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E.c.o,c'TXt- lbonairFresh ldea3 - Cleaner Future
Emission Techniques and Related SCRSystems by Ecocat and Albonair
ISilke Jürgens, AlbonairToni Kinnunen, EcocatTeuvo Maunula, Ecocat *fs-
25.5.2012
WWWECOCAT.COM WWW.ALBONAIR-COM
Gontents
o Ecocat and Albonair collaboration
o V-SCR catalyst
o Urea dosing technologyo Optional elements
o Hydrolizing catalysto Ammonia slip catalyst
o Summary
É,coclxf
Ecocat in Brief
Overview
Ecocat Oy ("Ecocat") is a leading emissiontechnology company operating in the growingmarket for catalytic convefters
r Leading industry pioneer with market presence
since 1985
r Ecocat is 150-T516949 and ISO14001 ceftified.
Broad range of application areas in the globalmarkets for
r Passenger & light commercial vehicles
r Heavy commercial vehicles (trucks, busses)
r Off-road (agricultural, rail, marine)
r Industry (stationary engines, VOC incinerators)
Capabilities for complete delivery of catalyticconvelters from substrate to canning
r In-house manufacturing of durable metallicsubstrates
r Coating expeftise for both metallic and ceramicsubstrates Canning capabilities for differentcatalyst types
ä
I
E,c.o,C,'Xf
Ecocat Group
\
\\
-/2^-Tt/
\JT\
nland
Finland h'Cþs
V
{' )ttf?
Nizhniy
ng
â-)$
/Ghina
Italy - Genoa
lran - Tehran\- Faridabad
0
JU
' Approximately 290 employees in five countries
' Sales agents close to customers
)
Éc.o,c,lxÍ
Ecocat's Products are Organized Around Four Business Areas
Passenger and LightGommercial Vehicles
lndustry
Heavy CommercialVehicles
É,g,oq'tl,r ir
Off-Road
Albonair - Company OverviewDevelopment of Albonair
Albonair isfounded as partof Hinduja'sAutomotiveSector100% privatelyowned byHinduja Group
ì
2008
Albonair deliversfirst prototypes ofSCR-Systems tocustomers
Albonair India isfounded to set up aproduction facilityfor a local customer
SOP of exhaustaftertreatmentsolutíons for thelndian marketAlbonair movesinto a newheadquafter inDortmund,Germany
SOP of EUROVl-UDS for anEuropean OEM
t
2007 2009 20'10 2012
Þ
Éc.o,q'rlT bonair
Albonair - Company OverviewGlobal Presence
Dortmund, GermanyHeadqua rterR&D
Sales
Customer Service
Ej
Detroit, USATesting facilitiesSales
Customer Service
Chennai, lndiaUrea Dosing Assembly Line
Housing Assembly Line
Sales
Customer Service
Taicang, ChinaUrea Dosing System assemblylineHousing assembly line
Sales
Customer Service
ECOCrlf bonair
bonairE.g,o,C'l,,jf,/ ,/Fast growing European company, OEM supplier status
,/,/High-class technology for diesel exhaust aftertreatment
,/ ,/Flexibility and intimacy to solve customers' challenges
,/,/Focusing on the key projects
,/,/Global presence with covering customer interface
,/ ,/Localized production sites and competence centers toserve customers
,/All the catalytic elements available, substrates andcoatings together with canning
r/All the SCR urea dosing system dosing componentsand system integration know-how available
Two companies matching perfectly to enhance own success togetherby prov¡d¡ng complete customized and well-integrated solutions
ECACIIT bonair
Complete diesel aftertreatment system
SCRDOC DPF
NOx à N,Urea ) NH3 NH3 ) N2 PaÉicle mass ) CO2coà co2Hydrocarbons ) CO2 and HrONO)NO2
_>
oUINJECTION
Based on application, normally only some of above are needed
Ecocat has the whole range of catalysts ¡n portfolio;substrates and coat¡ngs
Together with partners, the complete systemstailored to fulfill customers requirements
E,COCIIT bonair
ECOCIIT lbonairFresh ldea3 - Cleaner Fulute
WWW.ECOCAT.COM WIA'W.ALBONAIR.COM
Reactions in SCR systems
PreOxicat NO+O,
Hydrolysis CO(f{Hr)rCO + HrO CO,
SCR catalyst
PostOxicat 4 + 3Or+2Nr*6H2O
Optimization of DOG together with H-kat and SCR needed:NO, formation, backpressure, temperatures and costs
2NH3
NH3fast SCR
4I\H3
OzÐ4Nr+6HrO
NO
N02-SCR
standard SCR 4 NO +
4Nr+3H2O
3 Ñ, Ð 3.5 N, * 6Id.zO
É,COC,\T bonair
SCR activity by eng¡ne experiments
Criteria NO* conversion at 280"C
100
80
60
20
¡AI¡¡¡¡¡¡a!
40
sc¡-.9ãg. o-
94ãgðzz
0.7 0.8 0.9 1
Nominal NH3/NOx
NHr slip <20 ppm
--> 98o/o NO' conversion
1.2
0
1.1
Éc,ocr\T bonair
SCR activity by engine experimentsEngine 6.9 L; Catalyst 12.8L,500 cpsi
NOx conversion curve
àe^ÃFctrocL'õ cL
þRtrVO(ÐfJ-
-ð=z
100
80
60
28.000 h-1
465 ppm NO,61 . OOO h-1
1170 ppm
57. OOO h-1
990 ppm NO,
16.500 h-1
1420 ppm NO,
51.OOO h-1
930 ppm NO*
300 350 400 450Temperature, oC
40
20
0
200 250 500 550
É,c.oc,rlf
Effect of NH3 slip criteria limit
Urea€CR engine results- MAN 6.9L, 15 h agedKSCR2,500 cpsi,'12.7L
100
E90CL
å80s!s70ä60$9'oaz840x230(!'Ê 20o,
¿5 10
0
200 250 300 350 400
Temperature, oC
450 500 5s0
) No significant changes in performance) without any additional NH3 slip catalyst
eo.ooo h4SI.OOû trr
tS.SO0 trr
st.ooo ha s8.ooo trr
+ KSCR2, 20 ppm NH3<-KSCR2, l0 ppm NH3
Eco,g,'\T bonair
Effect of cell density (surface area)
Extruded ref
Ecocat 220 cpsiEcocat 350 cpsi
3o.ooo n"s1.ooo h"
61.ooo n' 58.ooo n"16.S00 tr"
Ecocat 500 cpsi Target conversions
Euro 6/tTS20l0100
90si80Ë170Ë= Go
8ã so
gR'40Ev 30
Ë20oro0
Euro 5
Euro 4
200 250 300 350 400
Temperature, oG
450 500 550
Ec.o,C,TXf
Ecocat SCR: the fïrst EPA and CARB approval for V-SCR (off-road)
Ér, srnè", UNITED STATES W PROTECTION AGENCY
OFFICE OF TRANSPORTATION AND AIR QUALITY.WASHINGTON-
DC 20460
EO Sra ¡6."
zfJq
CERTIFICATE OF CONFORMITY2OIO MODEL YEAR
Manufacû¡rer:Engrae Farnily:
.{æO SIS[, PO\\IER I]iC.-{sil)L08.4H6jl'
IR RESOURCES BOARD Acco stsu DIESEL lilc.I. Ne¡¡r Off-Road
Com pression-lgnition Engines
USEFUL LIFE(hours)
8000
TYPICAL EQUIPiIETTT APPUCATION
DISPL.ACEIUEilT(libn) FUEL TYPEENGINE FATILYMODEL
YEAR
8.4 & 9.8 DieselASIDLO8.4H6A2010
SPECIAL FEATURES & EIU]SS¡ION COHTROL SYSTEHS
Direct Cooler,E ter,
É,c.o,g.I\T
ïractor
High-Temp SCR
a
The reasons to develope improved V-SCR for high-temperature applications
The SCR chemistry need to be durable for high-temp applications, too. Of-road full-load drivings. Need to be applicable for the usage together with DPF (Euro5 and beyond). Cu-zeolite limitations (NrO formation, sulphur sensitivity, NO, sensitivity)
Éc,o,q'rxf bonair
a
a
Laboratory resultsHT700/20hlnlet: NO 1000 ppm, NO, 0 ppm, NH3 1000 ppm,Or10 o/o, H2O I %, N, bal.
600 cpsi, SV = 50 000 h-1
100908070605040302010
0
-10-20
150 200 250 300 350 400 450 500 550 600Temperature, oC
a
s,9g,otroox
oz
HT700"Ct20h1000 oom NO \.
\\
1+ Thermally sta ble VSCR-wl+Std V-SGR-w1249 REF
Ec,o,C,/XÍ bonair
a
a
Laboratory resultsHT700/20hlnlet: NO 600 ppm, NO2 400 ppm, NH3 1000 ppm, Or10 o/o, H2O 8 %, N, bal
600 cpsi, SV = 50 000 h-1
100908070605040302010
0
-10
-20
a
si.9g,otro()xoz
150 200 250 300 350 400 450 500 550 600Temperature, "C
HT700'C l20h600 ppm NO400 ppm NO,
+ T hermally sta ble V-SC R-w1241
+ Std V-SCR-w1249 REF
/
\-I
! I
E.co,c'tNf
Eco,C,lxf lbonairFre3h ldeas - Gleaner FuluTo
WWW.ECOCAT.COM WIIVW.ALBONAIR.COM
AI bonai r Prod uct Portfol io
Diesel Particulate FilterDiesel Oxidation
Catalyst
Selective Catalytic Reduction System
DPF I DOC Urea Tank ACU & UDS
C
SCR-Muffler & Nozzle
q..
,) Albonair offers complete exhaust aftertreatmentsystems
t
É,c.o,c,txf bonair
Urea Dosing Units for Different Markets
EURO 4 (e.g. Emerging Markets)
@
EURO 6 (e.9. Europe)
å
o
Tier 4 Final (e.g. Off-Road vehicles) EURO 6 Passenger Car (e.9. Europe' USA)
E,c.o,Ç,IlT bonair
Products & TechnologyLocation of Products
u ¡.:A lå¡lli
r-r- -n.1,- n
I'I'ST Eh"I JTE õP ATI EI Ii5CF
F.'lUFFLERUR=q
irü 5lll:i 5 T STE lr,1
{''tËt
t II
l,-- -------- ---.¡-
-17
,-r-
-]
Ec.o,C,tXÍ bonair
Concept of Albonair's SCR SystemSchematics
Urea level
Urea temperature
EngineCoolant
Urea
Air
Air Supply (vehicle
air or electrical airpr
Dosing System
Air pressure
Urea pressure
CANUrea temperature
Electronics (ACU)
Actuators
Air
Urea Sensors
SCR Muffler with lnjection Nozzle
Temp Nozzle NOx
Exhauststream
AdBlue Tank
ine Coolant
Temp.Sensor
EngineECU
sil-.\-,-5-T
Eq,o,g,T\f ir
Goncept of Albonair's SCR SystemFormation of Different AdBlue Dosin temss ra
System Spray Formation Characteristics
Pressure Atomizer(Airless)
HotExhaust > Energy for atomization
from the liquid pressure
> lncrease of pressure leads toimproved spray quality
> Energy for atomizationfrom air pressure
> Typically high air consumption
> Energy for atomizationmainly from air pressure
> Low air consumption
> No contact between AdBlue and
air in the dosing system / nozzle
to avoid crystallization and
deposits
Twin Fluid Atomizer with internalmixing(Air Assisted)
Albonair's Concept is based on:Twin Fluid Atomizer withexternal mixing (Air Assisted)
AdBlue
t
Air
HotExhaust
Gas
-}l
..a'-a¡'. "-
t'l-r .'.'. '.'oï;..::.'.'..:.r e .'.'1..o r . . ¡' ' i
iE
AdB ue II
...
o o'3aa
o'raa a*
-+.:
HotExha ust
Gas
-Air
Air +
ECOCr\f
Technical BackgroundEvaporation Rates for Different Droplet Distributions
Albonair Air-AssistedDosing System
>.:c(uôEof-o
i5
@Exhaust velocity 50 m/s and Low temperature (300 'C)
Air.less DoslngSystem
100 300
80
ñ(u
GÉ.coÞGoo-GU
60
40
2096
00 100 200 300 400 500 600
Evaporation Length [mm]
700 800
Even at 300 "C smalldroplets of SMD 2t ¡tmeva porate com pletelywithin 600 mmVery poor evaporationfor big droplets SMD
96 pm
o 200
Particle Size [pm]
É,c.(),C,IIT bonair
Technical BackgroundNH, and HNCO decomposition improve with Albonair UDS
100o/o
80o/o
60%
40o/o
t-]
75o/o 50o/o
@1200 minr
Test Conditions:HD Dieselengine L2l,
Hydrolyse Tube 600mm,Measurement HNCO and NHt
using FTIR
Significant increase of AdBlueHydrolysisBetter Nox-Conversion at the SCR
CatalystLess deposits in the exhaustsystem
0o/o
o/to0
00o/o
co'6oCL
Eooo'1oo
õït80%
60%
40%
20o/o
Oo/o
2
10Oo/o
10Oo/o
25o/o
75o/o 50%@2000 minr
r-l
i"tfl'l
ffia
Albonair: NH.
Albonair: HNCO
Airless: NH.
Airless: HNCO
bonair
25%
É,COC,IT
Gatalyst Eff¡ciency improved at low Exhaust Mass FlowLittle NH.-Slip
Low Exhaust Mass Flow
200 - 250 kelh100
90
80
ñoooc' 70coIÀ
o
860r.,*oz
50
40.#Albonair
{-Airless30
775 2r5 235
Temperature ('C)
19s 255 275
High Exhaust Mass Flow
500 - 1000 kelh100
90
80
sooÉ' 70trolrt
oE60o(,Ixoz
50
40*Albonair
*Airless30
215 235
Temperature ('C)
175 195 255 275
É,coctlT
The importance of proper urea distributionAdBlue Concefitr¡t¡ol(normolhcdl
4.003.r03.603.¡10
3.203.002 ôr')
2.ó02.402.¿02.00t.801.60t..0t.20t.000.E0
0.600.400.200.00
Proper design is an essential part of SCR technology to ensurethat urea is well distributed and decomposed to ammoniabefore SCR catalyst Ad8luc Concmù¿úm
(noímlBcd)
4.003.E03.603.{03.20l.o02ìO2.60¡.102.202.001,801.601a0r20to00,r00.600.400,200.00
É,c,o,c,llT ir
ECOClITlbonairFTesh ldeas - Cleaner Fulurc
WWW.ECOCAT.COM WWW.ALBONAIR.COM
Urea hydrolysis
Thermal or catalytic hydrolysis of urea important in thelimited space of exhaust lines at Iow temperatures
(NH z)zCO > thermolysis
HNCO + HzO > hydrolysis
+ enhancement with EcoXcell mixers in particular at low temperatures+ possible to have good mixing, urea nozzle near to SCRand combinatory properties
Ec.o,c,tlT ir
Metallic substrate for mixers and H-catalysts
EcoXcell@. Welded, mixer-type structure for coated catalysts having efficient 3D mass
and heat transfer. EcoXcell 20" for SCR applications+ Hydrolysis catalyst coating+ SCR catalyst coating
ECOÇ,llT
fm 3^-ll
C,I }G'
Velocity(Ve<tor 1)
.. 104.5
69.7
34.8
0.0
[m s^- l]
É,coctlT
How to utilize H-cat in SCR?
1) Combination of SCR catalyst coated EcoXcell mixer-catalyst and SCR catalystmixing and total SCR catalyst amount
Exhaust gas
*Urea
2) Small EcoXcell substrat e (25 cpsi) as urea dosing mixer: to enhance hydrolysiscatalyst reactions to avoid any urea accumulation
Exhaust ga5++Urea
Note: also inlet tube (and cone) surfaces can be coated by H-Cat,to avoid any accumulation and coffosion
Eq.o,c'ttT bonair
H cat onlylaboratory experiments
Product distribution with blanco substrateNominal inlet: 1000 ppm NO, no NOrr 500 ppm Urea, l0'/' O2r8 oÁ H2O, N2 balanceSV = 100 000 h-l
Urea hydrolysis products- blanco substrate
1200
ECLCL
0
1 205 230 260 300
Temperature before cat, oC
350 450
1
600
400
200
n NOx
r HNCO
r NH3
80
-25 % of urea unreacted, îo additional NHt
oo¡oo¡ooaolooaoo
unreacted urea
E,c,o,C,tNf
H cat onlylaboratory experiments
Product distribution with HT700 KHI.1+KH2.2 (good adhesion/improved selectivity)Nominal inleû 1000 ppm NO, no NO2,500 ppm Urea, l0 o/o O2r8 "/" H2O, N2 balanceSV = 100 000 h-l
Urea hydrolysis products- KHl .1+KH2.2 (w8090-200 cps¡)HT700 aged
0
1 205 230 260 300
Temperature before cat, oC
350 450
zECLçL
1200
1 000
800
600
400
200
! N20
tr NOx
I r HNCO
r NH3
80
ooaoolooaoaaounreacted urea
ot
Almost only NH3!!
no by-products
É,g.Q,c,llT
The enhancing effect of H-kat at low temperature
T
NOx conv.To NH3 slip <20ppm
100
90
80
70
60
50
40
30
20
l0
r NOx conv.To NH3 slíp <20ppm
01500 mm no H-kat '1500 mm no H-kat 550 mm with H-
(245 deg C) (285 deg C) kat (245 deg C)550 mm no H-kat 550 mm no H-kat
(245 deg C) (285 deg C)550 mm with H-kat (285 deg C)
Significant effect on SCR acitivity by utilising H-kat in front of SCR obtainedStudied by 4.9 lengine (H-kat size D105 x L 100 mm)
É,COCI\T bonair
The role of ASC, NH3 slip control
cASof
98 98 98 99 98
ECLCLoN
si.9g.oco(J
xoz(ú
o+,'tro
100
90
80
70
60
50
40
30
20
10
0
MODE 10 (230.C) MODE 9 (260"C) MODE3 (310"C) MODE2 (400'C) MODEI(480'C)
88
230"C
2o.ooo h-t 480'Cst.ooo n-t
310'C¿3.ooo n-t
400'c48.ooo h-t260'C
t g.ooo n-t
N Pt-DOC+KSCR2-300 cpsi FRESH
r Pt-DOC+KSGR2 300 cpsi - Burner aged 570'C/100h
ø Pt-DOC+KSGR2-300cpsi+4PUASC- Burner aged 570'C/100h
7779 77
66
Éc.o,g'tlT
SUMMARY
Ecocat-Albonair combination provides uniquê, one source solution
All the elements available for meeting Euro6 requirements
SCR chemistry proven to be extremely durable
Gompetitive and cost-efficient urea dosing systems
Glear technical benefits for NOx performance
H-CAT and ASC elements available for the most challenging targets
o
o
o
a
a
o
Ec.(',C,,\T