improved system performance and reduced cost of a … lnt, and scr aftertreatment system meeting...
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© 2008 Eaton Corporation. All rights reserved.
Improved System Performance and Reduced Cost of a Fuel Reformer, LNT, and SCR Aftertreatment System Meeting Emissions Useful Life Requirement
Damodara Poojary, Jacques Nicole, James McCarthy, Jr., & Hanlong YangEaton Corporation
2010 DOE DEER ConferenceDetroit, MISeptember 30, 2010
2 22010 DOE DEER Conference – Detroit, MI
Agenda
• Introduction to Eaton Aftertreatment
• System cost reduction
• Durability demonstration of cost reduced system
• Fuel doser and system packaging
• Summary
3 32010 DOE DEER Conference – Detroit, MI
Agenda
• Introduction to Eaton Aftertreatment
• System cost reduction
• Durability demonstration of cost reduced system
• Fuel doser and system packaging
• Summary
4 42010 DOE DEER Conference – Detroit, MI
IntroductionEaton Aftertreatment System
How it Works:
• Engine NOx is reduced by the Lean NOx Trap (LNT) and Selective Catalytic Reduction (SCR) catalysts.
• The LNT stores NOx and undergoes controlled periodic regeneration, releasing the NOx as nitrogen and NH3.
• The SCR collects the released NH3 and uses it to continuously treat the remaining NOx.
• A Diesel Particulate Filter (DPF) traps Particulate Matter (PM) and undergoes periodic regeneration.
LNT – Lean NOx Trap
SCR – Selective Catalytic Reduction
DPF – Diesel Particulate Filter
Controller ModuleDiesel
Pipe/mixer assembly sensors
fuel pressure control & shut-off
Reformer
• Hydrogen/CO Production
LNT
• 1st Stage NOx Control
• NH3Production
DPF
• PM Control
SCR
• 2nd Stage NOx Control
• NH3 Storage and Usage
fuel doser
5 52010 DOE DEER Conference – Detroit, MI
IntroductionTypical Performance
• Proven Vehicle Performance• Tens of thousands of miles of EAS operation on MD and HD vehicles• Fuel consumption as low as 1.3% • Consistent NOx reduction performance meeting EPA 2010 standards• No vehicle drivability issues
Engine Out NOx
LNT Out NOx
SCR Out NOx
NO
x C
once
ntra
tion
[ppm
]
SAE 2009-01-2835
Time, sec
6 62010 DOE DEER Conference – Detroit, MI
Agenda
• Introduction to Eaton Aftertreatment
• System cost reduction
• Durability demonstration of cost reduced system
• Fuel doser and system packaging
• Summary
7 72010 DOE DEER Conference – Detroit, MI
PGM reduction in the Reformer, LNT and DPFPGM cost of the 2010 system is 36% lower than previous publication
System Cost ReductionRelative PGM Cost vs Time
0%
20%
40%
60%
80%
100%
120%
2005 2006 2007 2008 2009 2010
Rel
ativ
e sy
stem
PG
M (%
of 2
005
leve
l)
SAE 2009-01-2835
8 82010 DOE DEER Conference – Detroit, MI
Agenda
• Introduction to Eaton Aftertreatment
• System cost reduction
• Durability demonstration of cost reduced system
• Fuel doser and system packaging
• Summary
9 92010 DOE DEER Conference – Detroit, MI
System Configuration• Fuel doser, Fuel reformer, LNT, DPF, SCR
Sulfur Loading Assumptions• Total Sulfur in exhaust: 12 ppm on a fuel basis
• 7 ppm from diesel fuel & 5 ppm from oil
Triggered DeSOx Event: 0.5 g/L Sulfur on LNT• LNT Sizing: 1.5 times engine displacement
Off-Highway Analysis• 500 DeSOx events required - 8000 hour useful emissions life
• One DeSOx event every 16 hours
On-Highway Analysis - Medium Duty Vehicles• 225 DeSOx events required - 185,000 miles useful emissions life
• One DeSOx event every 822 miles
On-Highway Analysis - Heavy Duty Vehicles• 500 DeSOx events required - 435,000 miles useful emissions life
• One DeSOx event every 870 miles
DurabilityAftertreatment Durability Aging
10 102010 DOE DEER Conference – Detroit, MI
ECU accurately controls reformer/LNT temperatures
System Control - DesulfationReformer and LNT Temperature Control
0
100
200
300
400
500
600
700Te
mpe
ratu
re (C
)
0
100
200
300
400
500
600
700
Fuel
inje
cted
(g/m
in)
300
400
500
600
700
0 100 200 300 400
Ref. inlet gas Temp.
Ref. model Temp.Ref. Outlet gas Temp.
Reformer Fueling
SCR outlet gas Temp.
LNT Outlet gas Temp.LNT brick center
DPF outlet gas Temp.LNT brick edge
Time, sec
11 112010 DOE DEER Conference – Detroit, MI
Durability – 500 Desulfation EventsPrevious End of Life Aging
0
10
20
30
40
50
60
70
80
90
100
0 100 200 300 400 500After DeSOx #
Effic
ienc
y [%
]
Sulfur Loading 50% Load 75% Load 100% Load
Final Performance (Optimized)1800-50: 93.5%
1800-75: 87.2%
1800-100: 78.7%
100% LoadSCR Cont.
50% Load
Sulfur Loading
75% Load
Constant Control Settings
Stable SCR Contribution
Reference: SAE 2009-01-2835
12 122010 DOE DEER Conference – Detroit, MI
0
10
20
30
40
50
60
70
80
90
100
0 100 200 300 400 500After DeSOx #
Effic
ienc
y [%
]Durability – Comparison with Cost Reduced SystemNOX Reduction Efficiency
Final Performance (Optimized)1800-50: 93.5%1800-75: 87.2%1800-100: 78.7%
100% Load
SCR Cont.
50% Load
Sulfur Loading
75% Load
Constant Control Settings
Performance of cost reduced system is stable and meets end of life EPA 2010 emission standards
Reference: SAE 2009-01-2835Added EATON-2010 Data
Durability of cost reduced system @ B75
13 132010 DOE DEER Conference – Detroit, MI
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
2.2
B25 A50 B50 C50 A75 B75 C75 A100 B100 C100 13mode
NO
x, g
/hp-
hr
Engine Out NOx (g/hp-hr)System Out NOx (g/hp-hr)
System out NOx meets EPA 2010 emissions standards
Cost Reduced System – Emission ResultsPerformance Under Various Modes
NTE limit
14 142010 DOE DEER Conference – Detroit, MI
Agenda
• Introduction to Eaton Aftertreatment
• System cost reduction
• Durability demonstration of cost reduced system
• Fuel doser and system packaging
• Summary
15 152010 DOE DEER Conference – Detroit, MI
Fuel DoserImproved Spray Quality
Early injector(poor atomization with
larger droplets)
Optimized injector(improved atomization
& smaller droplets)
• Early injectors showed a small cone angle with large drop diameters
• Improved injector shows larger cone angles having smaller drop sizes
• Smaller droplets yields better mixing in a smaller volume
16 162010 DOE DEER Conference – Detroit, MI
System PackagingEfficient Packaging
SCR
DPF
LNT
REFSCR
DPF LNT
REF
REF – Reformer
LNT – Lean NOx Trap
DPF – Diesel Particulate Filter
SCR – Selective Catalytic ReductionREF
LNT
DPF
SCR Doser
Flex
DPFREFLNT
SCR
2010 MinNOx Conference
2010 MinNOx Conference
Improved mixing for compact
packaging
17 172010 DOE DEER Conference – Detroit, MI
System PackagingApplication Examples
Inlet Cone
Tran
sitio
n to
SC
R
LNTDPF REF
SCRSCR
Tran
sitio
n to
SC
R
HD On-Highway TruckHD On-Highway Truck
REF DPFLNT SCR
MD On-Highway TruckMD On-Highway Truck
Off-Road Construction VehicleOff-Road Construction Vehicle
REFREF LNTLNT DPFDPF
SCRSCR
REF – Reformer
LNT – Lean NOx Trap
DPF – Diesel Particulate Filter
SCR – Selective Catalytic Reduction
18 182010 DOE DEER Conference – Detroit, MI
Agenda
• Introduction to Eaton Aftertreatment
• System cost reduction
• Durability demonstration of cost reduced system
• Fuel doser and system packaging
• Summary
19 192010 DOE DEER Conference – Detroit, MI
Summary
• Demonstrated durable system performance that meets EPA 2010 on-highway emission standards
• System PGM cost 36% lower than previously published durability results
• Flexible and compact packaging options to meet OEM needs
20 202010 DOE DEER Conference – Detroit, MI
Acknowledgements
• Eaton Aftertreatment Team
• OEM Partners & Suppliers
• Portions of this section is based on work funded by the State of Texas through a grant from the Texas Environmental Research Consortium (TERC) with funding provided by the Texas Commission on Environmental Quality (TCEQ)