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Lakshminarayanan Govindaraj
SCR-Solutions for BS IV and BS V Regulations
Commercial Vehicle Megatrends India 2012
25-27 April 2012 , Chennai, India
Albonair
2007 2008 2009 2010 2012
1 CVM 2012 1
»Albonair is founded
as part of Hinduja
Automotive Sector
»100% privately
owned by Hinduja
Group
»Albonair delivers first
prototypes of SCR-
Systems to customers
»SOP of exhaust
aftertreatment
solutions for the
Indian market
»Albonair moves into
a new headquarter
in Dortmund,
Germany
»SOP of EURO VI-
UDS for an
European OEM
»Albonair India is
founded to set up a
production facility for a
local customer
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3
India Emission Standard & SCR
Albonair’s SCR Solution for India
Summary
Agenda
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4
Summary
Development of Emission Standards and the Need of SCR
Stronger Emission Standards require SCR-Systems
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EURO norms ≙ BS ≙ BS ≙ BS ≙ BS normsnormsnormsnorms
Basics of SCR Technology
» SCR is the abbreviation for Selective Catalytic Reduction
» Principles of SCR is known and used for reduction of nitrogen oxides in the exhaust gas
of power plants since the 1970´s
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» SCR is a method to reduce nitrogen oxides (NOx) in oxygen rich exhaust gases
» Nitrogen oxides are converted to nitrogen and water on the surface of a catalyst by
adding ammonia to the exhaust gas
» To transfer SCR to the automotive sector ammonia has to be replaced by urea
Basics of SCR Technology
Conversion of Nitrogen Oxide (NOx) into Nitrogen (N2) and Water (H20)
NO2 NO
NH3
N2
SCR-Catalyst
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NO2
CO2O2
NO N2
O2H2O CO2
Ammonia
Basics of SCR Technology
Conversion of Nitrogen Oxide (NOx) into Nitrogen (N2) and Water (H20)
H2ONO2NO NH3++ 2 N2 + 32
AdBlue
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NO NH3O2
H2ONO2NO NH3++ 2 N2 + 32
++ 44 H2ON2 + 64
NO2 NH3O2 ++ 42 H2ON2 + 63
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India Emission Standard & SCR
Albonair’s SCR solution for India
Summary
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3
4
Summary
Integration of SCR-Systems in commercial vehicles
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Concept of Albonair‘s SCR System for BS IV and BS VSchematics
Dosing System
Engine ECUCAN
Engine
Coolant Engine Coolant Actuators
Urea level
Urea temperature
Air pressure
Urea pressure
Urea temperature
Electronics (ACU)AdBlue Tank
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NOx sensor
SCR Muffler with Injection Nozzle
Exhaust stream
NozzleTemp. Sensor
Air
Urea
Engine Coolant
Air
Urea
Temp.
Sensor
Sensors
Air Supply (vehicle air
or electrical air pump)
Secondary
Droplet Breakup
Primary
Droplet Breakup
… initiated by
reciprocal effect of
exhaust flow and
… initiated by
AdBlue®-Injector
Mechanisms of Droplet Evaporation
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exhaust flow and
droplets
AdBlue®-Injector
System Spray Formation Characteristics
Pressure Atomizer
(Airless)
» Energy for atomization
from the liquid pressure
» Increase of pressure leads to
improved spray quality
Spray Formation of Different AdBlue Injection Systems
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Twin Fluid Atomizer with
internal mixing
(Air Assisted)
» Energy for atomization
from air pressure
» Typically high air consumption
Albonair’s Concept is based on:
Twin Fluid Atomizer with
external mixing (Air Assisted)
» Energy for atomization
mainly from air pressure
» Low air consumption
» No contact between AdBlue and
air in the dosing system / nozzle
to avoid crystallization and deposits
Albonair SCR-Tank Assembly with Dosing and Control Unit
Specification
» Integrated Urea Dosing System
» Aftertreatment Control Unit (ACU)
» Urea filter mesh
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» Urea filter mesh
» Urea Level Sensor
» Wiring-Harness
» Urea- and Coolant-Water (heated tank)
tubes
» Vented filler cap
» Tank brackets
Specification
» No moving parts
» Two temperature sensors (pre-
and post cat)
» No mixer
» No ammonia slip cat
Albonair SCR-Exhaust System
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» No ammonia slip cat
» Alumninized steel for outer
shell and clean side
components
» Circular and elliptical designs
» Engine power rating 90 kW …
165 kW, higher power ratings
possible
Small and Heat Resistant Injection Nozzle
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3D Drawing
Specification
» No mechanical parts
» No electrical parts
» High temperature resistant (up to
800oC)
» Small & flexible to mount
» Droplet Size < 20 µm SMD
Different Nozzle Designs – Small and Flexible to mountConnectors for AdBlue and Air hose have to be routed out of hot areas (>120° C)
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CFD-Analysis of the Spray Evaporation with the ALBONAIR Doser
AdBlue is homogenously distributed and evaporates fast due to small droplet size
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Conditions: Exhaust Gas Mass Flow: 170kg/h | Frequency: 2.1 Hz | Exhaust Gas Temperature: 260°C
Catalyst Efficiency improved at low Exhaust Mass Flow
80
90
100
Co
nv
ers
ion
Ra
te (
%)
Low Exhaust Mass Flow
200 - 250 kg/h
80
90
100
Co
nv
ers
ion
Ra
te (
%)
High Exhaust Mass Flow
600 - 1000 kg/h
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30
40
50
60
70
175 195 215 235 255 275
NO
x-C
on
ve
rsio
n R
ate
(%
)
Temperature (°C)
Albonair
Airless
30
40
50
60
70
175 195 215 235 255 275
NO
x-C
on
ve
rsio
n R
ate
(%
)
Temperature (°C)
Albonair
Airless
Albonair’s SystemBenchmark System
Improved Spray Quality avoids Deposition of Urea within the
Exhaust System
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» high amount of deposits » no significant amount of deposits
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India Emission Standard & SCR
Albonair’s SCR Solution for India
Summary
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4
Summary
Key Takeaways
Technical Aspects
» Optimized Distribution &
Evaporation of AdBlue
» Fast evaporation of AdBlue droplets
» Improved catalyst efficiency 60%
80%
100% Airless: NH3
Airless: HNCO
Albonair: NH3
Albonair: HNCO
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» Improved catalyst efficiency
especially at low temperatures
» No significant urea deposition in the
system0%
20%
40%
60%
Key Takeaways
Design Aspects
» Maintenance free – no service filters
in the system,
» Nozzle
» Compact design
» No mechanical parts
» No electrical parts
» High temperature resistant
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» High temperature resistant
» No possibility of congestion
» Modular Design for BS IV and BS V
» Autonomous Control Unit
» Just two components to attach to vehicle
» Tank assembly
» Muffler
Albonair: One-stop solution for SCR-Solutions
Selective Catalytic Reduction System
Urea Tank ACU & UDS SCR-Muffler & Nozzle
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» Albonair offers complete SCR-Solutions
» The Bharat Stage - 4 Norm was introduced in April 2010 and currently applied
in 20 major cities in India
» The government of India aims to include as many as 50 major cities of the
country in the BS – IV emission norms category by year 2015
» SCR is the mostly used solution to fulfill BS 4
» Emerging markets, as India, have special demands on SCR-Systems:
» Modular Systems
Summary
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» Modular Systems
» Easy, preferably no maintenance
» Robustness to bad environmental conditions as e.g. dusty AdBlue
» Bharat Stage 5 already in discussions. Preferably no change on BS IV Systems to
meet next stage requirements.
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Backup
Emission Standards for diesel trucks & buses in India
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% Change in the Emission
Year Norm CO HC Nox PM
1996 20 31 20
2000 BS I 60 54 44
2005 BS II 11 0 13 58
2005 BS III 48 40 29 33
2010 BS IV 29 30 30 80