-Metalit®
Comparison of a Mixer / Hydrolysis Catalyst regarding
Deposits at Low Temperature AdBlue Injection
Variant 1 with
Mixing Element
Variant 2 with
Hydrolysis Catalyst
N= 1200 1/min; Md = 215 Nm
Exhaust Mass: 326 kg/h; T = 230°C
AdBlue-Dosage = 560 g/h, α = 0.8
Compact SCR System for Heavy Duty and Non Road
Mobile Machineries
AdBlue-Injector
Mixing Element / Hydrolysis Catalyst DOC
LS/PE-Metalit®
SCR- Catalyst LS-Metalit®
Compact SCR System for Heavy Duty and Non Road
Mobile Machineries, Demonstrator
close coupled
DOC + 1. stage SCR
2.Stage
SCR
SCR only System Layout
Motor
DOC (2,2 ltr) static mixer
SCR 1 (6,5 ltr)
SCR 2 (4,0 ltr)
close coupled
NOx T NOx T
NOx
1. Stufe 2. Stufe
Cumulated NOx Emissions at alfa = 1 during NRTC
0 2 0 0 4 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0
0
1 0 0
2 0 0
3 0 0
0
5
0 . 0
3 0 . 0
6 0 . 0
9 0 . 0
time [s]
Acu
mu
late
d N
Ox [
g]
Acu
mu
late
d N
Ox [
g]
Acu
mu
late
d A
dB
lue [
g]
AdBlue-Mass
NOx Tailpipe
NOx after 1. Stage
NOx engine out
Accumulated NOx Emissionen after 1st and 2nd SCR Stage
during NRTC Test
1. SCR Stage
2.SCR Stage
post SCR 2
94,6 %
91,1 %
0 2 0 0 4 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0
0
3 0
6 0
9 0
0
3
time [s]
Acu
mu
late
d N
Ox [
g]
Acu
mu
late
d N
Ox [
g]
Total NOx Reduction and NH3 Slip during NRTC Test
Tailpipe
NH3 concentration
(no NH3 slip catalyst)
SCRa
94,6 %
time [s]
0 2 0 0 4 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0
0
3 0
6 0
9 0
0
1 0 0
NH
3 [
pp
m]
Acu
mu
late
d N
ox [
g]
Introduction
Challenges to achieve high efficient SCR
SCR Dosing System
Evaporation and Mixing Pipe
Close coupled compact SCR-System
Conclusion
High Efficient SCR for SCR only Applications for NRMM
Splitting of the Functions: Hydrolysis and NOx-Reduction
H-Kat H-Kat
MX MX
DEF (fluid) [(NH2)2CO•7H
2O]fl
gaseous NH3 + CO2 + H2O
Slip-Cat
Red
. C
at
LS
/PE
R
ed.
Ca
t L
S
Red
. C
at
LS
Hydrolysis-Function ☺
D 934 D 936 D 856 D 9508
One System Layout for several Engines and Applications
LTM Ober- / Unterwagen
LB LTR LR LRB LRS LHM HS
LPS HPS 2 Sizes of exhaust systems
~ 50 Applications
1 Pump 1 Injector