Diesel Emission Control Review 2007

DieselEmissionControlinReviewDept.ofEnergyDEERConferenceTimJohnsonAugust2007Summary• Regulations– EuropeanLDDregulationshaveimplicationstotheUSapproach– EuropeisformallyproposingEuroVI(HD)thisyear• Widerangeofscenariosconsidered–noindustryconsensus– CO2regulationappearstobethemostdominatinglongtermissue• Enginestrategiesaremakingimpressiveprogress– HDresearchenginesshowverylowPMlevelsundersteadystatefull-loadconditions– AdvancedcombustionmixedmodeenginesareemergingforLDandHD• NOxsolutionsareavailableforultra-lowemissions– SCRisaddressingcoldtemperatureandmixingissues– LNTsareperformingwelltodayatabout60-70%efficiency;hybridLNC/SCRsystemsemerging• DPFsystemsshowcontinuousimprovement– Verysophisticatedregenerationcontrolstrategies.– Newcatalystformulationsaddflexibilityandimprovedperformance– HCmixfromadvancedcombustionenginesmightpresentchallenges2CorningIncorporatedRegulatoryTrendsTosellEuro5carsintotheUSmarket,aminimumof50-60%%NOxcontrolisneededtohita42-statemarket(70%US).ForEuro6(2014),65%additionalNOxcontrolwouldaddressthe50-statemarket.0102030405060708090Addn’l65%NOxcontrolNOx,mg/km050100150200250Euro5,2009-11Bin8Bin555%NOxcontrol85%NOxcontrolNOx,mg/kmEuro6,Bin8Bin52014-154CorningIncorporatedUltrafineemissionsregulationinEuropeismovingforwardECJRC,PMPETHconf8-065X1011/km,dieselonlyEuro5.5particlelimitvaluesof3mg/km;P#5X1011/kmfor2011-12•Bestunfiltereddieselat1013/km,so95%numberefficiencyneeded.5CorningIncorporatedTheEUisconsideringfourdifferentEuroVIscenarios.ScenarioAScenarioBScenarioCScenarioDUS2010Est.FuelPenalty2-3%5-6%neutralneutralvs.EuroV•Number-basedPMstandardsconsidered.•ConsideringalsodoingEuroVII,butwillresultindelay.•Consideringfuelconsumptionvs.criteriaemissiontrade-off.00.10.20.30.40.50.60.70.80.91NOxorPM,g/kW-hrNOxPMX106CorningIncorporatedNon-roadengineandemissioncontrolsystemsaredescribedRegulationsTechnologyDPFsemergeonlyin2014inonesmallengineclass.AVLJune20077CorningIncorporatedNon-Roadhassignificantchallenges• US2007-likeregsin2011– EuropeandUS,withJapantobeformalized– CooledEGRlimitations– DPFsleadingconcept,butsomearelookingaatEuroIV/VSCRapproach• US2010-likeregsin2014– EGR+SCR+DPFseemstobeleading– Muchresistancetourea-SCR• Bestsolutionseemstobemixed-modewithHC-deNOx(LNTorLNC)andDPF– Timingfits• Hugewatchout– NRmovesintoengineeringin2009.ConflictswithUS2010,EuroVI,andUSLDD• Industryresourcecrunch,especiallyinsupplychainandfordynos• MediumsizedNRcompaniesappearbehind,already8CorningIncorporatedAB1493forcesthefleetaverage21%belowthe2006EUfleetactual.37%cutin7yearsrequired100125150175200225250275UStruckCAFE(unreformed)UStruckfleetUScarCAFEUScarfleetEUfleet-14%in11yearsACEAVoluntaryAgreementAB1493LDT2-7g/kmAB1493PC/LDT1-37%in7yearsCO2grams/kmEUTargetSlidecourtesyofMartec19951998200120042007201020132016USandEUtestcyclesarenotequivalent.ARBstandardincludesGHGlossesfromACsystem.AB1493LDT2definitionincludes8,500-10,000lb.gvwMDPVs.Fueleconomyconversionsat19.55lbCO2/gallongasolineand22.43lbs/gallondiesel.USfleetexcludesflexfuelcredits.9CorningIncorporatedVariousapproachescanbeusedtoachievehigherfueleconomy.However,improvementsgetincreasinglymoreexpensive.FEV,AVLEnviron.andMotorConf.9/06Comment:FueleconomyorCO2gainsarenotproportionaltocosts.Thereisapointofdiminishingreturns.Advancedgasoline10CorningIncorporatedEngineDevelopmentsHDDRESEARCHENGINESarehitting0.5/0.015NOx/PMontheESCOnaverage,60­70%NOxcontroland30%PMcontrolareneededtohitsteadystaterequirements0.0100.0200.0300.040PM,g/kW-hr0.050XESCThresholdBosch,SAEHDDSymp,9/05AdvancedEnginesMANCTIconf.;1/07XUnivWIvirtualengineof20010.20.40.60.81.01.21.41.61.82.0NOx,g/kW-hr12CorningIncorporatedHDresearchenginesareshowingimpressiveperformanceundersteadystateconditions.13CorningIncorporatedBothhardware(2-stageboost)andmultivariablecontrolalgorithmshelpintransientcontrolNOxlevelsareabout25%andPMabout10%higherontheUStransientcyclewithproperAVLJune2007transientcontrols.Otherfindingsofinterest:•Transientoperatingmodesarecloselycorrelatedtoaseriesofsteadystatepoints.•%EGRmaybeabettertransientcontrolparameterthanMassAirFloworEGRvalveopening.(Ford,ImperialCollege,SAE2007-01-1938)14CorningIncorporatedSwRI/HondadescribeadvancedcombustionstrategyforT2B5LDDengine.2.2literengineandsystemHighEGRandlocalequivratiocontrol(here)areusedtominimizesootformationunderstoichiometricorrichconditions.LocalizedcontrolofF/Aisusedforrich,mediumloadandforleanoperation.Lowload:HighEGRtopreventsoot.Medload:EGRreducedandlocalequiv.ratio(physicalmethod)isapplied.Highload:Standardcombustionutilized.•Retardedinj.andintakethrottleareusedforfastheat-up.DPFat250Cw/i30sec.LowNOxduetoadv.comb.•ThrottlingisalsousedtomaintainTunderlowloadandidlingconditions.Lowidlespeedused.•LNTregenathighloadusesrichcomb+postinj,ifnecessary.Mediumloadisrichcomb.LowNOxatlightload:noregen.Muchdiscussiononrich-leanmodeswitching.•TWCtoaddresscoldstart(Honda,SAE2007-01-1933)15CorningIncorporatedSwRI,Honda,SAE2007-01-1937Stoichiometricdieselisbeinginvestigatedasanon-roadalternativeDeere,DEER8-07Stoichiometricdie