After Treatment Training

8/8/2019 After Treatment Training

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Exhaust Aftertreatment

Advanced Emission Controls


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Content/Objectives

1. To understand engine and vehicle technology relating toemissions.

2. To understand Diesel Oxidation Catalyst (DOC) and DieselParticulate Filter (DPF).

3. To understand Regeneration.4. To understand DPF cleaning.5. Summary.


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Objective 1: To understand engine and vehicletechnology relating to emissions.

Cummins has made a largeCummins has made a large

investment in the developmentinvestment in the developmentof advanced combustionof advanced combustionsystems that reduce enginesystems that reduce engine --

out emissions at the sourceout emissions at the source inside the combustioninside the combustionchamber.chamber.


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One of CumminsOne of Cummins uniqueuniqueadvantages is integratingadvantages is integratingcritical subsystems.critical subsystems.

Cummins FiltrationCummins Turbo Technologies

Cummins Emission Solutions

Cummins Fuel Systems
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Cummins core inCummins core in --househouse

technologies include:technologies include: Combustion technologyCombustion technology Fuel systemsFuel systems ElectronicsElectronics Air handlingAir handling FiltrationFiltration AftertreatmentAftertreatment

CombustionTechnology

Fuel Systems

Electronics

Air HandlingFiltration

Aftertreatment
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The introduction of cooledThe introduction of cooledExhaust Gas RecirculationExhaust Gas Recirculation(EGR) technology in 2002 to(EGR) technology in 2002 tomeet the 2.5meet the 2.5 --g/hpg/hp --hr NOxhr NOx

standards created thestandards created thefoundation for our 2007foundation for our 2007products.products.


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The EGR system takes aThe EGR system takes ameasured quantity of exhaustmeasured quantity of exhaustgas and passes it through agas and passes it through acooler before mixing it with thecooler before mixing it with theincoming air charge to theincoming air charge to thecylinder.cylinder.

During combustion, EGRhas the effect of reducing

flame temperatures, which

in turn reduces NOxproduction--since NOx is

proportional to flametemperature.


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A key component to the CumminsA key component to the Cummins

EGR system is its VariableEGR system is its VariableGeometry Turbo. It features aGeometry Turbo. It features aunique patented oneunique patented one --piecepiecesliding nozzle which movessliding nozzle which moves

continuously to vary the powercontinuously to vary the powerof the turbine and the amountof the turbine and the amountof air delivered to the engine.of air delivered to the engine.

Air Handling

Cummins Turbo Technologies


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Another key component is theAnother key component is theHigh Pressure Common RailHigh Pressure Common Railfuel system, used on Cumminsfuel system, used on CumminsMidrange and HighMidrange and HighHorsepower engines.Horsepower engines. Fuel Systems


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A common rail injection systemA common rail injection systemfirst stores fuel under highfirst stores fuel under highpressure in a common railpressure in a common rail pressures that exceed 25,000pressures that exceed 25,000psi.psi.

Then with the use ofThen with the use ofelectronically controlledelectronically controlledinjectors, fuel is delivered intoinjectors, fuel is delivered into

the combustion chamber.the combustion chamber. Common Rail


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High fuel pressure produces aHigh fuel pressure produces afine mist of fuel that burnsfine mist of fuel that burnsbetter and cleaner in thebetter and cleaner in thecombustion chamber.combustion chamber.

In addition, for eachIn addition, for eachcombustion cycle, the commoncombustion cycle, the commonrail allows up to five injectionsrail allows up to five injectionsper cycle.per cycle.


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With common rail fuel systems,With common rail fuel systems,fuel consumption is improved,fuel consumption is improved,even with the use of ULSDeven with the use of ULSDfuels.fuels.

Because of the high system pressuresand the sophisticated injection system,superior fuel and fuel/water separator

filters are necessary to ensure trouble-free life.


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In order to meet EPA 2007In order to meet EPA 2007emissions regulations, engineemissions regulations, enginemanufacturers must now usemanufacturers must now useadvanced emission control advanced emission control devices.devices.

Advanced emission controldevices refer to exhaustaftertreatment devices or

systems.


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Any post combustion device, orAny post combustion device, orsystem attached to the exhaust ofsystem attached to the exhaust ofthe engine to reduce exhaustthe engine to reduce exhaustemissions, is an aftertreatmentemissions, is an aftertreatmentdevice or system.device or system.

Exhaust aftertreatment canreduce NOx, remove PM,

and in some applications,do both.

Particulate Matter (PM) is aform of carbon (i.e. soot)produced by incomplete

combustion of diesel fuel inthe engine.


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Cummins Engines useCummins Engines useaftertreatment devices thataftertreatment devices thatinclude a Diesel Oxidationinclude a Diesel OxidationCatalyst (DOC), as well as aCatalyst (DOC), as well as a

Diesel Particulate Filter (DPF).Diesel Particulate Filter (DPF).

A Cummins Particulate Filter isthe correct name for our

combination DOC and DPFaftertreatment system.

Aftertreatment


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Now lets discuss what a DOC and a DPFdo in the exhaust system.

Objective 2: To understand Diesel Oxidation Catalyst(DOC) and Diesel Particulate Filter (DPF).


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DOC (Diesel Oxidation Catalyst)DOC (Diesel Oxidation Catalyst)

is a flowis a flow --through honey combthrough honey combsubstrate with a catalyticsubstrate with a catalyticcoating applied to the surface.coating applied to the surface.

As exhaust passes over theAs exhaust passes over the

catalyst, a chemical changecatalyst, a chemical changetakes place, reducing carbontakes place, reducing carbonmonoxide (CO), hydrocarbonsmonoxide (CO), hydrocarbons(HC) and soluble organic(HC) and soluble organicfraction (SOF) of the soot.fraction (SOF) of the soot.

Precious Metal Coating

Straight through design

Exhaust flowSOF is unburned fuel.


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The catalytic coating is a materialThe catalytic coating is a materialused to promote oxidation byused to promote oxidation byincreasing the speed of aincreasing the speed of achemical reaction. It is typicallychemical reaction. It is typicallya precious metal, such asa precious metal, such asplatinum.platinum.

The DOC oxidizes, or converts,NOx (Nitric Oxide) to NO 2

Nitrogen Dioxide.


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DPF (Diesel Particulate Filter)DPF (Diesel Particulate Filter)is a device designed tois a device designed tophysically remove soot orphysically remove soot orparticulate matter in dieselparticulate matter in dieselexhaust.exhaust.

This matter is sometimesThis matter is sometimesreferred to as areferred to as a particulateparticulatetraptrap ..

Note: Cummins refers to a DPFas a filter, not a trap.

Diesel Particulate FilterWall Flow Design

Exhaust flow


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The DPF is placed after the DOCThe DPF is placed after the DOCin the system. As the oxidizedin the system. As the oxidizedNO2 passes through the DPF,NO2 passes through the DPF,it combines with the collectedit combines with the collectedcarbon (C) (soot) to form CO2carbon (C) (soot) to form CO2Carbon Dioxide, which leavesCarbon Dioxide, which leavesthe exhaust system as a clearthe exhaust system as a cleargas.gas.

The DOC oxidizes, or converts,NOx (Nitric Oxide) to NO 2

Nitrogen Dioxide.

NO2 Nitrogen Dioxide combineswith C carbon and becomes CO 2.


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Whats all this about regeneration?

Objective 3: To understand Regeneration.


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Regeneration is the controlledRegeneration is the controlledremoval (cleaning) of Particulateremoval (cleaning) of ParticulateMatter (soot) deposited in theMatter (soot) deposited in thediesel particulate filter.diesel particulate filter.

When operating conditionsWhen operating conditionsmaintain sufficient exhaustmaintain sufficient exhausttemperatures, the dieseltemperatures, the dieselparticulate filter is continuallyparticulate filter is continually

being cleaned.being cleaned.

Cummins engines aredesigned to maximize the

use of passiveregeneration.

This is known as PassiveRegeneration.


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Objective 3: To understand Regeneration. Passive regenerationPassive regeneration is theis the

continuous regeneration whencontinuous regeneration when

operating conditions maintainoperating conditions maintainsufficient exhaust temperatures.sufficient exhaust temperatures.

Soot is continually oxidized in theSoot is continually oxidized in theCummins Particulate Filter to fromCummins Particulate Filter to frominvisible carbon dioxide, so cleaninvisible carbon dioxide, so cleanexhaust comes out the tailpipe.exhaust comes out the tailpipe.

Cummins engines aredesigned to maximize the

use of passiveregeneration.

Passive regeneration is

totally transparent to thedriver.


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Active regenerationActive regeneration occurs whenoccurs whenthere is not sufficient heat in thethere is not sufficient heat in theexhaust. Exhaust temperaturesexhaust. Exhaust temperaturesare raised by injecting a smallare raised by injecting a small

quantity of fuel upstream of thequantity of fuel upstream of thediesel oxidation catalyst.diesel oxidation catalyst.

It requires 15-20 minutesto clean the filter; it does

not need to be continuousand occurs while thevehicle continues to

operate.

The resulting chemical

reaction over the dieseloxidation catalyst raises

exhaust temperatures highenough to oxidize the carbon

from the filter.


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Objective 3: To understand Regeneration.An aftertreatment injector, alsoAn aftertreatment injector, also

known as aknown as a dosingdosing injector,injector,

introduces a small amount of fuelintroduces a small amount of fuelinto the exhaust stream ahead ofinto the exhaust stream ahead ofthe DPF, which increases thethe DPF, which increases thetemperature of the exhaust, but,temperature of the exhaust, but,does not burndoes not burn ..

Dosing injector: Used toinject a small amount of

fuel into exhaust during anactive regeneration

event.Note: There is no actualflame or burning of the fuelthat is injected into the

system.


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Stationary regenerationStationary regeneration is theis theoxidation of soot while the vehicleoxidation of soot while the vehicle

is not being driven. It is performedis not being driven. It is performedbecause the normal driving cyclebecause the normal driving cyclewill not support passive or activewill not support passive or activefilter regeneration (the exhaustfilter regeneration (the exhaustdoes not get hot enough).does not get hot enough).

A few duty cycles (high idletime and short route

segments) occasionallyrequire a stationary

regeneration, such as:

Package delivery thatnever leaves the city

Urban pickup anddelivery trucks

Emergency trucks

Class 8 tractor inCanada at -20 F (orreally cold Celsius) goingfrom stoplight to stoplight


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PassiveRegeneration

Operate the vehicle

normally.

ActiveRegeneration

Dosing occurs there is nooperator interaction.

Put more load on engine requires driver interaction.

ChangeDuty-Cycle

ORStationary Regeneration


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The engineThe engine s Electronic Control Units Electronic Control Unit

(ECU) monitors the DPF(ECU) monitors the DPFperformance through the use ofperformance through the use ofsensors and determines if thesensors and determines if theaftertreatment system isaftertreatment system is

functioning properly.functioning properly.

Electronics


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Theres a lot of discussion regarding cleaning of the DPF what does this all mean?

How is cleaning different from regeneration?

Objective 4: To understand DPF cleaning.


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Cummins is ready with technologyCummins is ready with technologyto meet the 2007 emissionto meet the 2007 emissionstandards. Not only have westandards. Not only have weconducted extensive fleetconducted extensive fleettestingtesting wewe re alreadyre alreadydemonstrating our filterdemonstrating our filter --cleaning equipment andcleaning equipment andprocedures.procedures.


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As the exhaust stream flowsAs the exhaust stream flowsthrough the Cumminsthrough the CumminsParticulate Filter, theParticulate Filter, theparticulate matter gets oxidizedparticulate matter gets oxidizedand oil particles are trappedand oil particles are trappedand converted into ash, whileand converted into ash, whileclean air travels through theclean air travels through thewalls and out the exhaustwalls and out the exhauststack.stack.

Ash: Incombustible material,found in oil additives, that canonly be removed by cleaning.

Ash comes from theoil

Soot or particulatematter (PM) comes

from the combustionprocess

PM is oxidized(regeneration) in theDPF, while ash will

need to be removed(cleaned)


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As ash builds up in the DPF,As ash builds up in the DPF,engine backpressure willengine backpressure will

increase. When theincrease. When thebackpressure gets to a levelbackpressure gets to a levelwhere engine performance iswhere engine performance isclose to being inhibited, aclose to being inhibited, a

signal will be sent to thesignal will be sent to theoperator that it is time to cleanoperator that it is time to cleanthe DPF, at the next scheduledthe DPF, at the next scheduledservice interval.service interval.


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Over time (200,000Over time (200,000 400,000400,000miles [320,000miles [320,000 --640,000 km] in640,000 km] in

a typical linea typical line --haul operation),haul operation),ash will build up and need toash will build up and need tobe removed in a simplebe removed in a simplemaintenance procedure thatmaintenance procedure that ss

quick and convenient.quick and convenient.


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Equipment has been designed toEquipment has been designed toclean the filter by forcingclean the filter by forcingcompressed air through thecompressed air through thefilter in a sealed system,filter in a sealed system,vacuuming the ash into avacuuming the ash into a

plastic collection device.plastic collection device.


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To change the collection device,To change the collection device,

simply disconnect the vacuum,simply disconnect the vacuum,put a lid on the container andput a lid on the container anddispose of it according to localdispose of it according to localregulations.regulations.


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Depending on the size and theDepending on the size and theash load in the particulate filterash load in the particulate filterbeing cleaned, the collectionbeing cleaned, the collectiondevice will last up to a coupledevice will last up to a coupleof months.of months.


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The time required for the actualThe time required for the actualcleaning process varies, but oncleaning process varies, but onaverage it should take less thanaverage it should take less than30 minutes (less than the time for30 minutes (less than the time fora normal engine servicing).a normal engine servicing).

The total procedure, includingThe total procedure, includingdisconnecting and removing thedisconnecting and removing theCummins Particulate Filter fromCummins Particulate Filter fromthe vehicle, cleaning thethe vehicle, cleaning theparticulate filter element, then reparticulate filter element, then re --installing the entire unit shouldinstalling the entire unit should

take about 2.5 hours or less,take about 2.5 hours or less,depending on how accessible thedepending on how accessible themounting of the Cumminsmounting of the CumminsParticulate filter is on the vehicle.Particulate filter is on the vehicle.

* While actual costsmay vary, Cummins

estimates that aparticulate filtercleaning costs $300,

which includesremoval andinstallation.


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The particulate filter cleanerThe particulate filter cleanerruns on standard 110runs on standard 110 --voltvolt

power and uses standard shoppower and uses standard shopair.air.

Attachments are available to fitAttachments are available to fitevery size of particulate filterevery size of particulate filterfrom Cummins and most otherfrom Cummins and most otherengine manufacturers.engine manufacturers.

*This is a real benefitto service

departments, since

regardless of howmany different types ofengines they service,they only need to useone type of cleaning

machine.


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Caterpillar states that their DPF,Caterpillar states that their DPF,which does not include a DOC,which does not include a DOC,

can be cleaned on the vehiclecan be cleaned on the vehicle it does not have to beit does not have to beremoved.removed.

This type of cleaningwould have to occur

where the properequipment is in place

i.e., Caterpillarauthorized centers.

OEMs take different approaches with dealersregarding cleaning equipment and services.VolvoMack for example, does not requiredealers to provide DPF cleaning services.


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While proper maintenance is key,While proper maintenance is key,

engine manufacturers expectengine manufacturers expectthe exhaust aftertreatmentthe exhaust aftertreatmentsystems to last the life of thesystems to last the life of theengine.engine.

Engine life is defined as to thefirst rebuild.


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The particulate filter must be periodically cleaned due to ashbuild- up. Does this relate to the low ash oil being recommended for

2007 engines?



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Using the higher ash CIUsing the higher ash CI --4 oil will4 oil willshorten the DPF cleanoutshorten the DPF cleanoutinterval.interval.

Note: We will discuss in furtherdetail the use of CJ-4 and CI-4

lube oils in the EngineLubrication module.


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Summary.

Exhaust aftertreatment is required on 2007 certified engines to meetthe EPA emission regulations for NOx and PM.

Aftertreatment devices may include a Diesel Oxidation Catalyst(DOC), a Diesel Particulate Filter (DPF), or both.

Cummins uses a combination DOC and DPF, which is called aCummins Particulate Filter.


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Summary.

DDC, MBE, and Volvo-Mack use combination DOC and DPFdevices.

Caterpillar uses a DPF only.

The use of a DOC ensures better soot regeneration, at lower

temperatures, meaning less time in active regeneration.

Service intervals (off-engine cleaning) for the DPF can vary and areestimated by engine manufacturers to be between 200,000 -

400,000 miles for line haul operation.


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Summary.

It is critical to learn about the aftertreatment systems, terminology and

service requirements to understand the diesel engine lubricationsystem and recommended service interval strategies.

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