emissions control for lean gasoline engines3. production during rich operation and nox reduction...

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ORNL is managed by UT-Battelle for the US Department of Energy ORNL is managed by UT-Battelle for the US Department of Energy Emissions Control for Lean Gasoline Engines Jim Parks (PI), Todd Toops, Josh Pihl, Vitaly Prikhodko Oak Ridge National Laboratory ACE033 June 11, 2015 Sponsors: Gurpreet Singh, Ken Howden, and Leo Breton Advanced Combustion Engines Program U.S. Department of Energy This presentation does not contain any proprietary, confidential, or otherwise restricted information

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Page 1: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

ORNL is managed by UT-Battelle for the US Department of EnergyORNL is managed by UT-Battelle for the US Department of Energy

Emissions Control for Lean Gasoline EnginesJim Parks (PI), Todd Toops, Josh Pihl, Vitaly Prikhodko

Oak Ridge National Laboratory

ACE033June 11, 2015

Sponsors: Gurpreet Singh, Ken Howden, and Leo Breton

Advanced Combustion Engines ProgramU.S. Department of Energy

This presentation does not contain any proprietary, confidential, or otherwise restricted information

Page 2: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

2 DOE VTO Annual Merit Review – ace033

Project OverviewTimeline

Budget

Barriers Addressed

Collaborators & Partners• FY15: $377k

• FY14: $400k

• FY13: $500k

• General Motors• Umicore• University of South Carolina• University of Wisconsin• Cross-Cut Lean Exhaust

Emissions Reduction Simulations (CLEERS)

• Barriers listed in VT Program Multi-Year Program Plan 2011-2015:

– 2.3.1B: Lack of cost-effective emission control

– 2.3.1C: Lack of modeling capability for combustion and emission control

– 2.3.1.D: Emissions control durability

• Project began in FY12• Project ongoing with annual goals

through 2017

Page 3: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

3 DOE VTO Annual Merit Review – ace033

Objectives and Relevance

Enabling lean-gasoline vehicles to meet emissions regulations will achieve significant reduction in petroleum use

• Objective:– Demonstrate technical path to emission compliance that would allow the

implementation of lean gasoline vehicles in the U.S. market. • Lean vehicles offer 5–15% increased efficiency

over stoichiometric-operated gasoline vehicles • Compliance: U.S. EPA Tier 3 (originally Tier 2 Bin 2)

– Investigate strategies for cost-effective compliance• minimize precious metal content while

maximizing fuel economy

• Relevance:– U.S. passenger car fleet is dominated by gasoline-fueled vehicles. – Enabling introduction of more efficient lean gasoline engines can provide

significant reductions in overall petroleum use• thereby lowering dependence on foreign oil and reducing greenhouse gases

EPA Tier 3 Emission Regulations

>70% less NOx

>85% less

NMOG

70% less PM

Page 4: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

4 DOE VTO Annual Merit Review – ace033

gasoline95.5%

diesel4.5%

gasoline99.4%

diesel0.6%

cars33.4%

light trucks38.2%

motorcycles0.3%

buses0.9%

Class 3-6 trucks6.0%

Class 7-8 trucks21.1%

Relevance: small improvements in gasoline fuel economy significantly decreases fuel consumption

Lean gasolinevehicles can

decrease US gasoline

consumption by ~13 billion gal/year

• US car and light-truck fleet dominated by gasoline engines • 10% fuel economy benefit has significant impact

– Potential to save 13 billion gallons gasoline annually• HOWEVER…emissions compliance needed!!!

References: Transportation Energy Data Book, Ed. 33 (2012 petroleum/fuel use data)

Fuel Use:Cars

Fuel Use:Lighttrucks

Highway Transportation PetroleumConsumption by Mode

Page 5: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

5 DOE VTO Annual Merit Review – ace033

Milestones and Project Goals

FY13 FY14 FY15 FY16 FY17Fuel economy gain over stoichiometric 7% 10% 10% 12% 15%

Total emissions control devices Pt* (g/Lengine) 8 7 6 5 4

* - will use Pt equivalent cost to account for different costs of Pt, Pd and Rh; 5-year average value fixed at beginning of project

• FY2014, Q1: Measure transient NH3 formed from TWC in an TWC+SCR approach on engine

• FY2014, Q2: Characterize performance of Umicore prototype TWC catalysts for NH3production

• FY2014, Q3: Present results at CLEERS Workshop• FY2014, Q4: Define the potential impact of NOx storage components added to TWC

formulations on NH3 production for downstream NOx reduction over SCR catalysts• FY2015, Q2 [SMART]: Determine effect of aging and/or poisoning on TWC NH3

formation through flow reactor experiments• FY2015, Q4: Simulate transient load/speed operation of passive SCR on BMW lean

gasoline engine platform

5-year Average($/troy oz.) Pt-equivalent

Platinum $ 1,504 /troy oz. 1.0

Palladium $ 463 /troy oz. 0.3

Rhodium $ 3,582 /troy oz. 2.4

Gold $ 989 /troy oz. 0.7

Complete

On TrackFurther studies ongoing

In addition to milestones, a set of project goals has been adopted to ensure progression towards goal of low-cost emissions control solution for fuel efficient lean-burn gasoline vehicles

Complete

CompleteComplete

Complete

Further studies ongoing

Page 6: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

6 DOE VTO Annual Merit Review – ace033

Approach focuses on catalyst and system optimization of Passive SCR (and LNT+SCR)

TWC

LeanGasolineEngine

Key Principle: system fuel efficiency gain depends on optimizing NH3production during rich operation and NOx reduction during lean operation

Other Core Principles:• Expand range of temperature operation• Materials must be durable to temperature and poisons (S)• Understand Pt group metals utilization to minimize cost

Minimize rich period of lean-rich cycle

Minimize engine out Lean NOx emissions

Add NOx storage for lean NOx storage and rich phase NH3 production

Minimize NH3oxidation (keep

NH3 stored)

Maintain high NOx conversion over

temperature range

Control emissions during lean-rich

transitions

Lean

Maximize engine out Rich NOx emissions

Minimize engine out Rich CO/HC

emissions

Maximize NOx to NH3conversion efficiency

Maximize CO and HC oxidation efficiency

Clean up CO/HC emissions (if needed)

Rich

Minimize engine out Lean NOx emissions

Add NOx storage for lean NOx storage and rich phase NH3 production

Minimize NH3oxidation (keep

NH3 stored)

Maintain high NOx conversion over

temperature range

Control emissions during lean-rich

transitions

Lean

Page 7: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

7 DOE VTO Annual Merit Review – ace033

Iterative Bench Reactor + Engine Study Approach

Bench Flow Reactor with cycling and multi-catalyst (close-coupled

and underfloor) capabilitiesBMW 120i lean gasoline engine platform with

National Instruments (Drivven) open controller

Define exhaust conditions

Formulation-dependent TWC performance TWC performance vs. AFR with

realistic HC and H2 characterization

Controlled TWC+SCR system performance Realistic TWC+SCR system performance

with fuel efficiency measurement

TWC+SCR performance with refined load step cycle Combustion parameter optimization to

maximize NH3 production

Collaborations with modeling community and CLEERS

System study guidance

Prototype catalysts

Page 8: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

8 DOE VTO Annual Merit Review – ace033

Collaborations and PartnersPrimary Project Partners• GM

– guidance and advice on lean gasoline systems via monthly teleconferences

• Umicore– guidance (via monthly teleconferences) and catalysts for

studies (both commercial and prototype formulations)• University of South Carolina (Oleg Alexeev, Anton

Lauterbach)– Catalyst aging studies with student Calvin Thomas

• University of Wisconsin (Chris Rutland)– modeling of lean emission control systems

Additional Collaborators• CDTi

– catalysts for studies• CLEERS

– Share results/data and identify research needs• LANL

– Engine platform used for NH3 sensor study (see LANL AMR talk ACE079)• MECA

– GPF studies via Work For Others contract• DOE VTO Fuel and Lubricant Technology Program

– Engine platform used for ethanol-based HC-SCR studies (see AMR talk FT007 - Todd Toops)

Page 9: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

9 DOE VTO Annual Merit Review – ace033

Responses to 2014 ReviewersApproach: investigating alternatives to urea injection highly appropriate...low temperature limitations of urea based systems are a well-established barrier…nice evolution of understanding and following adjustment of approach…using EGR and other engine means to adjust NOx and potential H2 and/or NH3 production is needed... thorough job in devising a strong framework for the project

Technical Accomplishments: excellent outcome and worthwhile results…large amount of fundamental data displayed here was quite impressive…data appeared robust, but more may be needed in the regards, e.g., repeatability, aging, poisoning effects…investigate novel purge strategies to limit CO production during the rich purges…good correlation between laboratory results and vehicle…DeSOx strategies were critical to enabling this technology to proceed and effect of SO2/SO3 on both the LNT and SCR

Category ScoreApproach 3.80Tech Accomplishments 3.50Collaboration 3.70Future Research 3.60Weighted Average 3.61

Collaborations: excellent inclusion of both suppliers and OEMs…team was extremely strong…impressive

Future plans: anxious to see the aging data…combined TWC/NSC may be important enablers for meeting LEVIII and Tier II Bin 2 standards for lean systems…mixed thoughts on whether to focus on transients versus other key engine drivers like EGR or other engine calibrations…EGR understanding might be better to develop earlier, unless one sees more interesting transient results that can significantly impact the after-treatment fundamentals…need to include purge strategy to limit impact of the rich purges on CO, HC, and fuel economy…important to better understand the PM and HC emissions on the vehicle…keep an eye on N2O

Relevance: 5-10% fuel consumption savings in the 2020 timeframe may cost OEMs about $75 per percent, leaves $500 added cost to a lean burn versus a stoichiometric GDI engine, seems achievable…running lean enhancements…well focused on fuel economy targets.

Funding: if more funds needed to shift some work into the engine approaches, money should be made available, at least enough to get data for a new proposal…not sure why modeling had not been integrated into the tasks

FY2014 AMR Review(5 Reviewers)

[scores: 1 (min) to 4 (max)]

Page 10: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

10 DOE VTO Annual Merit Review – ace033

Responses to 2014 ReviewersApproach: investigating alternatives to urea injection highly appropriate...low temperature limitations of urea based systems are a well-established barrier…nice evolution of understanding and following adjustment of approach…using EGR and other engine means to adjust NOx and potential H2 and/or NH3 production is needed... thorough job in devising a strong framework for the project

Technical Accomplishments: excellent outcome and worthwhile results…large amount of fundamental data displayed here was quite impressive…data appeared robust, but more may be needed in the regards, e.g., repeatability, aging, poisoning effects…investigate novel purge strategies to limit CO production during the rich purges…good correlation between laboratory results and vehicle…DeSOx strategies were critical to enabling this technology to proceed and effect of SO2/SO3 on both the LNT and SCR

Category ScoreApproach 3.80Tech Accomplishments 3.50Collaboration 3.70Future Research 3.60Weighted Average 3.61

Collaborations: excellent inclusion of both suppliers and OEMs…team was extremely strong…impressive

Future plans: anxious to see the aging data…combined TWC/NSC may be important enablers for meeting LEVIII and Tier II Bin 2 standards for lean systems…mixed thoughts on whether to focus on transients versus other key engine drivers like EGR or other engine calibrations…EGR understanding might be better to develop earlier, unless one sees more interesting transient results that can significantly impact the after-treatment fundamentals…need to include purge strategy to limit impact of the rich purges on CO, HC, and fuel economy…important to better understand the PM and HC emissions on the vehicle…keep an eye on N2O

Relevance: 5-10% fuel consumption savings in the 2020 timeframe may cost OEMs about $75 per percent, leaves $500 added cost to a lean burn versus a stoichiometric GDI engine, seems achievable…running lean enhancements…well focused on fuel economy targets.

Funding: if more funds needed to shift some work into the engine approaches, money should be made available, at least enough to get data for a new proposal…not sure why modeling had not been integrated into the tasks

FY2014 AMR Review(5 Reviewers)

[scores: 1 (min) to 4 (max)]Comment Area Response

Reviewers complemented approach and accomplishments

Continuing approach and targeting projectgoals

Combustion parameters for optimal emissions control

Extended studies in this area

Interest in aging results Obtained hydrothermal and S aging results (studies ongoing)

Purge, lean-rich transitions, and transient control

Project moving more in this important direction

Modeling Outside of project scope but collaborations with modeling community

Page 11: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

11 DOE VTO Annual Merit Review – ace033

Summary of Technical Accomplishments• Completed full characterization on bench flow reactor of Umicore

prototype catalyst matrix– Fixed load cycle vs. load step cycle results– Using more challenging HCs

sample ID Description Pt (g/l) Pd (g/l) Rh (g/l) OSC NSCMalibu-1 Front half of TWC 0 7.3 0 N NMalibu-2 Rear half of TWC 0 1.1 0.3 Y N

Malibu-combo Full TWC 0 4.0 0.16 Y NORNL-1 Pt + Pd + Rh 2.47 4.17 0.05 Y YORNL-2 Pd + Rh 0 6.36 0.14 N NORNL-6 Pd 0 6.50 0 N NORNL-5 Pd + OSC high 0 6.50 0 H NORNL-4 Pd + OSC med 0 4.06 0 M NORNL-3 Pd + OSC low 0 1.41 0 L N

• Performed hydrothermal and S rapid aging of TWC (Malibu-1)– Using industry approved cycle methodology (ongoing)

• Preliminary results obtained from engine out NOx optimization studies– Ongoing studies targeting minimizing rich period of lean-rich cycle

• On engine studies of load step and lean-rich-lean transitions (ongoing)– Focus toward transient operation; details not discussed in this presentation

Catalyst Sample Matrix [OSC=oxygen storage capacity; NSC=NOx storage capacity]

Page 12: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

12 DOE VTO Annual Merit Review – ace033

Bench Reactor Formulation Study: TWC formulation affects NH3yield during rich operation, particularly at high temperatures

• Extensive data set: 5 formulations, 7 Ts, 5 λs, 2 conditions, 5 cycles

• Temperature, λ, TWC formulation all impact NH3selectivity

• Working to understand correlations between formulation & selectivity

Malibu1: Pd ORNL6: Pd ORNL5: Pd+OSC

ORNL2: Pd+Rh ORNL1: NSR

λ

λ

Results from fixed-load lean-rich cycles with feedback control based on NH3:NOx [see backup slide 24 for full details]

Page 13: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

13 DOE VTO Annual Merit Review – ace033

TWC formulation impacts fuel consumption through NH3selectivity (rich time) and NOx storage (lean time)

Rich Time(NH3 selectivity)

Lean Time(NOx storage)

Fuel Consumption Benefit over stoich operation

Fixe

d Lo

ad C

yclin

g*ric

h: 2

bar

BM

EP, λ

0.97

Load

Ste

p C

yclin

g*ric

h: 8

bar

BM

EP, λ

0.95 w/ NSC

w/ NSC w/ NSC

w/ NSC

bette

r

bette

r

better

*Feedback controlled cycles (cycle average NH3:NOx=1)

Catalysts with

varying PGMs

and OSC

Catalyst with NSC

Page 14: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

14 DOE VTO Annual Merit Review – ace033

TWC formulation impacts fuel consumption through NH3selectivity (rich time) and NOx storage (lean time)

Rich Time(NH3 selectivity)

Lean Time(NOx storage)

Fuel Consumption Benefit over stoich operation

Fixe

d Lo

ad C

yclin

g*ric

h: 2

bar

BM

EP, λ

0.97

Load

Ste

p C

yclin

g*ric

h: 8

bar

BM

EP, λ

0.95 w/ NSC

w/ NSC w/ NSC

w/ NSC

bette

r

bette

r

better

*Feedback controlled cycles (cycle average NH3:NOx=1)

Catalysts with

varying PGMs

and OSC

Catalyst with NSC

Page 15: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

15 DOE VTO Annual Merit Review – ace033

TWC formulation impacts fuel consumption through NH3selectivity (rich time) and NOx storage (lean time)

Rich Time(NH3 selectivity)

Lean Time(NOx storage)

Fuel Consumption Benefit over stoich operation

Fixe

d Lo

ad C

yclin

g*ric

h: 2

bar

BM

EP, λ

0.97

Load

Ste

p C

yclin

g*ric

h: 8

bar

BM

EP, λ

0.95 w/ NSC

w/ NSC w/ NSC

w/ NSC

bette

r

bette

r

better

*Feedback controlled cycles (cycle average NH3:NOx=1)

Catalysts with

varying PGMs

and OSC

Catalyst with NSC

Page 16: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

16 DOE VTO Annual Merit Review – ace033

TWC formulation impacts fuel consumption through NH3selectivity (rich time) and NOx storage (lean time)

Rich Time(NH3 selectivity)

Lean Time(NOx storage)

Fuel Consumption Benefit over stoich operation

Fixe

d Lo

ad C

yclin

g*ric

h: 2

bar

BM

EP, λ

0.97

Load

Ste

p C

yclin

g*ric

h: 8

bar

BM

EP, λ

0.95 w/ NSC

w/ NSC w/ NSC

w/ NSC

bette

r

bette

r

better

• Temperature affects performance dramatically for catalyst with NOx storage component (NSC)

• At low temps, NSC gives greater fuel efficiency; at high temps, Pd-only formulations better

• Combinations of Pd and NSC formulations of interest

*Feedback controlled cycles (cycle average NH3:NOx=1)

Catalysts with

varying PGMs

and OSC

Catalyst with NSC

Page 17: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

17 DOE VTO Annual Merit Review – ace033

TWC conversions highlight remaining emissions challenges: lean HC, rich CO

Rich λ=0.97

~2 bar BMEP

Lean λ=2.0

~2 bar BMEP

NOx conversion HC conversion CO conversion

Rich AFR CO control

challenging

Lean HC control challenging at low temps

(C3H8 shown)

Catalysts with

varying PGMs

and OSC

Catalyst with NSC

Page 18: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

18 DOE VTO Annual Merit Review – ace033

Aging and Poison Study: Dedicated thermal aging reactor built for industry-approved thermal cycle• Automated aging with TWC located

outside of heated zone

• Lean/Rich/Stoich. controlled through O2 flow rate

• UEGO sensors before and after reactor to ensure proper cycling

• Thermocouple locations:– Gas inlet– Catalyst inlet/midbed/outlet

• Using UEGO and thermocouples, monitor as a function of aging:– Light-off, WGS, OSC

• Age TWCs to 25h, 50h, and 100h

• Post aging, evaluate fully in fully-functional bench reactor– Material characterization at USC

Flow

in Mid OutQuartz Tubes (pre-heat)

Catalyst

gas

Heating Region

Heated Zone InsulatedInsulated

Heated Zone InsulatedInsulated

Phase 1 Phase 2 Phase 3 Phase 4Stoich. 330s Rich 10s Stoich. 10s Lean 10s

880885890895900905910915920

5 5.5 6 6.5

Tem

pera

ture

(°C)

Time (minutes)

In

Mid

Stoichiometric StoichiometricRich LeanStoich.

TWC

CO

CO

2

O2

N2

H2O

UEG

O

UEG

O

MFC inputLabview/CPU

Page 19: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

19 DOE VTO Annual Merit Review – ace033

High rich-phase NH3 selectivity remains after thermal aging despite WGS reactivity deactivationExperiment:• Catalyst hydrothermally aged:

Malibu-1 (Pd, no OSC)• Aged 100 hours at 900°C

(simulates lifetime)Minimally Affected by Aging:• NH3 production• HC slip• OSC (at 500°C)Significantly Affected by Aging:• CO slip• TWC light off temperature• WGS reactivity

0

0.2

0.4

0.6

0.8

1

1.2

60 60.1 60.2 60.3 60.4 60.5 60.6 60.7 60.8 60.9 61

Norm

alize

d Δλ

Time (Minutes)

Water-Gas-Shift (WGS) reactivity decreases during first 40 hours aging

40 hours

30 hours 20 hours

10 hours 0 hours

Decreasing WGS

Light-off temperature increases 100°C in first 10-20 hrs

0200400600800

10001200140016001800

0.95 0.96 0.97 0.98 0.99 1.00

PPM

Lambda

CO COC3H8 C3H8NH3 NH3NOx NOx

CO

em

issi

ons

incr

ease

NH3 unaffected at λ < 0.985

Fresh Aged 100h

Page 20: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

20 DOE VTO Annual Merit Review – ace033

Impact of sulfur exposure also evaluated for effects on passive SCR

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

0.50

Before(Avg.)

Rich -SO2

Stoich.- SO2

Lean -SO2

Oxy

gen

Sto

rage

(g/L

)

0%

2%

4%

6%

8%

10%

12%

14%

Before(Avg.)

Rich -SO2

Stoich.- SO2

Lean -SO2

CO

con

vers

ion

OSC at 300°C WGS at 300°C

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

300 400 500 600

C3H

8C

onve

rsio

n

Temperature (°C)

Before

Rich - SO2

Propane conversion post S aging at 300°C,λ = 0.97

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

300 400 500 600

NH

3Yi

eld

Temperature (°C)

Before

Rich - SO2

Ammonia yield post S aging at 300°C, λ = 0.97

Experiment:• Catalyst exposed to S:

Malibu-1 (Pd, no OSC)• Aged w/ 50 ppm SO2 at 300°C

for 4 hours under:– Rich (λ=0.97)– Stoich (λ=1.00)– Lean (λ=2.00)

• deS ramp to 600°C after SMinimally Affected by S:• NH3 production• OSC (at 300°C)Significantly Affected by S:• HC slip during rich conditions• WGS reactivity (at 300°C)

Page 21: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

21 DOE VTO Annual Merit Review – ace033

0

5

10

15

20

25

30

25 27.5 30 32.5 35

Engi

ne O

ut N

Ox

(mg/

sec)

Spark Timing (DBTDC)

lambda=0.97lambda=1.00

Adjusting rich spark timing can improve fuel efficiency (but not lean EGR)

OEMRich Period Spark Timing Adjustment:

Goal is more NOx/NH3

2000rpm, 4 bar

Investigated changing EGR level, but no significant effect observed (open throttle causes lack of dP to

push EGR at low loads)

0

5

10

15

20

25

0 10 20 30 40 50 60

Engi

ne O

ut N

Ox

(mg/

sec)

EGR Valve Setpoint (duty cycle in %)

1500rpm, 2bar2000rpm, 4bar

OEM

OEM

Lean Period EGR Adjustment:Goal is less NOx

43% gain in Engine Out NOx= +2.8% gain in fuel efficiency*

(rel. to OEM point) 0%2%4%6%8%

10%

29 35

Fuel

Eff

icie

ncy

Gai

n(v

s. S

toic

h)

Spark Timing (DBTDC)

+2.8%Fuel eff.

OEM

*calculated based on load step cycle and ideal SCR

Page 22: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

22 DOE VTO Annual Merit Review – ace033

0%

2%

4%

6%

8%

10%

12%

14%

16%

Fuel

Con

sum

ptio

n Be

nefit

(vs.

Sto

ich.

)

FY13 FY14 FY15 FY16 FY17

Remaining Challenges

0

1

2

3

4

5

6

7

8

9Pt

-Equ

ival

ent (

g/Li

ter e

ngin

e)

FY13 FY14 FY15 FY16 FY17B

etter

Fuel Economy PGM [Cost]

Bet

ter

BMW 120iTWC+LNT

• Improve system level fuel economy (reduce NH3 production fuel penalty)• Address catalyst performance during transients and rich-lean transitions• Determine technique to enable NSC functionality over temperature range • Broaden aging studies to include SCR

max

0

1

2

3

4

5

BMW 120i Passive SCR

Cata

lyst

Vol

ume

(lite

rs)

LNT

TWCTWC

SCR

Size

Bench Flow Reactor StatusEngine-Based Study Status

max

calc

Page 23: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

23 DOE VTO Annual Merit Review – ace033

Future Work: Addressing Remaining Challenges

• Catalyst formulation studies on bench flow reactor– Revisit TWC+SCR with new information from prototype catalyst matrix– Combine Pd-based and NSC-containing TWCs to optimize– Examine SCR formulations for NH3 oxidation

• Continue aging studies including studying select prototype formulations– Perform materials characterization (just starting) [TEM, BET/Chemi, XRD]– Continue aging of TWC formulations including with sulfur while cycling– Study aging of SCR

• Continue engine-based studies to maximize system fuel efficiency – Continue spark-timing studies for more efficient NH3 production– Study select prototype TWC formulations on engine– Understand transient and switching effects on Passive SCR/LNT+SCR

Page 24: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

24 DOE VTO Annual Merit Review – ace033

SummaryRelevance Enabling lean gasoline vehicles will significantly reduce US

petroleum use

Approach

Focus on non-urea Passive SCR and LNT+SCR

Evaluate catalyst formulations on bench flow reactor for cost-effective emissions control

Study fuel penalty and realistic performance on lean gasoline engine research platform

CollaborationsIndustry: GM and catalyst suppliers Umicore and CDTi

Universities: Univ. of South Carolina and the Univ. of Wisconsin

National Labs: LANL (platform supported NH3 sensor study)

Technical Accomplishments

Completed full characterization on bench flow reactor of Umicore prototype catalyst matrix

Completed hydrothermal and S rapid aging of TWC (Malibu-1)

Preliminary results obtained from engine out NOx optimization studies

Future Work Bench reactor, aging, and engine studies ongoing toward 5-year project goals of fuel efficiency and cost (Pt-equivalent)

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25 DOE VTO Annual Merit Review – ace033

Technical Backup slides

Page 26: Emissions Control for Lean Gasoline Engines3. production during rich operation and NOx reduction during lean operation. Other Core Principles: • Expand range of temperature operation

26 DOE VTO Annual Merit Review – ace033

BMW 120i engine features three main combustion modes

0

200

400

600

-360 -300 -240 -180 -120 -60 0 60 120 180 240 300 360

Inje

ctor

Driv

e Vol

tage

(V) [

data

offs

et b

y 20

0 V]

Crank Angle Degrees (CAD)

Lean Stratified

Lean Homogeneous

Stoich Homogeneous

=Main Spark

=Restrike 1500 rpm, 26% Loadλ=1.9

1500 rpm, 65% Loadλ=1.38

1500 rpm, 31% Loadλ=1.0

• Spray guided combustion system design

• Piezoelectric injectors operate at different voltages as well as different durations

• Multiple sparks enable ignition under lean operation

• In addition to three main combustions modes, there is also an OEM rich homogeneous mode for LNT control of NOX emissions to meet EURO V NOXemission standards

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27 DOE VTO Annual Merit Review – ace033

Catalysts Studied in Project• Thanks to Umicore for supplying prototype catalysts (labelled ORNL-x)

• The Malibu catalyst is from an SULEV Chevrolet Malibu commercially available vehicle (represents existing state of the art)

Note: OSC=oxygen storage capacity; NSC=NOx storage capacity

sample ID Description Pt (g/l) Pd (g/l) Rh (g/l) OSC NSC

Malibu-1 Front half of TWC 0 7.3 0 N N

Malibu-2 Rear half of TWC 0 1.1 0.3 Y N

Malibu-combo Full TWC 0 4.0 0.16 Y N

ORNL-1 Pt + Pd + Rh 2.47 4.17 0.05 Y Y

ORNL-2 Pd + Rh 0 6.36 0.14 N N

ORNL-6 Pd 0 6.50 0 N N

ORNL-5 Pd + OSC high 0 6.50 0 H N

ORNL-4 Pd + OSC med 0 4.06 0 M N

ORNL-3 Pd + OSC low 0 1.41 0 L N

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28 DOE VTO Annual Merit Review – ace033

Conducted transient flow reactor experiments to estimate TWC effects on fuel consumption• Used feedback-controlled

cycles on flow reactor to evaluate dynamic TWC response in context of passive SCR

• Evaluated two different simulated engine cycles (fixed load, load step)

fixed load load steprich lean rich lean

load (BMEP) 2 bar 2 bar 8 bar 2 bar

SV (h-1) 27000 45000 60000 45000

NOx (ppm) 600 360 1200 360

max lean time 50% 80%simulates cruise “hill” transient

Rich Leanλ 0.95 0.96 0.97 0.98 0.99 1.00 2

O2 (%) 0.96 1.02 1.07 1.13 1.17 1.22 10

CO (%) 2.0 1.8 1.6 1.4 1.2 1.0 0.2

H2 (%) 1.0 0.9 0.8 0.7 0.6 0.5 0

NO (ppm) 600 (or 1200) 360

C3H8 (ppm C1) 3000 1900

H2O (%) 11 6.6

CO2 (%) 11 6.6

TWC SV (hr-1) 27000 (or 60000) 45000

• Compositions & flows selected to mimic BMW GDI engine exhaust

• Space velocity changed with λand load

• C3H8 chosen as challenging HC