Technologies for Meeting Future Heavy-Duty Diesel Emission Standards

Dr. Rasto Brezny Manufacturers of Emission Controls Association

www.meca.org

ECT 2017: Enabling Cleaner and Greener India, Progressing Towards BS VI Norms

New Delhi, India November 2-3, 2017

U.S. vs. Europe Heavy-Duty Engine Transient Cycle Emission Standards

5.0

3.5

2.0

0.4

3.2

5

1.5

0.2

6

0.0

3

16

.0

3.0

3.0

1.0

13

.0

1.3

1.3

1.3

0

2

4

6

8

10

12

14

16

18

Euro III Euro IV Euro V Euro VI U.S. 2004 U.S. 2007 U.S. 2010 U.S. 2024?

Diesel NOx Diesel PM X 100

2005 2008 2013

g/k

Wh

Note: Euro VI NOx limit is 0.46 g/kWh on the WHTC

Euro VI includes 6.0 X 1011/kWh particle number limit

for diesels on WHTC

2000

DPF+

SCR

DPF+

SCR

Tighter

NOx

Needed

for O3

SCR DPF

SCR

Focus:

Low Temp.

NOx

3

Early systems Repackaged

2010

2016 2024

Evolution of NOx Control Technology

Most of these improvements are already commercialized on light-duty vehicles in Europe.

A natural optimization has resulted in 2017 systems being 60% smaller, 40% lighter, and cheaper than 5 years ago.

4

Simultaneous CO2 and NOx Reductions Achievable

• Aligned regulations are allowing optimization of criteria and GHG technology • Some 2016 and 2017 engine families are already certified below 0.1 g/bhp-hr,

three at 0.06 g/bhp-hr NOx.

5

CARB and MECA Demonstrating HD Ultra Low NOx Technologies

• Program started in 2013 at SwRI with focus on Volvo 2014 MD13TC diesel engine with turbocompounding and Cummins ISX12G CNG engine

• Objective is to demonstrate 90% reduction below current HD NOX standards • 0.02 g/bhp-hr on certification and vocational cycles

• Fully aged, production ready technology

• Solution must be consistent with path toward meeting future GHG standards • CO2, CH4, N2O

6

Calibration to Address Cold Start and Low Speed Operation

• Cold start engine calibration modified to reduce cold start engine out

NOx and fast heat-up of catalyst.

• During hot operation return to original calibration to maintain fuel economy and GHG

Increased Temperatures Decreased Engine Out NOX

7

Diesel Aftertreatment Technology Options

Advanced Approach

Examined 33 out of 500 possible configurations of component and heat addition options

Traditional Approach

8

Multiple potential pathways to achieve NOX emissions below 0.02 g/bhp-hr

Target

0.05 20

0.10 40

0.15 60

0.20 80

0.25 100

0.30

0.35

0.40

0.45

0.50

500 0 1000 1500 2000

600/2

0 0

Cu

mu

lati

ve

Hyd

roc

arb

on

s (

g)

Time (s)

Ve

hic

le S

pe

ed

(k

m/h

r)

3 mm

400/6 900/2

Next Generation Substrates Reduce Backpressure and Fuel Consumption

• Higher cell density and geometric surface area for better conversion

• Reduced back pressure with thinner, porous walls

• Higher catalyst loading in porous substrates

900/2

600/3

400/4

400/6

SAE 2015-01-1009 9

10

Source : Anforderungen an Partikelfiltersysteme für Dieselmotoren, A.Mayer, TTM

Engine Out

Emissions

Alternately Open / Plugged Channels

Porous Ceramic Wall

Tailpipe Emissions

Soot Particles

10

New Substrates for SCR Coated Filters

Catalyst Development focused on Low Temperatures

11

• Passive NOx Adsorbers (PNA) can replace traditional DOC and combine NOx trap, HC trap and DOC into single device

• Thermal durability and sulfur tolerance being improved

• Optimization of PNA NOx desorption and SCR conversion window

Low Temperature NOx Conversion (200oC)

PNA SCR

Improved Packaging Increases Low Temperature Performance

12

DOC

SCR/DPF

Urea Injector

13

OBD Sensor Manufacturers Addressing Issues

• Particle mass and number sensor variability and accuracy improving near OBD threshold

• Gas sensor development continues with efforts to enable lower emission standards

• New sensor technologies for measuring SCR system functions

14

Summary

• Euro VI and U.S. 2010 emission control strategies have continued to evolve through innovation by OEMs and suppliers on engines, catalysts, substrates and packaging

•Next generation Low-NOx technologies are already being demonstrated on diesel passenger cars and nonroad engines in Europe

• Real world compliance requires careful calibration of engine for low temperature operation and urea dosing strategies.

• Sensor development is addressing future OBD needs

•Opportunity exists for significant reductions in the off-road diesel sector