Advanced Petroleum Based FuelsAdvanced Petroleum Based Fuels--Diesel Emission Control Diesel Emission Control

(ABPF(ABPF--DEC) UpdateDEC) UpdateShawn D. Whitacre

June 1, 2005

Presented at 4th Japan Clean Air Program Conference – Tokyo, Japan

Advanced Petroleum Based Fuels – Diesel Emission Control Study

Government/Industry Sponsorship

Participating Companies/OrganizationsAutomobile:DaimlerChryslerFordGMToyota

Government:CARB/SCAQMDDOEEPA NRELORNL

Emission Control:Argillon ArvinMeritorBentelerClean Diesel Tech.CorningDelphiDonaldson Co.EngelhardJohnson MattheyMECANGKRhodiaRobert Bosch Corp.STT Emtec ABTenneco Automotive3MUmicore

Energy/Additives:American Chemistry

CouncilAPIBPCastrolChevron OroniteChevronTexacoCibaConoco-PhillipsCromptonErgonEthylExxonMobilInfineumLubrizolMarathon AshlandMotivaNPRAPennzoil-Quaker StateShell Global SolutionsValvoline

Engines:CaterpillarCummins Detroit DieselEMAInternational Truck

& EngineJohn DeereMack Trucks

Technology:Battelle

APBF-DEC Projects

NONOxx Adsorber/DPFAdsorber/DPF SCR/DPFSCR/DPF LubesLubes

SwRI

Caterpillar C12

No vehicle

FEV SwRI Ricardo AEI

CumminsISB

1.9L TDI 6.6L Isuzu Duramax

15L Cummins ISX

Audi A4 Avant

Chevrolet Silverado

Project Summaries

NOx Adsorber/DPFPassenger Car Platform

• FEV Engine Technologies• Vehicle: Audi A4 Avant• Engine: 1.9L TDI• Catalyst aging study completed

– 2200 hour aging– Final report: Summer 2005– Evaluation of criteria and unregulated

pollutants and air toxins

Project Objective

TIER 1:

after 100,000 miles

4 NOx 1.25 g/miles

4 PM 0.1 g/mile

TIER 2 BIN 5:

after 120,000 miles

4 NOx 0.07 g/miles

4 PM 0.01 g/mile

PM [g

/mile

]

0.00

0.02

0.04

0.06

0.08

0.10

NOx [g/mile]0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4

Diesel Future II:Advanced Engine Control &Advanced Aftertreatment (NAC + DPF)

TIER 2BIN 5

TIER 2BIN 8

EU 4

EU 3

TIER 1

Audi A4 1.9 l TDIStation Wagon

European Certification

Development Catalyst Configuration and SpecificationsEmission Control System

EngineExhaust

Pre-Catalyst

UnderbodyNAC CDPF

ECS-A: DOC + NACECS-B: NACCell Density: 400 cpsiVolume: 1.34 LDiameter: 4.16 inchLength: 6 inchWall Thickness: 4.5 mil

All ECS: CDPFCell Density: 200 cpsiWall Thickness: 14 milSubstrate Material: SiCVolume: 2.5 LDiameter: 5.66 inchLength: 6 inchCell Geometry: Square

SubstrateMaterial: Cordierite

Cell Geometry: Square

All ECS: NACCell Density: 350 cpsiWall Thickness: 5.5 milVolume: 2.5 LDiameter: 5.66 inchLength: 6 inch

Test Cell Emission PerformanceFTP Cycle (Un-aged System)

System A

System B

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

NOx [g/mi]0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45

Tier 2 Bin 5 *

CO[g/mi]

PM[g/mi]

Euro 4

* EMISSION LIMITS AFTER 120,000 MILES

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

HC [g/mi]0.125 0.1 0.075 0.05 0.025

Tier 2 Bin 8 *

Tier 2 Bin 8 *

CO at 4.2 g/mi

Tier 2 Bin 5 *

Euro 4

Passenger Car Platform – Aging Results(LA4 Composite)

40%

50%

60%

70%

80%

90%

100%

0 50 100

150

200

250

300

350

400

450

500

550

600

650

700

750

800

850

900

950

1000

1050

Age (hours)

NO

x C

onve

rsio

n

LA4 Composite(D15) LA4 Composite(BP15)Desulfation

More details: SAE 2005-01-1755

NOx Adsorber/DPFSUV Platform

• Southwest Research Institute• Vehicle: 2002 Chevrolet Silverado• Engine: 2002 Isuzu Duramax 6.6L• Catalyst aging study completed

– 2000 hours– Final Report: Summer 2005– Evaluation of criteria and unregulated

pollutants and air toxics

Project Objective

0

1

2

3

4

5

6

Emis

sion

s (g

/mile

)

THC NOx CO PM

Stock (with EGR)

Stock (no EGR)

Target (Tier 2,Bin 5)

FTP Drive Cycle Only

-99%

-88%

Emissions Control System

DuramaxNAC1SFI1

SFI2

Oxi-Cats1,2,3

DieselBurner

DPF

NAC2

NAC1

Volume (2nd Generation System):3.5L x 2 + 7L x 2 + 3.5L + 12.5L = 37.0L Front Oxi NAC Rear Oxi DPF

ECS : Eng = 5.6:1NAC : Eng = 2.1:1

0

50

100

150

200

250

300

350

400

0 200 400 600 800 1000 1200 1400Time, seconds

Tem

pera

ture

(°C

)

Downpipe Location (Average = 162°C)

Targeted Temperature Window for >90%

NAC NOX Reduction Efficiency

Measured Exhaust Temperature - On-Vehicle

Approach 2: Supplemental Energy-Diesel Burner

Supplemental Energy-Diesel Burner

Diesel Burner DetailsEngine Exhaust In

Combustion Chamber Location

Burner Head

Diesel Burner Management

0

100

200

300

400

0 200 400 600 800 1000 1200 1400Time, seconds

Gas

Tem

pera

ture

at C

atal

yst ,

°C

More details: SAE 2004-01-0584

Program AchievementsLow Hours, <1ppmS DECSE Fuel

0

1

2

3

4

5

NO

x M

ass

Emis

sion

, g/m

ile

HLA HFET US06

Baseline EO EO with EGR Integrated ECS

-98% -97%

-83%

SUV Platform – Aging Results(LA4 Composite)

80%

85%

90%

95%

100%

0 50 100

150

200

250

300

350

400

450

500

550

600

650

700

750

800

850

900

950

1000

1050

1100

1150

1200

1250

1300

1350

1400

1450

1500

1550

1600

1650

1700

1750

1800

1850

1900

1950

2000

2050

Age (hours)

NO

x C

onve

rsio

n

LA4 Composite (D15) LA4 Composite (BP15) Standard-D 15Desulfation

NOx Adsorber/DPFHeavy-Duty Platform

• Ricardo, Inc (Chicago)• Vehicle: None• Engine: 2002 Cummins ISX 15L• Catalyst aging study completed

– 2000 hours– Final report in progress

Project Scope• Develop system capable of meeting

2010 emissions standards:- 0.20 g/bhp.h NOx and 0.01 g/bhp.h PM

• Develop sulfur management strategy• Conduct 2000 hour catalyst aging test

- Transient and steady-state evaluations of:- Regulated emissions- Currently unregulated emissions

Test Engine• Cummins ISX 15L• 475 hp Rating• DOHC 4V central

EUI• Cooled EGR, VGT • Advanced electronic

controls• 2002/2004 Base

engine out emissions(pre-production)

Emission Control System

CumminsISX

NAC1

DOCDOC

DPF

NACDPF

NAC

NOx Sensors

NOx Sensor

Full Flow System(no bypass)

Device Dimensions (Diameter x Length)

Volume

Upstream DOC 12” x 6” 11.1 L DPF (x2) 12” x 14” 25.9 L (51.8 L total) NOx Adsorber Catalyst (x2)

12” x 12” 22.2 L (44.4 L total)

Clean-up DOC 12” x 6” 11.1 L Total Volume: 118 L

Aging Results - NOx

FTP Composite NOx

0.00.51.01.52.02.5

0 250 500 750 1000 1250 1500 1750 2000

Age (hours)

NO

x (g

/bhp

-hr)

NOx Mean Desulfation

Engine-out Level

More details: SAE 2005-01-1760

Trends Analysis - NOx

0

0.2

0.4

0.6

0.8

1

1.2

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Aging Hou rs

NO

x (g

/bhp

-hr)

Fresh Pre-Desulfat ion A verage Post- Desulfation

EPA 2010 standard

Heavy-duty SCR/DPF(Southwest Research Institute)

• Vehicle: none• Engine: Caterpillar C12 w/ LPL EGR• Two systems evaluated:

– System A: 6000 out of 6000 hours– System B: 6000 out of 6000 hours– Also testing NOx sensor durability

SCR - System Design

INTAKE MANIFOLD

MANIFOLD

ATA

A

FTER

CO

OLE

R

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

INTA

KE

THR

OTT

LE

T (IMP)

N

TPS

PRESSURE CONTROL

UREA PUMP

UREA INJECTION CONTROLUREA

EGR COOLER

EGR VALVE

LPL EGR

Heavy-duty SCR/DPF Aging Study(HD FTP Composite NOx 8-ppm S fuel)

Effects of Aging on NOx (Composite)(Mean and 95% Prediction Interval)

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

A B A B A B A B A B

0 200 2000 4000 6000

Unit / Age (Hours)

NO

x (g

/bhp

-hr)

Lubricants Project

Phase IPhase I

Determine the impact of lubricant properties and composition on engine-out/catalyst-in emissions

Determine if lubricant formulation impacts the performance and durability of NOx adsorber catalysts

Phase IIPhase II

Lubricants Project Status• Phase I Completed in 2003• Final Report available• Phase II Testing completed Aug 2004• Final reporting underway•• Detailed results to be presented in Detailed results to be presented in

later sessionlater session

Future Direction• APBF-DEC projects to wrap up in 2005• At present time, no formal plans to

continue the activity• Anticipate future collaborative activities

in fuels and lubricants research:– Fuels for advanced combustion– Non-petroleum based fuels– Lubricant impact on PM