ab gas nach be hand lungs strategie n

7/25/2019 Ab Gas Nach Be Hand Lungs Strategie n

1/29

Copyright Tenneco Inc. This document and the information embodied herein is the property of Tenneco Inc. and is disclosed in confidence for informational purposes only.

It may not be copied, disclosed or used for any purpose without the prior written consent of Tenneco Inc..

Abgasnachbehandlungsstrategien

zur Einhaltung der Euro VI- bzw.EU-Stufe IV- Emissionsgrenzwerte

CVC-Jahrestagung

19. November 2010

Dr. Wolfgang Reuter

Geschftsfhrer Heinrich Gillet GmbH

Vice President TENNECO Emission Control Europe


2/29



Emission Control Fabricated Manifolds

Manifolds-Converter Modules

Downpipes

Converters

Diesel Particulate Fil ters

Mufflers Complete Exhaust Systems

Af tertreatment Systems for

commercial vehicles

Shock Absorbers

Struts

Elastomers/Vibration Control

Components

Load Assist Products

Springs

Advanced Suspension Systems

Ride Control

Product Lines


3/29


4/29



Commercial Vehicle Product Range

Largest CustomersLargest Customers

Deutz

Daimler

International

Volvo Global Trucks

PACCAR / DAF

Scania

Caterpillar

John Deere


5/29



Non Road Product Range

Ai r Pump

Air/Fuel Block

Controller

Urea Tank

DCU Box

Coolant Line

Urea

Injector

Mixer

DPF

TRUE-Clean

Ignition

Coils & Plugs

SCR

Diesel Particulate Filters

Regeneration Burners

SCR Systems

Urea Dosing & Injectionn


6/29



Diesel Particulate Filters

Converters

Manifold-Converter Modules

Exhaust Heat Exchanger

Center Mufflers

Fabricated Manifolds

Rear Mufflers

Complete Exhaust System

Light Vehicle Product Range


7/29



Emission Control Europe, Edenkoben, Pfalz

..

South Africa

12

1

14

13

15

2

1116

6 3

5

4 18 178

7

9 10

2019

21

1. Edenkoben, Heinrich Gillet GmbH2. Emden (JIT)

3. Saarlouis (JIT)

4. Zwickau (JIT)

5. Ingolstadt (JIT)

6. Gent (JIT)

7. Iwuy (JIT)

8. Etain

9. Rennes (JIT)

10. Laval

11. Tredegar

12. Arendal (JIT)13. Vittaryd

14. St. Petersburg

15. Togliatti

16. Poznan (JIT)

17. Rybnik

18. Hodkovice (JIT)19. Palmela (JIT)

20. Valencia

21. Port Elizabeth

Main Plant

Plant & Engineering Center

JIT Plant


8/29



Global Emissions Regulation Timeline


9/29



Emission Limits in Europe

for Heavy Duty Trucks - onroad

0

0,02

0,04

0,06

0,08

0,1

0 1 2 3 4 5

NOx [g/kWh]

PM[g/kWh]

EU III EU III ESC 2000NOx 5,0 g/kWh

PM 0,1 g/kWh

EU IV ESC/ETC 2005

NOx 3,5 g/kWh

PM 0,02/0,03 g/kWh

EU V ESC/ETC 2008

NOx 2,0 g/kWh

PM 0,02/0,03 g/kWh

EU VI ESC/ETC 2013

NOx 0,4 g/kWh

PM 0,01 g/kWh

PM# Limit is planned

EU V EU IV

EU VI


10/29



Emission Limits in Europe

for Heavy Duty Vehicles - offroad

2008 2009 2010 2011 2012 2013 2014 2015 2016

130 - 560

75 - 130

56 - 75

37 - 56

19 - 37

8 - 19


11/29



Strategies to Meet Future Limits

Particu

lates

NOx

Stage IV

Stage IIIB

High Pressure CR (90%)

w/o EGRSCR (>80%)

Fuel

Consumption


12/29



Technology Strategy Drivers

Operation mode

Engine raw emissions

Fuel efficiency requirement

Local air quality requirements(operation restrictions)

Available fuel quality (Sulfur)

System cost

Particulates

NOx

Fuel

Consumption


13/29



Diesel Aftertreatment Strategy in Europe

ON-ROAD EU VI (2012+)

SCR &/or Cooled EGR

Wallflow DPF (>95%) Open filters unlikely

OFF-ROAD Stage III B (2011+) Agriculture SCR

Construction DPF

(Open filters possible)

OFF-ROAD Stage IV (2014+)

Wallflow or open DPF

Urea SCR system


14/29



DPF - Filtration

ASH

Wallflow filter Open filter

Cordierite, SiC, AT or sintered metal Sintered metal, foam, wire mesh

>95% filtration efficiency


15/29



T [C]600100

VEHICLEOPERATION

RANGE

TRUCKS

PASSENGER CARS

450250

DPF - Regeneration

O2 Regeneration

with additive (FBC)

O2 Reg.

Active

regeneration

required

CSFCRT

(NO2 Regeneration)

At lower temperatures active regeneration support is mandatory


16/29



Competing Regeneration Technologies

CRT - Plus

Diesel

Vaporizer / Injector

Diesel

Burner

DOC yes yes yes no

Regeneration supportEngine /

throttle

Engine /

throttleSmall burner

Full size

burner

Regeneration mode continuous periodic periodic periodic

Application range limited unlimited unlimited unlimited

Sulfur tolerance low low low high

Secondary emissions NO2 NO2 NO2 noneCost O - -- -

D

OC

DPF

Small Burner

Insulation

Fullsize Burner

Exhaust Throttle Injector / Vaporizer

Intake Air Thrott le

Late / Post Injection


17/29



TRUE-Clean for DPF Regeneration

Air supply Air/Fuel

block

Controller Ignitioncoils

Nozzle CombustionChamber

Delta P

DPF

Spark plugsw/ ion sensing

Fuel supply


18/29



DeNOx Technologies

Liquid based SCR:

AdBlue

Denoxium (Kemira)

Guanidinium Formate (AlzChem)

Solid based SCR:

Solid urea (Pierburg) Ammonia Carbamate (FEV)

Metal Amine (Amminex)

HC - Lean NOx Catalyst

Lean NOx trap (LNT)

Source: FEV

Source: Yara


19/29



HC-LNC Mixer

DOC

Flow

HC-

Injection

NOx + HC N2 + CO2 + H2O (+ N2O + NO)CAT

HC LNC (Lean NOx Catalyst)

Alternative to Urea SCR technology

Uses HC (diesel fuel, E85, ) to reduce NOx

Innovative GE Ag coating technology

Strongly demanded by rail, on-road & offroad equipmentmanufacturers

Tenneco is licensee of GE technology


20/29



Advantages of HC-LNC Versus AdBlue

Existing reductant infrastructure ULSD & E85

Improved packaging less tank volume

Reduced weight

no need to carry water

Eliminate freeze issues

No deposit concern

No corrosion concern

Less complex system

integration

Lower system cost

OEMs

Catalyst

Integration


21/29



HC-LNC Development Status

HC-LNC is installed in several demo

vehicles

500hrs high temperature (


22/29


23/29



Pump

Serviceable filter

Urea pressure transducer

Heat and power relays

DCU (Dosing Control Unit) with TEN

dosing algorithm

Learn pack for fastcalibration

Integrated heating

Environmentally sealedwith SAE J2044 fluid connections

Urea Dosing Control Unit (DCU)

Filter

Pump

DCU


24/29



SCR System Integration Objectives

Efficient catalyst usage uniform flow distribution

Efficient conversion of urea into ammonia

Efficient mixing of ammonia & exhaust gas

No ammonia slip

No deposits

Low backpressure

Compact, low cost and

low weight system

Deposits with non-optimized SCR system


25/29



SCR System Integration Parameters

Operation parameters (flow rate & gas temperature)

Injector spray quality (droplet diameter, spray angle, etc)

Injector position

Injector temperature

Mixer design

Mixer position and orientation

Pipe & cone design

SCR catalyst NH3 storage capacity (buffer effects)

Skin temperatures (insulation design)

High number of parameters requires a systematic approach


26/29



System Integration 3 Step Approach

STEP1 Simulation

Design tuning for flow uniformity

Injector & Mixer Positioning

Pressure loss analysis

STEP2 Hot Flow Bench

Steady state NOx conversion

Design adjustments Fine tuning of injector & mixer position

Deposit evaluation

STEP3 Engine Bench

Design validation under transient testing

Focus on overall NOx conversion efficiency, ammonia

slip and depositsw/o mixer TENNECO

mixer

Stage IV / EU VI


27/29



Stage IV / EU VI

The Integration Challenge

Package constraints

Challenging flow conditions

Short urea evaporation &mixing length

Thermal management

SCR light-off

Avoidance of deposits DPF regeneration

Extreme skin temperature

requirements (200C)

Meet acoustic targets

>350C

DOC

DPF

SCR

Urea Injector


28/29



Integrated Stage IV System

Ai r Pump

Air/Fuel Block

Controller

Urea Tank

DCU Box

Coolant Line

Urea

Injector

Mixer

DPF

TRUE-Clean

Ignition

Coils & Plugs

SCR

C l i


29/29



Conclusions

Upcoming EU VI and Stage IV legislation will require a combination of

DPF and SCR technologies

The challenge is the integration of all required functions into a compact,

robust and cost efficient aftertreatment unit Tenneco owns all simulation and testing tools for effective EU VI and

Stage IV system integration

TRUE-Clean and Vaporizer Technologies are cost efficient and

reliable solutions for active DPF regeneration

Urea SCR is mainstream technology for near future limits

Tenneco offers turnkey urea dosing & injection system

Tenneco develops a HCLNC system as an alternative to urea SCR

ab gas nach be hand lungs strategie n

Documents