shaping the future exhaust after treatment systems
TRANSCRIPT
Shaping the Future
Exhaust After Treatment
Systems
Exhaust After-Treatment
Reducing the exhaust pollution emitted from the vehicle by using “clean-up” technology within the exhaust pipe system.
Exhaust Catalysts are the primary technology used
Exhaust After-Treatment
Standard Spark-Ignition (petrol) engines have relied on a “3-Way” Catalyst to reduce CO, HC & NOx
Until recently Compression-Ignition (diesel) engines in passenger cars have not needed after treatment systems, recent legislation is changing this.
The introduction of Direct Petrol Injection (DPI or GDI) systems has further complicated the emissions after treatment requirements
SI Emissions After-Treatment
Conventional 3 – Way Catalysts
Require the engine to operate at or near stoichiometric air-fuel ratio (lambda = 1)
Platinum, Palladium and Rhodium in Aluminium Oxide washcoat
SI Emissions After-Treatment
Conventional 3 – Way Catalysts
Accelerate both oxidation and reduction reactions through the use of small quantities of Platinum, Palladium and Rhodium metals
Carbon Monoxide is oxidised to Carbon Dioxide
Hydrocarbons are oxidised to Carbon Monoxide and Water
Oxides of Nitrogen are reduced to Nitrogen and Oxygen
The presence of the catalytic material ensures that the above reactions occur at lower temperatures and quicker than they would have otherwise.
The reactions are exothermic. The exhaust temperature leaving the catalyst is higher than that entering the catalyst
SI Emissions After-Treatment
The 3-Way Catalyst requires the engine
to oscillate near lambda = 1
Catalyst Efficiency
SI Emissions After-Treatment
Catalyst “Light Off” Temperature The 3-Way Catalyst achieves acceptable
conversion efficiencies when it is above a
certain temperature
Catalysts take time to start to work!!
www.bosal.com -
CI Emissions After -Treatment
Carbon Monoxide is not a concern
HC is dealt with via Oxidation Catalysts (One Way)
Major emphasis is on NOx and particulate matter treatment NOx after-treatment options include;
Cooled EGR Selective Catalytic Reduction NOx Absorbers (NOx Storage Catalyst, Lean NOx Traps)
CI – HC After-Treatment
Oxidation Catalysts simply help to complete the ‘partial combustion’ that formed the HC in the first place.
Pre light off performance is critical (most of the HC is produced at cold start)
Fortunately hydrocarbons are stored on the catalyst at low temperatures and released at high (post light off) temperatures.
The release might not be fully completed before light-off is reached – leads to poorly understood phenomena
Storage and release regimes may be repeatedly crossed in light-duty driving
Pattern of storage/release/oxidation strongly depends on the species of hydrocarbon. Heavy molecules are much more easily stored than light molecules
Selective Catalytic Reduction (SCR) Systems
Ammonia-SCR systems react ammonia (NH3) with the NOx to form nitrogen (N2) and water (H2O).
There are three reaction pathways:4NH3 + 4NO + O2 = 4N2 + 6H2O2NH3 + NO + NO2 = 2N2 + 3H2O8NH3 + 6NO2 = 7N2 + 12H2O
Any source of ammonia can be used as the reductant but most commonly the source is an aqueous solution of urea (typically 30-35%)
This decomposes in the exhaust stream in two stages to form ammonia and carbon dioxide (CO2)
CI – NOx After-Treatment
NOx - Selective Catalyst Reduction
(CRT – Continuously Regenerating Trap – Particulates )
Diesel Exhaust Fluid (DEF) Tank
NOx - Selective Catalyst Reduction
Diesel Exhaust Fluid (DEF) Tank
Selective Catalytic Reduction (SCR) Systems
Hydrocarbon-SCR (lean NOx reduction) systems use hydrocarbons as the reductant.
The hydrocarbon may be that occurring in the exhaust gas or it may be added to the exhaust gas.
The advantage of this system is that no additional reductant source (e.g. urea) need be carried but these systems cannot yet offer the performance of ammonia-SCR systems.
The reaction pathways depend on the hydrocarbon used but the following describes the total reaction in the system:HC + NOx = N2 + CO2 + H2O
CI – NOx After-Treatment
CI – NOx After-TreatmentSelective Catalytic Reduction (SCR) Systems
Absorber Catalyst (Lean NOx Trap)
Under lean conditions NO2 is absorbed onto the catalyst and stored as a nitrate
Under fuel rich conditions the nitrate is released as NO and then reduced to N2
Absorber material also absorbs sulphur (from fuel) forming a stable sulphate so reducing the trap’s efficiency
CI – NOx After-Treatment
Two main methods of particulate reduction Oxidation Catalysts
Reduce gaseous compounds CO, HC and CO2 and the heavy (near liquid) hydrocarbons on the particulate. Do not affect the core carbon matter. Expect a reduction in particulate matter of ~ 25%
Particulate Filter
Basically a solid (carbon) particle trap with high temperature regeneration (oxidation) capability. Passive and active systems in use;
Passive – continuous oxidation without additional energy input
Active – oxidation with energy input (eg fuel)
Expect 90-95% clean up rates
CI – Particulates After-Treatment
Oxidation Catalysts The diesel oxidation catalyst is designed to oxidize carbon monoxide, gas phase hydrocarbons, and the SOF fraction of diesel particulate matter to CO2 and H2O:
At high temperatures oxidation of sulphur dioxide to sulphur trioxide occurs which combines with water forming sulphuric acid:
….hence the need for low sulphur fuels
CI – Particulates After-Treatment
Particulate Filters (DPF)
Filt
erin
g Effi
cien
cy (
%)
Particle “Diameter” (microns)
10-210-3 10-1 101100
Diff usionI nterception I nertia
Sedimentation
Total Effi ciency
Filt
erin
g Effi
cien
cy (
%)
Particle “Diameter” (microns)
10-210-3 10-1 101100
Diff usionI nterception I nertia
Sedimentation
Total Effi ciency
Some organics and sulphuric acid pass through the filter.
These can nucleate downstream to form new
particles (NB: smaller than the trapped ones)
Regeneration every 300 to 1000Km
(Ash disposal every 120,000 Km)
CI – Particulates After-Treatment
Particulate Filters (DPF) Regeneration
Passive RegenerationPassive regeneration takes place automatically on motorway-type runs when the exhaust temperature is high. Many cars don't get this sort of use though so manufacturers have to design-in 'active' regeneration where the engine management computer (ECU) takes control of the process.
Active RegenerationActive Regeneration occurs when the level of soot in the filter reaches around 45%. The ECU makes small adjustments to the fuel injection timing and increases the exhaust gas temperature. This increases the exhaust temperature which then initiates the regeneration process, burning away the soot trapped in the DPF.
CI – Particulates After-Treatment
Particulate Filters (DPF) Regeneration
Metallic catalysts are used to reduce the temperatures required to burn the particulates (regeneration)
Two systems: Additive (aDPF): the metallic catalyst is added to the fuel (Active)
Coated or Catalysed (cDPF): the metallic catalyst is imbedded in the washcoat of the filter (Passive)
cDPF present less of a control challenge and is suited to retro fit applications, aDPF is used where the conditions for cDPF cannot be assured
CI – Particulates After-Treatment
Example After Treatment System
Combination of Oxidation, Filter Systems and NOx trap systems (JM)
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