Emitec SCR

High efficiency SCR system for most effective NOx reduction
and best fuel economy for on- and off-road applications

Dr. Ulrich Pfahl, Emitec Inc.
Detroit, June 20th, 2012
Exhaust Emission Legislation & Strategies

SCR System Layout & Development
Requirements of Urea Dosing System Air Assisted / Airless
Conclusion
Agenda

Conclusion
Agenda
Fuel Consumption
Engine Technology
Euro VI
Engine Technology
Euro IV
PM [mg/kWh]
60
30
EU IV
EU V
EU VI
High Efficient SCR: > 95%

1
Exhaust Emission Legislations & Technologies

Example : Commerical Vehicle - ETC
NOx [g/kWh]

Conclusion
Agenda
Silencer
Silencer
SCR
Euro IV : > 70% NOx efficiency
SCR
SLIP
DOC
Silencer
Silencer
Euro V : > 85% NOx efficiency
Hyd.
DPF/SCR
SLIP
DOC
Silencer
Silencer
Euro VI : > 95% NOx efficiency
NH3 Formation
{(NH2)2CO 7H2O}fl
{(NH2)2CO}fl + 7 H2O
water evaporation
{(NH2)2CO}fl
HNCO + NH3
thermolysis of urea
HNCO + H2O
CO2 + NH3
hydrolysis of isocyanic acid
NOX Reduction
4 NO + O2 + 4 NH3
4 N2 + 6 H2O
2 NO2 + 2 NO + 4 NH3
standard reaction with NO
4 N2 + 6 H2O
fast reaction with NO+NO2
NOx Conversion Rate [%]
100
90
NO2 / NO
50%
80
70
60
NO2 / NO
0%
50
40
30
20
10
0
0
100
200
Temperature [C]
SCR Processes
300
400
NH3 Formation
{(NH2)2CO 7H2O}fl
{(NH2)2CO}fl + 7 H2O
water evaporation
{(NH2)2CO}fl
HNCO + NH3
thermolysis of urea
HNCO + H2O
CO2 + NH3
hydrolysis of isocyanic acid
Adblue Droplet
Hitting the Target Surface
Evaporation
Develop System according to Critical SCR Processes :

Good evaporation of DEF optimized amount of DEF injected per time per unit
targeted area , in order to minimize the temperature loss in the system
Optimum hydrolysis of isocyanic acid Preference for Hydrolysis Catalyst
Good uniformity of NH3 Optimized Mixing Tube Design
SCR Processes

Conclusion
Agenda
Air Assisted / Airless

Mass Per Droplet Size
Key Considerations of Urea Dosing System Design
Droplet Size Distribution
Droplet Mass Distribution

100
Cumulative Mass %
Relative Distribution
Density
1.2
0.8
0.6
0.4
0.2
0
0
20
40
Droplet Size in Microns
60
80
60
40
20
0
0
10
20
30
40
50
60
Droplet Size in Microns
Air assisted SCR System: Measured Droplet Size - and Droplet Mass
Distribution at 20 l/min Airflow
5 m
< 5 mm
30 m
70 m
1110 mm
6100 mm
Evaporation distance requ. at 200 kg/h exhaust mass flow @ 430 C

Technical University Munich, tube- 55 mm

Temperature
Layout Exhaust Gas Temperature ( injector
location, insulation), Injection Strategy
OxiCatalyst
600
Urea
Dosing
SCR
Temp. upstream SCR Cat [C]
500
EU V Engine
400
300
EU VI / US 2010 Engine
200
100
0
0
200
400
600
800
1000
1200
1400
1600
1800
Time [s]
New Conditions for HD Truck Catalyst Systems;

Exhaust Gas Temp. EU V / US 2010 (EU VI); 13mode steady state
Exhaust Temperature EHC Not Active

Ehxaust Temperature EHC Active
300
3000
275
2500
Benefit in
Temperature with
EHC
250
2000
225
1500
200
1000
175
500
150
0
0
250
500
750
1000
1250
1500
1750
Exhaust Mass Flow [kg/h]
Temperature [C]
Exhaust Mass Flow
2000
t [sec]
Temperature Profile of a Commercial Vehicle with and without

Electrically Heated Catalyst (EHC): City Driving Cycle

Temperature
Mixing Pipe Design - Tasks
Avoid Deposit formation
Good Uniformity
Creation of NH3
NOx-Reduction [%]
NH3- Slip [ppm]
100
60
95
50
90
40
85
30
80
20
75
10
70
0.88 0.9 0.92 0.94 0.96 0.98
NH3-Uniformity
0
0.88
Alpha = 1.00
0.9
0.92 0.94 0.96 0.98

NH3-Uniformity
Calculated NOx-Reduction and NH3 Slip as Function of

NH3-Uniformity and DEF-Dosing Rate
NOx Efficiency, %
100
90
80
70
60
50
40
30
20
10
0
High Load
Points
B50
A50
B50
A50
NOx Efficiency, %
DEF Injector Initial Layout
A25 B100 B25

ESC Load Point
C100
C25
100
90
80
70
60
50
40
30
20
10
0
A25 B100 B25
ESC Load Point
C100
C25
DEF Injector New Layout
NOx Reduction @ selected US EPA 13mode / ESC load points
100
98
NOx Efficiency
96
94
Test conditions:
constant speed / torque

constant temperature and massflow and
92
exhaust gas condition
90
88
86
0.85
0.9
0.95
Alpha (-)
exhaust gas 714 kg/h, T = 420 C, NO x = 543

ppm; NO2/NOx = 0,27
theoretical DEF demand for (alpha = 1) = 1100
ml / h
1.05
setup with Fe-Zeolithe catalyst [242 x (110 + 110)]

10,1 ltr
alpha = 0,87 1.04
NOx Efficiency with Optimized Airless Dosing Layout & Strategy

Summary of Sweep Test
Average Concentration
Engine parameters
With H-Cat
Without H-Cat
NH3
HNCO
NH3
HNCO
54,7
32,5
17,3
17,9
A 25 Load Point:
Exh Gas Temp: 310 C
Exh Gas Massf.: 850 kg/h
Hydrolysis Cat ( H-Cat) gives significant Advantage for

NH3 formation
NH3-distribution Example
6th ICPC, Graz, 25. - 26.04.2011
Design w/o Hydrolysis-Cat
Design with Hydrolysis-Cat
after 10 h Load point A 25
after 10 h Load point A 25
Hydr.-Cat Inlet
Hydr.-Cat outlet
Catalyst System Validation of Mixing Pipe - Deposits

6th ICPC, Graz, 25. - 26.04.2011
watercooled
injector
SCR catalyst
LS Technology
Liebherr SCR Production System

6th ICPC, Graz, 25. - 26.04.2011
hydrolysis
catalyst

Temperature
Mixing Pipe Design - Tasks
Avoid Deposit formation
Good Uniformity
Creation of NH3
SCR Catalyst Structure
Conversion Efficiency
Ammonia Slip
120
160
140
100
120
100
60
40
Washcoat
200cpsi Standard
40
Mass Transfer
20
200/400cpsi LS
80
60
20
Std
LS
Std
80
+ 14%
70
60
40
30
20
200/400 LS
50
200 cpsi
NOx Conversion Efficiency [%]
90
100
[%]
WM [%]
80
+4%
10
0
200
250
300
350
Temperature [C]
Influence of Cell Structure on NOx Conversion Efficiency
LS
18 [mm]
LS/PE-Foil
Flow
Position A
Position H
Concentration
Tracer gas [%]
100
80
60
40
20
0
Radial Mixing after a substrate length of 18 mm LSPE

Tracer Gas injected into a single Channel; 200kg/h; 300C
100
90
88
NOx Conversion Efficiency, %
80
79
70
60
50
40
30
20
10
0
Ceramic System
Metallic System
Comparison of Ceramic and Metallic Systems:

NOx-Emission Reduction in ETC
7. FAD-Konferenz , November 2009
100
97
90
88
NOx Conversion Efficiency, %
80
79
70
60
50
40
30
20
10
0
Ceramic System
Metallic System
Metallic System, DEF increased 20%

Euro VI Development
Comparison of Ceramic and Metallic Systems:

NOx-Emission Reduction in ETC
50
180
Maximum Value
45
160
Average Value
40
140
35
120
30
100
25
80
20
60
15
40
10
20
0
Ceramic-SCR
With NH3-Slip
Catalyst
Metallic-SCR
without NH3-Slip
Catalyst
Metallic-SCR
without NH3-Slip
Catalyst
DEF incr. 20%
NH3-Slip, [ppm] (Average Value)
NH3-Slip, [ppm] (Max. Value)
200
Metallic-SCR
with NH3-Slip
Catalyst
DEF increased 20%
Comparison of Ceramic and Metallic Systems : NH3 Slip in ETC


Conclusion
Agenda
EHC
Hydr.
SCR
SLIP
DOC
Silencer
Silencer
Silencer
Emicat
LS
Mixer
LS
PM Metalit
LS/PE
High Efficient SCR System Development
LS
Vertraulich / Confidential
Copying of this document and giving it to others is strictly forbidden without express authority of Emitec!
Capacity 60 l/h
up to 1000 l/h
Digital Dosing Pump

Urea Injection
Air-Assisted
Capacity 7,5 l/h
Capacity 2 l/h
and 8 l/h
Capacity 2 l/h
and 8 l/h
Emitec NoNOx SCR Platforms
Urea Injection
Airless Urea Injection
Airless Urea Injection
Thank You

Emitec SCR

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Emitec SCR

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Droits d'auteur :

Formats disponibles

High efficiency SCR system for most effective NOx reduction

and best fuel economy for on- and off-road applications

Exhaust Emission Legislation & Strategies

Exhaust Emission Legislation & Strategies

High Efficient SCR: > 95%

Exhaust Emission Legislations & Technologies

Exhaust Emission Legislation & Strategies

Euro IV : > 70% NOx efficiency

Euro V : > 85% NOx efficiency

SCR System Layout & Development

Euro VI : > 95% NOx efficiency

hydrolysis of isocyanic acid

standard reaction with NO

fast reaction with NO+NO2

NOx Conversion Rate [%]

hydrolysis of isocyanic acid

Hitting the Target Surface

Develop System according to Critical SCR Processes :

Exhaust Emission Legislation & Strategies

Air Assisted / Airless

Key Considerations of Urea Dosing System Design

Droplet Size Distribution

Droplet Mass Distribution

Droplet Size in Microns

Droplet Size in Microns

Evaporation distance requ. at 200 kg/h exhaust mass flow @ 430 C

Air Assisted / Airless

Key Considerations of Urea Dosing System Design

Temp. upstream SCR Cat [C]

New Conditions for HD Truck Catalyst Systems;

Exhaust Temperature EHC Not Active

Exhaust Mass Flow [kg/h]

Exhaust Mass Flow

Temperature Profile of a Commercial Vehicle with and without

Air Assisted / Airless

Key Considerations of Urea Dosing System Design

NH3- Slip [ppm]

0.92 0.94 0.96 0.98

Calculated NOx-Reduction and NH3 Slip as Function of

DEF Injector Initial Layout

A25 B100 B25

DEF Injector New Layout

NOx Reduction @ selected US EPA 13mode / ESC load points

constant speed / torque

exhaust gas condition

exhaust gas 714 kg/h, T = 420 C, NO x = 543

setup with Fe-Zeolithe catalyst [242 x (110 + 110)]

alpha = 0,87 1.04

NOx Efficiency with Optimized Airless Dosing Layout & Strategy

Hydrolysis Cat ( H-Cat) gives significant Advantage for

Design w/o Hydrolysis-Cat

Design with Hydrolysis-Cat

after 10 h Load point A 25

after 10 h Load point A 25

Catalyst System Validation of Mixing Pipe - Deposits

Liebherr SCR Production System

Air Assisted / Airless

Key Considerations of Urea Dosing System Design

NOx Conversion Efficiency [%]

Influence of Cell Structure on NOx Conversion Efficiency

Radial Mixing after a substrate length of 18 mm LSPE

NOx Conversion Efficiency, %

Comparison of Ceramic and Metallic Systems:

7. FAD-Konferenz , November 2009