Diesel Exhaust Emission Control Technologies for Asian Market 亚洲市场柴油机废气排放控制技术
Mukaram Syed
ArvinMeritor, Inc. 阿文美驰公司 Technical Center, Columbus, Indiana, USA
AVECCAVECC 2004 2004 1
OutlineOutline • Introduction • Diesel Engine Exhaust • Challenges • Technology Solutions • Thermal Regenerator (PM) • Urea-SCR (NOx) • On-board Plasma Fuel Reformer (NOx)
AVECC 2004 2 ArvinMeritor’sArvinMeritor’s GlobalGlobal ReachReach • ArvinMeritor is a global supplier to the commercial vehicle and light vehicle markets • ArvinMeritor supplies $8B of automotive components globally • 10 Years of business experience in China
6 manufacturing locations
3 additional manufacturing sites broke ground in 2004
Conduct business with major On- and Off-road OEMs in China:
Changan Ford Beijing CEV FAW Shanghai GM Jinhua Neoplan FAW Penglai Shanghai VW Golden Dragon CNHTC FAW VW Volvo Sunwin Bus Dandong Huanghai Dongfeng Citroen Volvo Silver Bus Suzhou KingLong Hainan Mazda Shanxi Eurostar Anhui Ankai China Brilliance Yaxing Group
AVECC 2004 3
LightLight VehicleVehicle SystemsSystems
Motion Control Roof Systems Systems
Door Access Systems Controls
Filtration Systems Coil Coating
Air and Emissions Technologies Modular Suspension Systems Wheel Products
AVECC 2004 4 CommercialCommercial VehicleVehicle SystemsSystems • #1 supplier of commercial vehicle components
AVECC 2004 5
ManufacturingManufacturing FacilitiesFacilities WorldwideWorldwide
Europe Czech Republic France Asia Germany China Hungary India Italy Philippines Netherlands Taiwan Spain Thailand UK
North America Canada Mexico South Africa USA Cape Town Ga-Rankuwa South America Argentina Brazil Venezuela
AVECC 2004 6 FacilitiesFacilities inin ChinaChina
Manufacture Location
CVC Location
Represents new sites planned for 2004 ArvinMeritor LVS (Yantai) Co. Ltd. Xuzhou Meritor (Equity TBD) Axle Co. Ltd. 60:40 Joint Venture ArvinMeritor LVS (Shanghai) Co. Ltd. Pudong CVC- 100% ARM
ArvinMeritor LVS Meritor Huayang (Shanghai) Co. Ltd. Braking Co., Ltd. (ShiYan) Anting CVC – 100% ARM 60:40 Joint Venture Future CVC ArvinMeritor LVS Planned for Nanjing (Chongqing) Co. Ltd. ArvinMeritor CVS For Mazda/Ford 60:40 Joint Venture (Shanghai) Co. Ltd. B2E Free Trade Zone Zhenjiang Meritor - 100% ARM LVS Co. (II) Ltd. 100% ARM AVECC 2004 7
ChallengeChallenge toto DieselDiesel EnginesEngines
• Emissions
Toxic hydro-carbons
HC and CO
Particulate matter (PM)
NOx
PM versus NOx trade-off
Integrated PM + NOx solutions
AVECC 2004 8 EmissionEmission ControlControl TechnologiesTechnologies Particulate Matter NOx
Oxidation Catalyst (DOC) Exhaust Gas Recirculation (EGR)
Catalyzed Soot Filter (CSF) Selective Catalytic Reduction (SCR) Thermal Regenerator (TR) On-board Plasma Fuel Reformer
DOC + CSF
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ParticulateParticulate MatterMatter ReductionReduction -- Challenges Challenges
• The filtration system should be reliable throughout the engine/vehicle operation • Exhaust backpressure should not exceed engine limitations • Filter should maintain performance for all duty cycles • System should perform over lifetime of the engine/vehicle • Catastrophic failure occurs if the filter is not regenerating • Regeneration must be controlled and reliable • PM filter systems must be durable and serviceable
AVECC 2004 10 ThermalThermal RegeneratorRegenerator (TR)(TR) • What the product is: • On-demand active regeneration technology for DPFs Muffler • What the product does: • Generates heat to eliminate soot from the filter • >90% PM reduction efficiency Filter • Active control maintains 650C inlet gas temperature • How regeneration works: • Regenerates automatically at any engine condition including idle and low load Combustion • Reliable ignition under any operating condition Chamber • Requires no precious metal • Does not generate excessive NO2 • Works with both low and high Sulfur fuel • Removable filter module design for easy ash Controller cleaning
AVECC 2004 11
OnOn RoadRoad OperationOperation withwith ThermalThermal RegeneratorRegenerator SupportedSupported FilterFilter RegenerationRegeneration Delivery Truck (7 L DI/TCI Diesel Engine) 3000 1200 Engine speed Temperature maintained at 650ºC regardless of driving 2000 condition 1000
1000 800
Temp. upstream Filter Engine speed (rpm) speed Engine 0 Temp. downstream Filter 600
Thermal Regenerator off 200 400 Exhaust gas back pressure 100 200 Exhaust gas temperature (deg. C) Thermal Regenerator on pressure (mbar)
Exhaust gas back gas Exhaust 0 0 400 500 600 700 800 900 1000 AVECC 2004 Time (sec) 12 TypicalTypical TRTR SystemSystem PerformancePerformance
0.20 Engine Baseline Engine With Aged TR-DPF
0.15
0.10
Composite FTP, g/bhp-hr FTP, Composite 0.05 94 % PM Reduction
0.00 PM AVECC 2004 13
ModularityModularity ofof ThermalThermal RegeneratorRegenerator
AVECC 2004 14 CertificationCertification
• VERT Certified w/2000 hour durability test (Europe) • U.S. Environmental Protection Agency (EPA) and California Air Resources Board (CARB) retrofit verification in-process • ArvinMeritor has partnered with fleets, and engine and vehicle manufacturers to demonstrate the ability of the Thermal Regenerator (TR-DPF) technology to meet upcoming US2007 regulations
AVECC 2004 15
FieldField ExperienceExperience
• Beginning in 1989, systems were manufactured in serial production and installed in European applications • Main applications: city busses, garbage trucks, delivery vehicles having EURO 1 emission status • In the US units are being demonstrated in many applications, i.e.: • Class-8 truck • Vocational truck & bus • Off-road equipment
AVECC 2004 16 NOxNOx Reduction:Reduction: SCRSCR • NOx Reduction: Selective Catalytic Reduction (SCR) System • What the product is • Optimized SCR system • What the system does • High conversion of NOx (60 – 90%). • No regeneration necessary SCR Muffler Unit • High sulfur tolerance • A mature, accepted technology in Europe • What the system requires • Urea, carried in an on-board tank that requires refilling, reacts with NOx over a catalyst to form Nitrogen and water
AVECC 2004 17
IntegratedIntegrated SCRSCR SystemSystem
Urea dosing CAN
ECU SCR catalyst air tank valve
pump
valve
SCR/silencer
AVECC 2004 18 SCRSCR TestTest ResultsResults (ESC)(ESC)
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On-Board Plasma Fuel Reformer Fuel
Air • Plasma-initiated partial oxidation
• Converts any hydrocarbon fuel Electric Current into hydrogen-rich gas
• H2, CO, light HC • On-board & On-demand • Consumes < 250 W Reaction Chamber
Hydrogen-rich gas
AVECC 2004 20 H2-Assisted NOx Adsorbers System
Power
Air Fuel Fuel Reformer
Reformate
NOx Trap A
To Tailpipe Engine
NOx Trap B
Switching Valve
AVECC 2004 21
NOx Reduction Efficiency - Fixed Fuel Penalty
100 90 80 70 60 50 Diesel Reformate 40 30
Nox Adsorbed - % 20 10 0 100 150 200 250 300 350 400 Exhaust Temperature - deg C
AVECC 2004 22 PotentialPotential IntegratedIntegrated PMPM ++ NOxNOx Systems Systems
TR DPF
Air Intake EGR Valve EGR Cooler
• NOx reduction with low pressure EGR • Guaranteed filter regeneration by TR-DPF allows use of EGR to optimum NOx benefit • PM reduction with TR-DPF • Increased soot output due to PM-NOx trade-off effect is overcome by the use of TR technology AVECC 2004 23
PotentialPotential IntegratedIntegrated PMPM ++ NOxNOx Systems Systems
Reductant (Urea)
DOC TR DPF (optional) SCR
• NOx reduction with SCR • Proposed system allows operation of both Urea dosing and SCR catalyst in optimum temperature window • PM reduction with TR-DPF • The filter regeneration even at the cold location is guaranteed by TR
AVECC 2004 24 ThankThank YouYou ForFor YourYour AttentionAttention !!
Mukaram Syed Brooke Huntington Principal Engineer Market Development Manager ArvinMeritor, Inc. ArvinMeritor, Inc. Commercial Vehicle Exhaust Commercial Vehicle Exhaust Ph: (812) 341-2405 Ph: (812) 341-2053 Fax: (812) 341-2101 Fax: (812) 341-2101 Email: [email protected] Email: [email protected] Address: Technical Center, 950W 450S, Bldg.3 Address: Technical Center, 950W 450S, Bldg.3 Columbus, IN 47201, USA Columbus, IN 47201, USA
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