E.c.o,c'TXt- lbonairFresh ldea3 - Cleaner Future

Emission Techniques and Related SCRSystems by Ecocat and Albonair

ISilke Jürgens, AlbonairToni Kinnunen, EcocatTeuvo Maunula, Ecocat *fs-

25.5.2012

WWWECOCAT.COM WWW.ALBONAIR-COM

Gontents

o Ecocat and Albonair collaboration

o V-SCR catalyst

o Urea dosing technologyo Optional elements

o Hydrolizing catalysto Ammonia slip catalyst

o Summary

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Ecocat in Brief

Overview

Ecocat Oy ("Ecocat") is a leading emissiontechnology company operating in the growingmarket for catalytic convefters

r Leading industry pioneer with market presence

since 1985

r Ecocat is 150-T516949 and ISO14001 ceftified.

Broad range of application areas in the globalmarkets for

r Passenger & light commercial vehicles

r Heavy commercial vehicles (trucks, busses)

r Off-road (agricultural, rail, marine)

r Industry (stationary engines, VOC incinerators)

Capabilities for complete delivery of catalyticconvelters from substrate to canning

r In-house manufacturing of durable metallicsubstrates

r Coating expeftise for both metallic and ceramicsubstrates Canning capabilities for differentcatalyst types

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Ecocat Group

\

\\

-/2^-Tt/

\JT\

nland

Finland h'Cþs

V

{' )ttf?

Nizhniy

ng

â-)$

/Ghina

Italy - Genoa

lran - Tehran\- Faridabad

0

JU

' Approximately 290 employees in five countries

' Sales agents close to customers

)

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Ecocat's Products are Organized Around Four Business Areas

Passenger and LightGommercial Vehicles

lndustry

Heavy CommercialVehicles

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Off-Road

Albonair - Company OverviewDevelopment of Albonair

Albonair isfounded as partof Hinduja'sAutomotiveSector100% privatelyowned byHinduja Group

ì

2008

Albonair deliversfirst prototypes ofSCR-Systems tocustomers

Albonair India isfounded to set up aproduction facilityfor a local customer

SOP of exhaustaftertreatmentsolutíons for thelndian marketAlbonair movesinto a newheadquafter inDortmund,Germany

SOP of EUROVl-UDS for anEuropean OEM

t

2007 2009 20'10 2012

Þ

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Albonair - Company OverviewGlobal Presence

Dortmund, GermanyHeadqua rterR&D

Sales

Customer Service

Ej

Detroit, USATesting facilitiesSales

Customer Service

Chennai, lndiaUrea Dosing Assembly Line

Housing Assembly Line

Sales

Customer Service

Taicang, ChinaUrea Dosing System assemblylineHousing assembly line

Sales

Customer Service

ECOCrlf bonair

bonairE.g,o,C'l,,jf,/ ,/Fast growing European company, OEM supplier status

,/,/High-class technology for diesel exhaust aftertreatment

,/ ,/Flexibility and intimacy to solve customers' challenges

,/,/Focusing on the key projects

,/,/Global presence with covering customer interface

,/ ,/Localized production sites and competence centers toserve customers

,/All the catalytic elements available, substrates andcoatings together with canning

r/All the SCR urea dosing system dosing componentsand system integration know-how available

Two companies matching perfectly to enhance own success togetherby prov¡d¡ng complete customized and well-integrated solutions

ECACIIT bonair

Complete diesel aftertreatment system

SCRDOC DPF

NOx à N,Urea ) NH3 NH3 ) N2 PaÉicle mass ) CO2coà co2Hydrocarbons ) CO2 and HrONO)NO2

_>

oUINJECTION

Based on application, normally only some of above are needed

Ecocat has the whole range of catalysts ¡n portfolio;substrates and coat¡ngs

Together with partners, the complete systemstailored to fulfill customers requirements

E,COCIIT bonair

ECOCIIT lbonairFresh ldea3 - Cleaner Fulute

WWW.ECOCAT.COM WIA'W.ALBONAIR.COM

Reactions in SCR systems

PreOxicat NO+O,

Hydrolysis CO(f{Hr)rCO + HrO CO,

SCR catalyst

PostOxicat 4 + 3Or+2Nr*6H2O

Optimization of DOG together with H-kat and SCR needed:NO, formation, backpressure, temperatures and costs

2NH3

NH3fast SCR

4I\H3

OzÐ4Nr+6HrO

NO

N02-SCR

standard SCR 4 NO +

4Nr+3H2O

3 Ñ, Ð 3.5 N, * 6Id.zO

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SCR activity by eng¡ne experiments

Criteria NO* conversion at 280"C

100

80

60

20

¡AI¡¡¡¡¡¡a!

40

sc¡-.9ãg. o-

94ãgðzz

0.7 0.8 0.9 1

Nominal NH3/NOx

NHr slip <20 ppm

--> 98o/o NO' conversion

1.2

0

1.1

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SCR activity by engine experimentsEngine 6.9 L; Catalyst 12.8L,500 cpsi

NOx conversion curve

àe^ÃFctrocL'õ cL

þRtrVO(ÐfJ-

-ð=z

100

80

60

28.000 h-1

465 ppm NO,61 . OOO h-1

1170 ppm

57. OOO h-1

990 ppm NO,

16.500 h-1

1420 ppm NO,

51.OOO h-1

930 ppm NO*

300 350 400 450Temperature, oC

40

20

0

200 250 500 550

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Effect of NH3 slip criteria limit

Urea€CR engine results- MAN 6.9L, 15 h agedKSCR2,500 cpsi,'12.7L

100

E90CL

å80s!s70ä60$9'oaz840x230(!'Ê 20o,

¿5 10

0

200 250 300 350 400

Temperature, oC

450 500 5s0

) No significant changes in performance) without any additional NH3 slip catalyst

eo.ooo h4SI.OOû trr

tS.SO0 trr

st.ooo ha s8.ooo trr

+ KSCR2, 20 ppm NH3<-KSCR2, l0 ppm NH3

Eco,g,'\T bonair

Effect of cell density (surface area)

Extruded ref

Ecocat 220 cpsiEcocat 350 cpsi

3o.ooo n"s1.ooo h"

61.ooo n' 58.ooo n"16.S00 tr"

Ecocat 500 cpsi Target conversions

Euro 6/tTS20l0100

90si80Ë170Ë= Go

8ã so

gR'40Ev 30

Ë20oro0

Euro 5

Euro 4

200 250 300 350 400

Temperature, oG

450 500 550

Ec.o,C,TXf

Ecocat SCR: the fïrst EPA and CARB approval for V-SCR (off-road)

Ér, srnè", UNITED STATES W PROTECTION AGENCY

OFFICE OF TRANSPORTATION AND AIR QUALITY.WASHINGTON-

DC 20460

EO Sra ¡6."

zfJq

CERTIFICATE OF CONFORMITY2OIO MODEL YEAR

Manufacû¡rer:Engrae Farnily:

.{æO SIS[, PO\\IER I]iC.-{sil)L08.4H6jl'

IR RESOURCES BOARD Acco stsu DIESEL lilc.I. Ne¡¡r Off-Road

Com pression-lgnition Engines

USEFUL LIFE(hours)

8000

TYPICAL EQUIPiIETTT APPUCATION

DISPL.ACEIUEilT(libn) FUEL TYPEENGINE FATILYMODEL

YEAR

8.4 & 9.8 DieselASIDLO8.4H6A2010

SPECIAL FEATURES & EIU]SS¡ION COHTROL SYSTEHS

Direct Cooler,E ter,

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ïractor

High-Temp SCR

a

The reasons to develope improved V-SCR for high-temperature applications

The SCR chemistry need to be durable for high-temp applications, too. Of-road full-load drivings. Need to be applicable for the usage together with DPF (Euro5 and beyond). Cu-zeolite limitations (NrO formation, sulphur sensitivity, NO, sensitivity)

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Laboratory resultsHT700/20hlnlet: NO 1000 ppm, NO, 0 ppm, NH3 1000 ppm,Or10 o/o, H2O I %, N, bal.

600 cpsi, SV = 50 000 h-1

100908070605040302010

0

-10-20

150 200 250 300 350 400 450 500 550 600Temperature, oC

a

s,9g,otroox

oz

HT700"Ct20h1000 oom NO \.

\\

1+ Thermally sta ble VSCR-wl+Std V-SGR-w1249 REF

Ec,o,C,/XÍ bonair

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Laboratory resultsHT700/20hlnlet: NO 600 ppm, NO2 400 ppm, NH3 1000 ppm, Or10 o/o, H2O 8 %, N, bal

600 cpsi, SV = 50 000 h-1

100908070605040302010

0

-10

-20

a

si.9g,otro()xoz

150 200 250 300 350 400 450 500 550 600Temperature, "C

HT700'C l20h600 ppm NO400 ppm NO,

+ T hermally sta ble V-SC R-w1241

+ Std V-SCR-w1249 REF

/

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! I

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Eco,C,lxf lbonairFre3h ldeas - Gleaner FuluTo

WWW.ECOCAT.COM WIIVW.ALBONAIR.COM

AI bonai r Prod uct Portfol io

Diesel Particulate FilterDiesel Oxidation

Catalyst

Selective Catalytic Reduction System

DPF I DOC Urea Tank ACU & UDS

C

SCR-Muffler & Nozzle

q..

,) Albonair offers complete exhaust aftertreatmentsystems

t

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Urea Dosing Units for Different Markets

EURO 4 (e.g. Emerging Markets)

@

EURO 6 (e.9. Europe)

å

o

Tier 4 Final (e.g. Off-Road vehicles) EURO 6 Passenger Car (e.9. Europe' USA)

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Products & TechnologyLocation of Products

u ¡.:A lå¡lli

r-r- -n.1,- n

I'I'ST Eh"I JTE õP ATI EI Ii5CF

F.'lUFFLERUR=q

irü 5lll:i 5 T STE lr,1

{''tËt

t II

l,-- -------- ---.¡-

-17

,-r-

-]

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Concept of Albonair's SCR SystemSchematics

Urea level

Urea temperature

EngineCoolant

Urea

Air

Air Supply (vehicle

air or electrical airpr

Dosing System

Air pressure

Urea pressure

CANUrea temperature

Electronics (ACU)

Actuators

Air

Urea Sensors

SCR Muffler with lnjection Nozzle

Temp Nozzle NOx

Exhauststream

AdBlue Tank

ine Coolant

Temp.Sensor

EngineECU

sil-.\-,-5-T

Eq,o,g,T\f ir

Goncept of Albonair's SCR SystemFormation of Different AdBlue Dosin temss ra

System Spray Formation Characteristics

Pressure Atomizer(Airless)

HotExhaust > Energy for atomization

from the liquid pressure

> lncrease of pressure leads toimproved spray quality

> Energy for atomizationfrom air pressure

> Typically high air consumption

> Energy for atomizationmainly from air pressure

> Low air consumption

> No contact between AdBlue and

air in the dosing system / nozzle

to avoid crystallization and

deposits

Twin Fluid Atomizer with internalmixing(Air Assisted)

Albonair's Concept is based on:Twin Fluid Atomizer withexternal mixing (Air Assisted)

AdBlue

t

Air

HotExhaust

Gas

-}l

..a'-a¡'. "-

t'l-r .'.'. '.'oï;..::.'.'..:.r e .'.'1..o r . . ¡' ' i

iE

AdB ue II

...

o o'3aa

o'raa a*

-+.:

HotExha ust

Gas

-Air

Air +

ECOCr\f

Technical BackgroundEvaporation Rates for Different Droplet Distributions

Albonair Air-AssistedDosing System

>.:c(uôEof-o

i5

@Exhaust velocity 50 m/s and Low temperature (300 'C)

Air.less DoslngSystem

100 300

80

ñ(u

GÉ.coÞGoo-GU

60

40

2096

00 100 200 300 400 500 600

Evaporation Length [mm]

700 800

Even at 300 "C smalldroplets of SMD 2t ¡tmeva porate com pletelywithin 600 mmVery poor evaporationfor big droplets SMD

96 pm

o 200

Particle Size [pm]

É,c.(),C,IIT bonair

Technical BackgroundNH, and HNCO decomposition improve with Albonair UDS

100o/o

80o/o

60%

40o/o

t-]

75o/o 50o/o

@1200 minr

Test Conditions:HD Dieselengine L2l,

Hydrolyse Tube 600mm,Measurement HNCO and NHt

using FTIR

Significant increase of AdBlueHydrolysisBetter Nox-Conversion at the SCR

CatalystLess deposits in the exhaustsystem

0o/o

o/to0

00o/o

co'6oCL

Eooo'1oo

õït80%

60%

40%

20o/o

Oo/o

2

10Oo/o

10Oo/o

25o/o

75o/o 50%@2000 minr

r-l

i"tfl'l

ffia

Albonair: NH.

Albonair: HNCO

Airless: NH.

Airless: HNCO

bonair

25%

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Gatalyst Eff¡ciency improved at low Exhaust Mass FlowLittle NH.-Slip

Low Exhaust Mass Flow

200 - 250 kelh100

90

80

ñoooc' 70coIÀ

o

860r.,*oz

50

40.#Albonair

{-Airless30

775 2r5 235

Temperature ('C)

19s 255 275

High Exhaust Mass Flow

500 - 1000 kelh100

90

80

sooÉ' 70trolrt

oE60o(,Ixoz

50

40*Albonair

*Airless30

215 235

Temperature ('C)

175 195 255 275

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The importance of proper urea distributionAdBlue Concefitr¡t¡ol(normolhcdl

4.003.r03.603.¡10

3.203.002 ôr')

2.ó02.402.¿02.00t.801.60t..0t.20t.000.E0

0.600.400.200.00

Proper design is an essential part of SCR technology to ensurethat urea is well distributed and decomposed to ammoniabefore SCR catalyst Ad8luc Concmù¿úm

(noímlBcd)

4.003.E03.603.{03.20l.o02ìO2.60¡.102.202.001,801.601a0r20to00,r00.600.400,200.00

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ECOClITlbonairFTesh ldeas - Cleaner Fulurc

WWW.ECOCAT.COM WWW.ALBONAIR.COM

Urea hydrolysis

Thermal or catalytic hydrolysis of urea important in thelimited space of exhaust lines at Iow temperatures

(NH z)zCO > thermolysis

HNCO + HzO > hydrolysis

+ enhancement with EcoXcell mixers in particular at low temperatures+ possible to have good mixing, urea nozzle near to SCRand combinatory properties

Ec.o,c,tlT ir

Metallic substrate for mixers and H-catalysts

EcoXcell@. Welded, mixer-type structure for coated catalysts having efficient 3D mass

and heat transfer. EcoXcell 20" for SCR applications+ Hydrolysis catalyst coating+ SCR catalyst coating

ECOÇ,llT

fm 3^-ll

C,I }G'

Velocity(Ve<tor 1)

.. 104.5

69.7

34.8

0.0

[m s^- l]

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How to utilize H-cat in SCR?

1) Combination of SCR catalyst coated EcoXcell mixer-catalyst and SCR catalystmixing and total SCR catalyst amount

Exhaust gas

*Urea

2) Small EcoXcell substrat e (25 cpsi) as urea dosing mixer: to enhance hydrolysiscatalyst reactions to avoid any urea accumulation

Exhaust ga5++Urea

Note: also inlet tube (and cone) surfaces can be coated by H-Cat,to avoid any accumulation and coffosion

Eq.o,c'ttT bonair

H cat onlylaboratory experiments

Product distribution with blanco substrateNominal inlet: 1000 ppm NO, no NOrr 500 ppm Urea, l0'/' O2r8 oÁ H2O, N2 balanceSV = 100 000 h-l

Urea hydrolysis products- blanco substrate

1200

ECLCL

0

1 205 230 260 300

Temperature before cat, oC

350 450

1

600

400

200

n NOx

r HNCO

r NH3

80

-25 % of urea unreacted, îo additional NHt

oo¡oo¡ooaolooaoo

unreacted urea

E,c,o,C,tNf

H cat onlylaboratory experiments

Product distribution with HT700 KHI.1+KH2.2 (good adhesion/improved selectivity)Nominal inleû 1000 ppm NO, no NO2,500 ppm Urea, l0 o/o O2r8 "/" H2O, N2 balanceSV = 100 000 h-l

Urea hydrolysis products- KHl .1+KH2.2 (w8090-200 cps¡)HT700 aged

0

1 205 230 260 300

Temperature before cat, oC

350 450

zECLçL

1200

1 000

800

600

400

200

! N20

tr NOx

I r HNCO

r NH3

80

ooaoolooaoaaounreacted urea

ot

Almost only NH3!!

no by-products

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The enhancing effect of H-kat at low temperature

T

NOx conv.To NH3 slip <20ppm

100

90

80

70

60

50

40

30

20

l0

r NOx conv.To NH3 slíp <20ppm

01500 mm no H-kat '1500 mm no H-kat 550 mm with H-

(245 deg C) (285 deg C) kat (245 deg C)550 mm no H-kat 550 mm no H-kat

(245 deg C) (285 deg C)550 mm with H-kat (285 deg C)

Significant effect on SCR acitivity by utilising H-kat in front of SCR obtainedStudied by 4.9 lengine (H-kat size D105 x L 100 mm)

É,COCI\T bonair

The role of ASC, NH3 slip control

cASof

98 98 98 99 98

ECLCLoN

si.9g.oco(J

xoz(ú

o+,'tro

100

90

80

70

60

50

40

30

20

10

0

MODE 10 (230.C) MODE 9 (260"C) MODE3 (310"C) MODE2 (400'C) MODEI(480'C)

88

230"C

2o.ooo h-t 480'Cst.ooo n-t

310'C¿3.ooo n-t

400'c48.ooo h-t260'C

t g.ooo n-t

N Pt-DOC+KSCR2-300 cpsi FRESH

r Pt-DOC+KSGR2 300 cpsi - Burner aged 570'C/100h

ø Pt-DOC+KSGR2-300cpsi+4PUASC- Burner aged 570'C/100h

7779 77

66

Éc.o,g'tlT

SUMMARY

Ecocat-Albonair combination provides uniquê, one source solution

All the elements available for meeting Euro6 requirements

SCR chemistry proven to be extremely durable

Gompetitive and cost-efficient urea dosing systems

Glear technical benefits for NOx performance

H-CAT and ASC elements available for the most challenging targets

o

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a

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