recent developments in integrated exhaust emission control technologies for diesel engines

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Recent Developments in Recent Developments in Integrated Exhaust Emission Integrated Exhaust Emission Control Technologies for Diesel Control Technologies for Diesel Engines Engines Manufacturers of Emission Controls Association May 2000

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Recent Developments in Integrated Exhaust Emission Control Technologies for Diesel Engines. Manufacturers of Emission Controls Association May 2000. Presentation Outline. Overview Diesel Oxidation Catalysts and Particulate Filters Control Technologies for NOx Emissions Control Systems - PowerPoint PPT Presentation

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Recent Developments in Integrated Recent Developments in Integrated Exhaust Emission Control Technologies Exhaust Emission Control Technologies

for Diesel Enginesfor Diesel Engines

Manufacturers of Emission Controls Association

May 2000

Presentation OutlinePresentation Outline

Overview

Diesel Oxidation Catalysts and Particulate Filters

Control Technologies for NOx Emissions

Control Systems

The Importance of Low Sulfur Diesel Fuel

Conclusions

Can All Facets of the Diesel Emissions Issue Can All Facets of the Diesel Emissions Issue Be Addressed?Be Addressed?

Are Control Technologies Available to Remove Both Diesel PM (Mass and Number) and the Other HC-Based Toxic Emissions?

Are These Control Strategies Compatible with Further Reductions in NOx Emissions?

Yes, If an Integrated Approach Is Used - Advanced Engines, Integrated Emission Control Technologies, and Clean Fuels

Existing Technologies Provide Many Options and Existing Technologies Provide Many Options and Emerging Technologies Show Much PromiseEmerging Technologies Show Much Promise

Existing Emission Controls Can Greatly Reduce Diesel Emissions

– Oxidation Catalysts, Particulate Filters, and Modified Engine Components

Advanced Emission Control Technologies

– NOx Catalysts, SCR, NOx Adsorbers, Plasma Technology, Combined Systems

Technologies to Control Crankcase Emissions

New Engine Technologies

– Common Rail or Unit Injection, Cooled EGR, Advanced Fuel Spray, Pilot Injections, Variable Geometry Turbocharging

Advanced Fuels

– Low Sulfur, Low Aromatics, Other Properties

Integrated Emission Control Will Allow Diesel Engines to Meet the Future Challenges

Diesel Oxidation CatalystsDiesel Oxidation Catalysts

Carbon

SOF

NOx

CO

HC

Carbon

NOx

Water

Oxidation Catalysts Oxidize CO, HC, and SOF to Reduce PM, CO, HC, and Toxic Emissions.

Diesel Oxidation Catalysts Are Efficient and Diesel Oxidation Catalysts Are Efficient and ProvenProven

Oxidation Catalyst Control Capabilities– PM -- 20-50% Reduction

– CO and HC -- >90%

– Toxic HCs -- >70%

DOCs Destroy Large Fractions of Toxic EmissionsDOCs Destroy Large Fractions of Toxic Emissions

1.290.8

1.86

9.41

11.36

0.560.10.2

2.8

6.8

0

2

4

6

8

10

12

Formal

dehyd

e

Aceta

ldeh

yde

Acrolie

n

1,3

Butadie

ne

PAHs

Before After

Toxic Hydrocarbon Compounds Reduced by 68%

PAH Emissions Reduced by 56%

Greater Reductions Possible with Low Sulfur Fuel

mg/bhp-hr

Source: MECA 1999

Diesel Particulate FiltersDiesel Particulate Filters

Trapped PMCell Plugs

Exhaust(PM, CO, HC)Enter

Ceramic HoneycombWall

Exhaust (CO2, H2O)Out

Diesel Particulate Filters Are Efficient and Diesel Particulate Filters Are Efficient and Are Developing an Impressive Track RecordAre Developing an Impressive Track Record

Filter Control Capabilities– PM -- 80%->90% Reduction

– CO and HC -- >90%

– Toxic HCs -- >90% Reduction

Diesel Particulate Filters Nearly Eliminate PMDiesel Particulate Filters Nearly Eliminate PM

0.00

5

0.1

11

0.0

08

0.00

8

0.11

5

0.07

3

00.020.040.060.08

0.10.120.14

HC CO/10 PM

PM Emissions Below 0.01 g/bhp-hr Can Be Achieved

Significant Reductions in CO and HC Emissions Can Also Be Achieved

g/bhp-hr

Source: MECA 1999

PM

Filters Destroy Large Fractions of Toxic EmissionsFilters Destroy Large Fractions of Toxic Emissions

0

0.2

0.4

0.6

0.8

1

1.2

1.4

Before After

PAH Emissions Reduced by 89%

PAH, mg/bhp-hr

Source: MECA 1999

1.2

0.14

Filters Are Very Effective in Reducing Ultra-Fine Filters Are Very Effective in Reducing Ultra-Fine ParticlesParticles

Post filtered gas has the same particulate concentrations as the dilution air

Carbon-Based Ultra-Fine Particles Reduced by in Excess of 99.99 %

Peugeot SAE 2000-01-0473

NOx Control Technology

Technology Performance Range

NOx CO HC PM

Active Lean NOx 25-50 >70 >70 ~ 30

NOx Adsorber 50-70 >70 >70 > 30

SCR Urea >80 >50 >70 > 30

Plasma / NOx Cat. >65 >50 >50 ~ 30

NOx Technologies Are in Various Stages of NOx Technologies Are in Various Stages of DevelopmentDevelopment

Lean-NOx Catalysts Have Been Used on PCs in Europe and Are Expected to Be Offered Commercially in the U.S.

SCR Has Been Used on Stationary Sources, Marine Vessels, Locomotives and Have Been Used in Truck and PC Demonstration Programs

NOx Adsorbers Are in Vehicle Trials

Plasma Technology Is in the Laboratory Stage and Is Emerging on Vehicles

SCR

SCR ApplicationsSCR Applications

SCR Has Been Used Successfully on Stationary SCR Has Been Used Successfully on Stationary Sources and Is Now Used for Mobile SourcesSources and Is Now Used for Mobile Sources

SCR Control Capabilities– PM – 30-50% Reduction

– CO and HC -- >80%

– Toxic HCs – >80%

– NOx – 60 - >80%

SCR Test Results in European & US Steady State Test SCR Test Results in European & US Steady State Test CycleCycle

0

500

1000

1500

2000

2500

1 2 3 4 5 6 7 8 9 10 11 12 13mode

NO

x [g

/h]

NOx before catalyst: 6.79 g/bhphr NOx after catalyst: 1.34 g/bhphr

NOx conversion: 80%

Examples of Integrated SystemsExamples of Integrated Systems

Integrated System Using a DOC, DPF, and SCRIntegrated System Using a DOC, DPF, and SCR

Engine

Catalyst/Filter SCR Oxidation Cat

Removal of HC, CO, PM

Removal of NOx

Removal of NH3 slip if required

4-way conversion

Urea

Early Results Have Hit Euro V -- US HD2007 Is NextEarly Results Have Hit Euro V -- US HD2007 Is Next

Euro V regulations are easily met with combo system; 12 liter engine 25.5 liter DPF system, 17 liter SCR system.

JMI SAE 2000-01-0188

0

0.005

0.01

0.015

0.02

0.025

0 0.5 1 1.5 2 2.5 3 3.5 4

NOx Emissions (g/kW-hr)

PM

Em

issi

on

s (g

/kW

-hr)

CR-DPF + SCR2CR-DPF + SCR3

EUIV (2005)EUV (2008)

US 2007 (prop.)

Integrated System – Lean NOx Catalysis + Integrated System – Lean NOx Catalysis + FilterFilter

Integrate heat transfer and chemistry Integrate heat transfer and chemistry for simultaneous reduction of for simultaneous reduction of NOx, CO, HC, & PMNOx, CO, HC, & PM

LNCLNC(NOx reduction)(NOx reduction)

DPFDPF(CO, HC, and(CO, HC, andPM oxidation)PM oxidation)

DirtyDirtyExhaustExhaust

InIn

Clean AirClean AirOutOut

GainGainHeatHeat

LoseLoseHeatHeat

RecuperatorRecuperator

SupplementaSupplementary HC ry HC

InjectionInjection

Other Integrated SystemsOther Integrated Systems

Electric Turbocharger and Oxidation Catalysts

– Reduces PM, CO, HC, and Toxic HC Emissions

Engine Modifications (Cam Shafts, Engine Coating, Timing Changes) in Combination with PM Control Technologies

Plasma/Catalyst Technology

The Key Role of Fuel SulfurThe Key Role of Fuel Sulfur

All Catalyst-Based Exhaust Emission Control Technologies Are Adversely Affected by Sulfur

– Sulfur inhibition

– Sulfur Poisoning

– Formation of Sulfates

Consequently: Emissions Performance, Reliability, and

Durability Are All Compromised

The Key Role of Fuel Sulfur (cont.)The Key Role of Fuel Sulfur (cont.)

MECA Recommends That Fuel Sulfur Levels Be as Close to Zero as Possible

With Fuel Sulfur Capped at 15 ppm with Average Fuel Pool Levels <10 ppm, MECA Believes:

– A 0.01 g/bhp-hr PM Standard Can Be Achieved for All Onroad HDDE Vehicles in All Applications Now

– With Anticipated Advances in NOx Control Technologies, A 0.2 g/bhp-hr NOx Standard Can Be Achieved for All Onroad HDDE Vehicles in 2007

ConclusionsConclusions

Diesel- and Alternative Fuel-Powered Engines, as well as Advanced Technologies (e.g., Fuel Cells), All Will Likely Play a Role in the Future

A Variety of Demonstrated Technologies Are Available to Significantly Reduce Emissions from HDDEs

Conclusions (cont.)Conclusions (cont.)

The Ultimate Solution to Reducing Emissions from Diesel Engines Requires a Systems Approach Utilizing Advanced Engine Designs, Advanced Integrated Emission Control Technology, and Low Sulfur Diesel Fuel