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INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
INGAS – SPB2 – 24-Month Meeting Brussels 27/28 October 2010INGAS – SPB2 – 24-Month Meeting Brussels 27/28 October 2010 1
INGAS 24-Month Meeting BrusselsOctober 28. 2010Integrated GAS powertrain - Low emission, CO2 optimised and efficient CNG engines for passenger cars (PC) and light duty vehicles (LDV) Grant agreement no. 218447
SPB2
M. Weibel, K. Kallinen, M. Rink, M. Certic
Partners: Ecocat, Delphi, Katcon, AVL, Daimler, USTUTT, ICSC-PAS, POLIMI
Aftertreatment for Passenger Car CNG Engine
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
INGAS – SPB2 – 24-Month Meeting Brussels 27/28 October 2010INGAS – SPB2 – 24-Month Meeting Brussels 27/28 October 2010 2
AFTERTREATMENT B2 (DAI) Aftertreatment for Passenger Car CNG EngineFocus on CH4 abatementAssessment of Options for NOx Abatement (NSC)
Valid
ator
Project Structure
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
INGAS – SPB2 – 24-Month Meeting Brussels 27/28 October 2010INGAS – SPB2 – 24-Month Meeting Brussels 27/28 October 2010 33
SPB2: References and Objectives
INGAS: references and targets of the project
CH4 conversion efficiency (*)HC conversion efficiency
stoichiometric conditions (**)CH4 light off temperature (**) NOx conversion efficiency (**) NOx conversion efficiency (**)
[%] [%] [°C] [%] [%]
Reference SoA CNG (DoW) <80 on 100.000 km 90 gasoline starting 400 not developped not developped
Target INGAS SPB2 >90 on 160.000 km 90 CNG starting 330 >50 >90
NICE final status
Where we are (month 12) currently no value in NEDC currently no value in NEDCcurrently between 330°C and 400°C
depending on test and ageing conditions (laboratory scale)
no value in NEDC - regenerability of NSC as well as H2 production during
rich spike demonstrated
Where we are going (month 36) 90% 90%350°C after long term ageing + exhaust heat management for
faster lightoff>50% (based on modelling)
Key advantages SP B2 - 50 °C vs SoA DoWNSC to apply on technology way 2
(SP A2)SCR to apply on technology way 3 (SP A3)
(*) page 9 of DoW(**) page 38 of DoW
SP B2
not applicable
Main focus: Catalyst activity under = 1 conditions related to SPA2 objectives
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
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1. Counter current HEX with 3-way catalyst (TWC)
SPB2: Technical Approach
Methane
air
Cold startburner
TWC
TWC
- Integrated system (catalytic coated HEX) - Amplification of adiabatic temperature rise- Efficient control of catalyst operation temperature
3. Engine measures - for faster light-offwithout fuel penalty- Lambda strategies for enhanced CH4 conversion
TWC
2. Improved catalyst material for better CH4-lightoff
Three technological approaches for improving the methane conversion
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SPB2: Technologies and Approach
Development of specific active methane oxidation catalysts (WPB2.2) Catalyst preparation (precious metal and metal oxide technologies) Test of powdered catalysts, structured catalysts, substrates (metal and ceramics) Characterization studies
Development of a dedicated thermal management system (WPB2.3) Design and set-up of an integrated exhaust gas heating device (catalytic coated HEX) Modelling of heating device and catalytic combustion, simulation of behaviour Manufacturing, testing and optimisation of HEX
Development of operation strategies on engine test bench (WPB2.4) Identification of engine measures for faster light-off Testing of catalyst materials and HEX Optimization of operation strategies for improved CH4-Conversion
Demonstration of an exhaust gas aftertreatment system for Euro 6 (WPB2.5) Set-up of CNG engine and vehicle with the exhaust aftertreatment system (transient bench) Optimization of the catalyst heating including cold-start Demonstration of the system performance (Euro 6 legislation) in NEDC on engine test bench Validation of the catalyst activity in a vehicle configuration for Euro 6 compliance (SPA2)
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Del. N Deliverable Name Responsible Nature Due Date (month) Delivery Date (month)
DB2.1 Fuel requirements to B0 DAI R 3 delivered/approved P1DB2.2 Reference catalyst Ecocat P 3 delivered/approved P1DB2.3 Boundary/testing conditions DAI R 4 delivered/approved P1DB2.4 CH4-kinetics/model Polimi R 10 delivered/approved P1DB2.5 2 laboratory prototypes Delphi P 10 delivered/approved P1DB2.6 Bench prototype 1 Delphi P 13 delivered 22DB2.7 Catalyst samples Gen. 1/new formulations Ecocat P 16 delivered 21DB2.8 CH4/NOx strategy DAI R 18 completed in 25DB2.9 EAT operation strategy 1 USTUTT R 18 delivered 22DB2.10 Bench/vehicle prototype 2 Delphi P 21 delayed 28DB2.11 EAT operation strategy 2 AVL R 22 delayed 27DB2.12 Catalyst samples Gen. 2/new formulations Ecocat P 24 delayed 28DB2.13 Vehicle/EAT/Strategy to SPA2 DAI AVL R 31 31DB2.14 Results summary/assessment DAI R 33 33
Milestone N Milestone Name Due Date (month) Delivery Date (month)
MB2.1 Concept decision 11 delivered/approved P1MB2.2 Potential heat exchanger concept 18 delayed 27MB2.3 Principle feasibility 33 33
Reasons for delay:DB2.10 delayed from month 21 to 28: Optimization of HEX design – technical improvement of thermal inertiaDB2.11 delayed from month 22 to 27: Availability of engine test bench/mechanical engine problems and delayed delivery HEX1/CatalystsDB2.12 delayed from month 24 to 28: Optimization of catalyst formulations and availability of engine test benchMB2.2 delayed from month 18 to 27: Coupled to DB2.11
no critical delay in deliverables: MB2.3 will be completed
SPB2: Deliverables/Milestones
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SPB2: Presentation WP Activities
WPB2.2: Advanced Catalyst Development K. Kallinen, EcocatPartners: Ecocat, Polimi, ICSC-PAS, Daimler
WPB2.3: Exhaust heating/Catalyst Concepts M. Rink, USTUTTPartners: USTUTT, Delphi, Katcon, Daimler, Ecocat
WPB2.4: Engine Testing/EAT System Management M. Certic, AVLPartners: AVL, Daimler
Conclusion, Roadmap M. Weibel, Daimler
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24 months meeting Brussels – Belgium 27 - 28 October 2010
Results summary
WPB2.2
Advanced Catalyst Development
ECOCAT/POLIMI/ICSC-PAS/DAIMLER
InGas 24 months meeting: SPB2/WP2.2
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InGas 24 months meeting: SPB2/WP2.2
Objectives
• New catalyst formulations for methane oxidation – Light off temperature below 350°C– High thermal and sulfur stability
• Development of a modelling tool for methane oxidation, delivery of kinetic data and control strategy for methane
• Development of coating methods for up scaling and canning
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• Mixed oxides: Spinels, perovskites, hexaaluminates, pillared clays– Cu, Mn, Co, Cr, Ce, Zr, Pd, La, Al, different stoichiometries)
• Novel Pd-based formulations based on:– Identification of effective activation process
– Definition of role of support and active metal load (Al2O3, CeO2-Al2O3, La2O3-
Al2O3, ZrO2)
– Modification of active phase
• Physical and chemical characterization
– XRD, FT-IR, SEM/TEM, TG/DSG/DSC, BET,XPS, ICP-OES, TPR
• Catalytic testing under relevant boundary conditions
– Activity tests with different operation strategies
- Sulfur poisoning
- Hydrothermal ageing
InGas 24 months meeting: SPB2/WP2.2
Strategies, materials and methods
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InGas 24 months meeting: SPB2/WP2.2
50 000 h-1 aged 10h 800 deg - most active
0
20
40
60
80
100
100 200 300 400 500 600 700Temperature [oC]
CH
4 c
on
vers
ion
[%
]
CuMn(1:2)Cit/Puralox
Pd-1-CuMnAl(2.5:5:1)Ht/Puralox
Pd-2-CuMnAl(2.5:5:1)Ht/Puralox
Pd-2-Puralox
Ecocat
Pd-6-Puralox(org)
• Over 100 mixed oxide based catalyst formulations, over 150 catalytic tests (powder samples)
• Best catalysts are based on CuMn system and show activity exceeding the activity described in literature for mixed oxide catalysts
• Pd (6% loading) from organic precursor supported on modified alumina showed activity better than the reference
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
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InGas 24 months meeting: SPB2/WP2.2
0 2000 4000 6000 80000
20
40
60
80
100
lean @ 350°C
% C
H4
Con
vers
ion
Time (s)
Ecocat
2% Pd/La2O
3-Al
2O
3
2% Pd/CeO2-Al
2O
3
2% Pd/Al2O
3
2% Pd/ZrO2
At 1/3 Pd loading (2% w/w vs 6.3% w/w) CH4 conversion is slightly lower than the reference catalyst
• Pd based catalysts: effect of support and Pd loading (powder samples)
Significantly higher conversion perfomances have been obtained with 6% w/w Pd/CeO2-Al2O3
0 1 2 3 4 5 6 7 8 9 10 11 12 13 140
10
20
30
40
50
60
70
80
90
100
CH
4 con
vers
ion
(%)
Number of cycles
6% Pd/CeO2-Al
2O
3
2% Pd/Al2O
3
ecocat 2% Pd/CeO
2-Al
2O
3
T = 350 °C
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InGas 24 months meeting: SPB2/WP2.2
• Up-scaling and coating of the catalyst materials on the metal foil
CuMn2O4
+ Alumina+ Binder
CuMn2O4 + Alumina+ Binder+ Pd
ReferenceCatalyst + Pd
CuMn2O4 6-Pd/CeO2-Al2O3
• Good coating abilitiesfound on the metal surface • Combarable adhesion compared to the reference
6-Pd/CeO2-Al2O3
+ Binder
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InGas 24 months meeting: SPB2/WP2.2
• Laboratory testing for the new materials
– Laboratory light off tests (25-600°C): as fresh and
LS-1030°C/20h aged
(LS = lean 10 min + stoichiometric 50 min;
CO, CO2, H2O, C3H6, O2, N2)
Stoich.
λ=1
Lean
λ=1,78
O2, % 0,8 10
NO, ppm 600 500
H2O, % 10 8
CO2, % 9 7,5
CO, ppm 8000 1200
H2, ppm 2800 -
CH4, ppm 1800 1500
C2H6, ppm 100 300
C3H8, ppm - 100
C2H4O, ppm - 150
Samples are containing 195 g/cft Pd loading correspondingPd loading in 200 g/cft 0:39:1 Pt:Pd:Rh reference catalyst
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InGas 24 months meeting: SPB2/WP2.2
• Pd-CeO2-Al2O3 material in light off test at lean (fresh)
THC Conversion in Light-off performance
0
10
20
30
40
50
60
70
80
90
100
100 150 200 250 300 350 400 450 500 550 600Temperature before catalyst, °C
Co
nv
ers
ion
, %
896 6-PdCeO2-Al2O3
640 REF (Pd)
• Significant performance improvement achieved in respect of the reference• λ=1 tests as well as tests for the aged catalyst samples are in progress
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• The effect of Platinum addition in reference catalyst– 1,2 liter E4 bi-power vehicle with CNG over NEDC (ageing 40/80 h RAH)
InGas 24 months meeting: SPB2/WP2.2
• Increased catalyst durability found
1 1 11,1
1,0 1,0
1,8
1,6
1,51,4
1,1
1,3
1,8
1,5
1,9
1,7
1,4
1,7
0
0,2
0,4
0,6
0,8
1
1,2
1,4
1,6
1,8
2
THC CO NOx
Re
lati
ve
em
iss
ion
Pd-Rh/ Fresh Pt-Pd-Rh/ Fresh Pd-Rh/40 h Aged
Pt-Pd-Rh/40 h Aged Pd-Rh/80 h Aged Pt-Pd-Rh/80 h Aged
Fresh Fresh40 h 40 h 40 h80 h 80 h 80 hFresh
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InGas 24 months meeting: SPB2/WP2.2
Sample Fresh S-poisoning* Lean regeneration
@ 750°C
Rich regeneration
@ 600°C
Ecocat 74%** 28% 15% 50%
Pd/Al2O3 68 % 3% 17% 39%
Pd/CeO2-Al2O3 70% 3% 10% 55%
Pd/La2O3-Al2O3 63% 3% 6% 47%
Pd/ZrO2 47% 0% 42% 37%
*1 g S @ 300°C; ** Conversion data under lean conditions @ 350°C
• All the samples suffer for the sulfur poisoning• Significant regeneration achieved under rich conditions at 600°C
• S-poisoning/regeneration behaviour (powder samples)
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InGas 24 months meeting: SPB2/WP2.2
• Effect of Sulfur poisoning on Ref. catalyst
• DeSOx1: λ= 1 up to 750°C• DeSOx2: λ= 0.9 up to 750°C
=> Stoichiometric desulfation leads to nearly complete sulfur removal
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InGas 24 months meeting: SPB2/WP2.2
0 3 6 9 12 15 18 21 24 27 300
10
20
30
40
50
60
70
80
90
100
T=60s T=30s T=20s T=10s
Time [min]
CH
4 con
vers
ion
[%]
T = 450°C
150 200 250 300 350 400 450 500 550 6000
10
20
30
40
50
60
70
80
90
100 GHSV=100000h-1
GHSV=50000h-1
CH
4 con
vers
ion
[%]
Temperature [°C]
Ramp UP
• Identification of superior and more stable CH4 conversion performances under -sweep (0.98-1.02) than under constant feed conditions
-sweepConstant feed
• Improvement by the operation strategy (reference catalyst)
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InGas 24 months meeting: SPB2/WP2.2
• Ideal operation point is correlated to temperature and lambda• Sligthly rich operation under transient conditions improves CH4 conversion
• Improvement by the operation strategy (reference catalyst)
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InGas 24 months meeting: SPB2/WP2.2
• NOx Storage Catalyst
• Regeneration of NSC possible with methane above 400°C• Hydrogen can be produced by engine and it enables the regeneration at lower temperatures
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InGas 24 months meeting: SPB2/WP2.2
• The samples for the first round tests in engine bench
Samples for the test in AVL:• Ceramic substrates• 152,4 X 101,6 x 76,2 mm • V = 0,93 dm3, 600 cpsi, 3,5 mils• Washcoat K5.7, 50 g/m2:
– Sample 1: 170 g/cft Pt:Pd:Rh 0:40:1– Sample 2: 200 g/cft Pt:Pd:Rh 0:39:1– Sample 3: 200 g/cft Pt:Pd:Rh 1:38:1– Sample 4: 300 g/cft Pt:Pd:Rh 0:59:1
• Coated by Ecocat – canned by Catcon
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• Conclusion– Developed mixed oxides are better than systems described in the
literature but not alternatives for Pd based catalysts– Novel active Pd based formulations have been indentified and
scaled up for real catalytic testing, showing better performances than the reference catalyst
– Additional Pt on reference catalyst improved durability– Sulfur poisoning is an issue for the Pd based catalysts, but
regeneration is feasible– Operation strategy based on optimal controlling of lambda
oscillation provides improvement of catalyst performances
– Deliverables • DB2.4 CH4 kinetics/model and DB2.7 Catalyst samples Gen. 1/new
formulations
InGas 24 months meeting: SPB2/WP2.2
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InGas 24month meetingOct. 27th/28th 2010
Brussels
WPB2.3: Exhaust heating/Catalyst concepts
USTUTT/DELPHI/DAIMLER/KATCON
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• Improvement of operation strategies (cold start) based on simulation model
Outline / focus of 2nd year activity
• Experimental investigation of laboratory scale hex (USTUTT)
Identification of three main cold start strategies (DB2.9) (USTUTT)
• Successful development/manufacturing of bench scale prototype + setup (DELPHI / USTUTT / ECOCAT / KATCON)
• Design improvements for 2nd generation hex
Task B2.3.2
Task B2.3.1/2.4.1
Task B2.3.3
• Cold start experiments
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Development work TB2.3.3: Experimental investigation of lab scale EAT
FIC
Air
H2
CH4
FIC
FIC
TIR TIR
TIR
TC
Hood
TIR TIR TIR TIR
TIRTIRTIR
FID
PIR
PIR
General conditions:• Air flows up to 30 m3/h• CH4 conc. up to 5000
ppm • Inflow temperatures:
20 – 400 °C• Fuel lean operation• Hydrogen-assisted
heat up
Flowchart of test rig:
Measurement of axial temperature profiles, Δp, CH4 conversion
Assess heat exchanger efficiency, i.e. determine amplification factor adF T
Ta
max
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Strong influence of axial heat conduction in wall material!
Relation between hex efficiency and Amplification
factor:
Ahex
11
ICVT: 73 – 78 %
Delphi: 71 – 78 %
Both heat exchanger reach defined targets
Development work TB2.3.3: Experimental investigation of lab scale EAT
• Tin = 278 – 293 °C; Tmax = 630 °C; yCH4,in = 3400 – 4400 ppm
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Development work TB2.3.3: Cold start experiments: Cold start burner
1. Standalone Investigation of Promeos cold-start burner :• Characterization of stationary output (power, exhaust composition, mass flux)• Ignition procedure (burner exhaust + secondary air)
2. Cold start experiments with attached heat exchanger:• Burner exhaust + secondary air exit through outflow channels
• Same target temperature (600 °C) as for experiments before Lower values measured for CH4
intake due to backpressure of hex Setup with air fan and passive fuel
dosage is not appropriate
• Burner replaced in favour of more reliable and promising cold start solutions!
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Development work TB2.3.2: EAT operation strategies / simulation work
• Development of different operation strategies with simulation tool. Details can be found in DB2.9 (EAT operation strategy I)
• Basic idea: replace cold start burner with bypass/flap setup:
• Normal mode:Exhaust flows through
inflow and outflow channels of hex
• Bypass mode (test bench only!):
Hex is separated from exhaust flow
Protection in case of engine malfunction
• Cold start mode:Hot exhaust enters hex
at U-turn and exits through outflow channels.
Cat. light-off can be further reduced with H2 / CO – rich exhaust
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Development work TB2.3.2: EAT operation strategies / simulation work
• Bypass-Flap-Strategy simulated over complete NEDC:
• Exhaust via bypass from 0-80s
• During bypass phase, addition of hot gas flow
• After this phase, switch to normal mode
• EU 5/6 THC limits undercut in ANY case
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Development work TB2.3.2: EAT operation strategies / simulation work
• Simulation results were promising for bypass/flap strategy:
• System will be tested with 1st generation bench scale prototype at AVL
• Additionally, an electrically heated pre-cat will be implemented in the 2nd generation bench scale prototype:
Emitec EMICAT®
• In combination with hex, only short initial operation period required Rapid heat up Good controllability No secondary emissions
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Development work TB2.3.2: EAT operation strategies / simulation work
• Electric heater strategy simulated over complete NEDC:
• Heater operation during bypass phase (0-80 s)
• After this phase, switch to normal mode
• EU 5/6 THC limits significantly undercut
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• Main challenge during 2nd year: Scale-up of manufacturing process, i.e.:
Development work TB2.3.1: Hex development
• Assembly of “tubes” and stack: 1st brazing
• Attachment of header plates + 2nd brazing:
DELPHI: Scale-up is delicate due to multiple brazing steps!
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outflow
outflow
inflow
inflow
outflow U turn
outflow
outflow
inflow
inflow
outflow U turn
311
34
Development work TB2.3.1: Bench scale prototype development
Different approach proposed: split hex core into 4 single modules
Total cross sectional surface is increased by a factor of 6.7 Similar GHSV as laboratory experiments
Welding
TWC
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Development work TB2.4.1: Bench scale prototype development
Uncoated, single core (1 of 4) after brazing:
Complete package after coating and welding:
Insulation
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Development work TB2.4.1: Design improvements for 2nd generation hex
Channel height 2.9 mm
Channel width 50mm
Number of tubes 14x4=56
Number of channels 27x4=108
Metal sheet thickness tubes 0.15 mm
Metal sheet thickness fins 0.15
Cell density hex/coated part 133/250 cpsi
Coated length 120 mm
Overall finned length 301 mm
Channel height 2.9 mm
Channel width 50mm
Number of tubes 14x4=56
Number of channels 27x4=108
Metal sheet thickness tubes 0.15 mm
Metal sheet thickness fins 0.075 mm
Cell density hex/coated part 250/250 cpsi
Coated length 100 mm
Overall finned length 301 mm
• Gen. 1: • Gen. 2:
• Benefits: Lower thermal mass reduced thermal inertia Higher cell density heat exchange surface increased Decreased coated length increased hex length increased amplification
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Conclusions
• Simulation (Task B2.3.2):
Identification of EAT operation strategy on laboratory scale at USTUTT Promeos burner tested with coupled heat exchanger
• Engineering (Task B2.3.4):
Cold start strategies identified for efficient hex heat up (DB 2.9 ) Identification of hex design improvements
• Experimental (Task B2.3.3):
1st generation of laboratory and bench scale hex successfully manufactured by DELPHI, ECOCAT and KATCON (DB 2.5+2.6 )
Design modifications for 2nd generation defined
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Outlook
• Experimental (Task B2.3.3):
Tests with lambda-oscillations Testing of 2nd generation laboratory prototype: Setup of bypass/valve system similar to engine test bench + Cold start tests
• Simulation (Task B2.3.2):
Further improvement / validation of simulation model, based on lab and bench scale tests
Basic investigation of NSC strategy Simulations with non-NEDC data
• Engineering (Task B2.3.4):
2nd generation bench and laboratory scale prototypes (DB 2.10)
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24 Month Meeting Brussels,Subproject B2, WPB 2.4
AVL/DAIMLER
Status AVL (month 13-24) -Marko Certic , AVL List GmbH
Alois Fuerhapter, AVL List GmbH
INGAS Subproject SPB2
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• Main objectives:– To do baseline tests as input for the catalyst development – To perform engine tests with new TW catalyst formulations – To perform engine tests with HEX system – To develop operation / calibration strategies for HEX/EAT system – To evaluate the emission potential of EAT system
• Status Summary:– MCE engine is having various hardware problems causing delay also in A2 project
(camshafts phasing, cylinder head damage, DI injector not stabile, blow-by system, valve train, cyl. head bolt threads in block)
– Baseline testing performed both with DI and MPI, data evaluated and used as input for development of new catalyst coating formulas
– EAT/CH4 catalyst evaluation started – 2 formulations are tested in preconditioned condition
– HEX system on engine test bed ready for testing
SPB2: Overview WPB2.4
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INGAS – SPB2 – 24-Month Meeting Brussels 27/28 October 2010INGAS – SPB2 – 24-Month Meeting Brussels 27/28 October 2010 41
SPB2: Baseline investigations with H2 analysis
No. N BMEP MD PWR
- 1/min bar Nm kW
1 750 0.72 10.3 0.809
2 1200 0.72 10.3 0.809
3 1600 2.01 28.66 4.801
4 1600 3.41 48.76 8.169
5 1600 4.71 67.37 11.287
6 1800 3.4 48.55 9.153
7 1800 6.02 86.08 16.229
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SPB2: HEX setup on the test bed
HEX monolith
Status of work• Mechanical installation completed
• Test program defined in cooperation with DAI/USTUTT
• Exact operation with three flaps to be defined
Flaps
TWC(to compare sizes)
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SPB2: Catalyst heating with strategy similar to DI gasoline engine
0
10
20
30
40
50
60
70
80
MF_NOXEO MF_THCEO MF_EXH IMEP-Var SA SM_VAL2(multiplied by 100)
T_bef_cat(divided by 10)
[g/h] [g/h] [kg/h] [%] [°CAaTDC] [FSN] [°C]
InGAS DI single
InGAS MPFI
InGAS DI double
Refernce gasoline same T_ex
Refernce gasoline opt
No significant difference between DI and MPI for homogeneous operation
Significantly lower gaseous emissions at same exhaust gas temperature for postinjection, but combustion stability and soot emission have to be improved
N=1200 rpmBMEP= 1 bar
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0.50
1.82
0.60
1.4
2.8
1.04
2.73
6.03
0.99
1.37
4.21
2350
110
2040
116
CO [%] THC [ppm] deltaT exothermic [K] VPI[%] Smoothness Index[%]
Cylinders balanced, EOI 220Cylinders balanced, EOI 70 (1%CO)Cylinders unbalanced, EOI 220 (1%CO)
With DI technology cylinder unbalancing is possible, increasing CO and O2 content which promote exothermic reaction in catalyst
SPB2: Advanced operation strategy for Cat heating
At the same (increased) CO content the strategy of unbalanced cylinders shows better combustion stability and better over all running smoothness
N=2000 rpmBMEP= 2 bar
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INGAS – SPB2 – 24-Month Meeting Brussels 27/28 October 2010INGAS – SPB2 – 24-Month Meeting Brussels 27/28 October 2010 45
• Testing plan and measurement procedure defined together with Daimler
• EAT/CH4 catalyst testing steps
– Evaluation of each catalyst formulation itself by exact defined procedure for advanced catalyst characterisation
– Testing of advanced operation strategies • cylinder unbalancing for enhanced exothermic CO reaction• lambda oscillations (toggling) to simulate real life operation
• Following 2 samples tested at the moment
– cat #1: commercial product with 300 g/cft
– cat #2a: protoype cat with 170 g/cft
• Further 2 samples with different formulation are delivered to AVL last week and will be tested within the next weeks
• Measuring procedure to be improved if possible in order to shorten total time required per catalyst and to improve quality of resutls
SPB2: EAT/CH4 Catalyst Evaluation
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• Peak of conversion reached with rich mixture• Exact positioning of conversion peak is
temperature and/or engine operating point dependant
• Improvement of light off through adaption of lambda strategy
• Further improvement expected with usage of advanced engine operating strategies (cylinder unbalancing)
Methane conversion & Temperature rise in cat1600rpm/4.7bar bmep
0
20
40
60
80
100
120
0,850 0,900 0,950 1,000 1,050 1,100 1,150
Lambda [-]
Met
han
e C
on
vers
ion
[%
],
Tem
p. r
ise
in c
atal
yst
[K]
Cat #2a
Cat #1
SPB2: Lambda variations for TWC characterization
Comparison after PreconSummary Best points from Characterisation Step2
0
20
40
60
80
100
120
140
160
100 150 200 250 300 350 400 450 500
Temp. before cat [deg C]
Me
tha
ne
Co
nv
ers
ion
[%
],
Te
mp
. ris
e in
ca
taly
st
[K]
0,96
0,97
0,98
0,99
1,00
Lam
bd
a fo
r o
pti
mu
m c
on
v.
effi
cien
cy [
-]
Cat #1 Methane conv.
Cat #1 Temp. rise
Cat #2a Methane conv.
Cat #2a Temp. rise
Cat #1 Lambda opt.
Cat #2a Lambda opt.
Cat #2a
Cat #1
Comparison before PreconSummary Quick Characterisation (Lambda 1.00 +/-0.005)
0
20
40
60
80
100
120
100 150 200 250 300 350 400 450 500
before cat temp. [deg C]
Met
han
e C
on
vers
ion
[%
], T
emp
. ris
e in
cat
alys
t [K
]
Cat #1 CH4 Conv.
Cat #1 delta T
Cat #2a CH4 Conv.
Cat #2a delta T
Cat #2aCat #1
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• Continuation of advanced catalyst testing according to test procedure– 2 catalyst samples with 200 g/cft available and to be tested
– 1 catalyst sample with 300 g/cft is in procurement
– 2 additional sample open
• Tests with advanced operation strategies from combustion side (e.g. cylinder unbalancing)
• HEX System testing– basis evaluation same as for other prototype catalysts
– development of the strategies for operation with HEX
SPB2: Next Steps in WPB2.4 AVL (month25-30)
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SPB2: Summary / Conclusion
WPB2.2: Advanced catalyst development
- Developed mixed oxides are better than systems described in the literature but not alternatives for Pd based catalysts
- Novel active Pd based formulations have been indentified and scaled up for real catalytic testing, showing better performances than the reference catalyst
- Additional Pt on reference catalyst improved durability
- Sulfur poisoning is an issue for the Pd based catalysts, but regeneration is feasible
- Operation strategy based on optimal controlling of lambda oscillation and lambda setting provide improvement of catalyst performances
- Implementation of the NSC technology on a CNG engine possible. Regeneration of NSC with H2 generated in the rich phase
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WPB2.3: Exhaust heating – Catalyst concepts
- Identification of EAT operation strategy on laboratory scale
- Cold start strategies identified for efficient HEX heat up
- Identification of hex design improvements. Implementation on 2d generation HEX
- 1st generation of laboratory and bench scale HEX successfully manufactured
WPB2.4: Engine testing / EAT system management
- Baseline testing performed both with DI and MPI
- Engine measures for faster lightoff identified
- EAT/CH4 catalyst evaluation started – 2 formulations are tested in preconditioned condition. Improvement of light-off through adaption of lambda strategy
- HEX system on engine test bed ready for testing
SPB2: Summary / Conclusion
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INGAS – SPB2 – 24-Month Meeting Brussels 27/28 October 2010INGAS – SPB2 – 24-Month Meeting Brussels 27/28 October 2010 50
SPB2: Road Map Catalyst / HEX testing
INGAS - SPB2 New Time TableYear2 Year3
Month Main Partner 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
DB2.6 Bench proto.1 (Delphi)DB2.7 Catalyst samples Gen.1/new formulations (Ecocat)
Input Deliverables DB2.8 CH4/NOx operation strategy (DAI)DB2.9 EAT Operation strategy 1 (ICVT)
DB2.10 Bench/vehicle proto.2 (Delphi)DB2.12 Catalyst samples Gen.2/new formulations (Ecocat)
WPB2.4: Engine Testing/EAT System ManagementLeader: AVLPartner: DAI, ICVTTaskB2.4.1: Engine/EAT Set-up/Base Line Investig. AVL
AVL
TaskB2.4.2: EAT/CH4-Catalyst Evaluation AVL, DAI HEX CH4 Cat. HEXDB2.11 EAT operation strategy 2 (AVL)
WPB2.5: Engine Bench System Integration/OptimizationLeader: AVLPartner: DAI, Delphi, ICVTTaskB2.5.1: System Integration/Calibration AVL HEX
TaskB2.5.2: System Management/Optimiz.Transient AVL HEX CH4 Cat. HEX + Cat. In SPA2DB2.13 Vehicle/EAT/Strategy to A2 (DAI)
DB2.14
Results Summary/Assessment
to B0.2 (DAI)
MilestonesMB2.2 Potential Heat exchanger Concept/New Catalyst Formulation demonstrated
MB2.3 Principle Feasibility demonstrated
Catalysts tested: Catalysts tested: Catalysts tested:Pd/Rh 170 g/ft3 Pd/CeO2 200 g/ft3 Best formulationPd/Rh 200 g/ft3 Pd/CeO2 300 g/ft3Pd/Rh 300 g/ft3 New formulationPt/Pd/Rh 200 g/ft3
Catalysts tested:Pd/Rh 170 g/ft3Pd/Rh 200 g/ft3Pd/Rh 300 g/ft3Pt/Pd/Rh 200 g/ft3
Catalysts tested:Pd/CeO2 200 g/ft3Pd/CeO2 300 g/ft3New formulation ?
Catalysts tested:Best formulation
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