low emisssions potential of egr-scr-dpf and …...bshc bsco bsnox bspm bsfc 092001-h1 092001-h2 r...

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 Results Results


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 ResultsResults


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 ResultsResults


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 ResultsResults


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 Results Results


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


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


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


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


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


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


EGR+CB-DPF+SCR As-Received


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 Results Results


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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low emisssions potential of egr-scr-dpf and …...bshc bsco bsnox bspm bsfc 092001-h1 092001-h2 r...

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