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Urea SCR- the Volvo Way Urea SCR- The Volvo Way CLEERS Workshop 2007 Urea SCR- The Volvo Way Ann W Grant Volvo Technology AB Göteborg Sweden Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /1 Urea SCR- The Volvo Way BUSINESS AREAS at AB Volvo Mack Trucks Renault Trucks Volvo Trucks Volvo Buses TRUCKS Volvo Construction Volvo Financial Volvo Penta Equipment Volvo Aero Services Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /2 Urea SCR- The Volvo Way THE VOLVO GROUPAB Volvo ORGANISATION Business Mack Renault Volvo Volvo Volvo Volvo Volvo Financial Areas Trucks Trucks Trucks Buses CE Penta Aero Services Trucks 3P Powertrain Parts Technology Business Units Business Logistics Information Technology Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /3 Urea SCR- The Volvo Way FACTS ABOUT VTEC • We are 381 employees • VTEC turnover is €36M • Established 1969 • Innovation Areas -services -production - vehicles -powertrain - electronics -processes & methods • Innovation Services - intellectual asset management - standardisation intelligence Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /4 Urea SCR- The Volvo Way Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /5 Urea SCR- The Volvo Way Volvo diesel engines with Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /6 Urea SCR- The Volvo Way Global production of Heavy Duty Diesel Engines 2004* Volvo Powertrain 161.000 DC Powersystems Weichai Power Caterpillar Cummins Scania MAN Yaroslavl * Engine Production 2004, 9 - 18 litre (excluding licensees / JV’s) Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /7 Urea SCR- The Volvo Way New Heavy Platform - common technology • One Cylinder Head • Overhead Camshaft • Four Valves per Cylinder • Central Vertical Injector • Electronic Unit Injectors • Electronic Management System • Rear End Transmission • Integrated Engine Brake • Wet Liners Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /8 Urea SCR- The Volvo Way Legislative Demands Exhaust Emission Standards Euro 2 (1996) Euro 3 (2001) PM (Particulate Matter) [g/kWh] Matter) PM (Particulate Euro 5 (2009) Euro 4 Euro 6 (2013?) (2006) 2012 NOx [g/kWh] Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /9 Urea SCR- The Volvo Way Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /10 Urea SCR- The Volvo Way Exhaust Emission Strategy - HD Diesel - Europe 0.10 EU3 0.08 Cooled 0.06 EGR 0.04 Trade-off DPF Present HD Diesel Particulates –Particulates g/kWh 0.02 η=65% EU5 EU4 SCR SCRη= 80% 0 0 2 4 6 8 10 12 14 NOx –g/kWh Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /11 Urea SCR- The Volvo Way Engine Optimization and Fuel Consumption • Variation in injection timing Higher engine-out NOx gives better fuel consumption (~3%) Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /12 Urea SCR- The Volvo Way SCR vs. EGR – Euro 3 baseline SCR EGR Fuel consumption Heat rejection Power density Reliability Maintenance Euro 5/6 capability Total cost Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /13 Urea SCR- The Volvo Way Euro 4 legal requirement Certification Euro 4 step I Euro 4 step II before Oct 1- 05 Mandatory Additional requirement Certify new Driver warning if: Driver warning if: engines for Euro 4 • AdBlue tank is empty • > 5 g. NOx/ kWh • Dismounted catalyst 40% torque reduction if: • Lack of AdBlue dosing • > 7 g. NOx/ kWh Oct 1 Oct 1 Oct 1 2005 2006 2007 2008 Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /14 Urea SCR- The Volvo Way SCR - Selective Catalytic Reduction Power plants Marine applications Heavy duty vehicles Established technology Catalytic converters for Test around the world, since 1970. marine applications to mainly Europe. Possibility to reach 95% meet NOx-emission Meet legal requirement of NOx-conversion with NH3 levels <2 g/kWh. NOx-emission <3,5 → . 2 g/kWh. Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /15 Urea SCR- The Volvo Way The selected solution UREA SCR • Oxidation catalyst upstream (NO2 production) • Cleanup catalyst for removal of NH3 slip Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /16 Urea SCR- The Volvo Way SCR - Selective Catalytic Reduction AdBlue tank AdBlue level sensor AdBlue pump and AdBlue injection system control unit SCR catalyst AdBlue injector Muffler NOx sensor Additional catalytic Clean-up catalyst: converter Removal of NH3 to avoid smell Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /17 Urea SCR- The Volvo Way SCR – Muffler and AdBlue injection Inlet Temp sensor Inlet AdBlue Injection nozzle Outlet NOx sensor Pre catalyst AdBlue injection nozzle Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /18 Urea SCR- The Volvo Way SCR installation on Volvo B7R/RLE AdBlue pump and dosing unit Lefthand side variant AdBlue tank Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /19 Urea SCR- The Volvo Way SCR system weight SCR installation on Volvo B7R/RLE between100 -125 kg Temp. sensor SCR muffler AdBlue injector NOx sensor Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /20 Urea SCR- The Volvo Way AdBlue tank and filling neck The industry has agreed on a automotive AdBlue tank filling neck AdBlue tanks 34, 40 60 l insert standard to facilitate sealed depot system B Filling neck insert drawing. B = 43.5 -/+0.1 mm C = > 26.8 mm C Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /21 Urea SCR- The Volvo Way AdBlue: Urea (NH2)2CO • Meets requirements: • non toxic, regarded safe to transport, handle and store • Frequently used in other applications • Fertilizer, food industry … Freezing -11 °C @ 32,5 % Urea • Water soluble point °C wt% 0 • > 50% (108g/ 100 ml H2O) 015304560 • 32,5 % eutectic point -3 • Weight 60 g/mol -6 • Melting point 135 °C -9 • Meets DIN 70070 standard • Corrosive to certain metals -12 • (zinc, copper, non alloyed steel) • Produced in large volumes at a stable price Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /22 Urea SCR- The Volvo Way Urea Infrastructure Development: Some European experiences Basically three avenues for urea distribution • fuel stations and/or truck stops • filling in a fleet depot • Small canisters available for purchase Automotive Urea Infrastructure • Urea tank to be filled each time diesel is filled • On board diagnostics monitor urea level and notify driver • The infrastructure will be needed to ensure the compliance to emission legislation • First step is establishment of a minimum infrastructure to ensure the availability for the first trucks and buses on the market Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /23 Urea SCR- The Volvo Way Adblue urea filling – Fuel stations • Open system • Major oil companies develops infrastructure (Total, Shell, OMV) • Slim Line spout nozzle (Elaflex ) • Magnetic Ring in the urea tank filler neck inlet prevents spilling • Public urea filling station (Total Stuttgart ) • New stations being added continuously • Website Adblue4you.com shows where Adblue can be found in certain European countries Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /24 Urea SCR- The Volvo Way Urea filling – Depot option • Sealed / open depot filling system • Spill-free coupling offers urea filling integrated in a depot system for diesel fuel ( Identic ) • Spill free couplings are today used for filling diesel fuel • Volvo partner YARA (Norsk Hydro) can support customers with infrastructure and AbBlue supplies Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /25 Urea SCR- The Volvo Way Production capacities of urea in 2002 Norsk Hydro DSM Agro Sluiskil, Geleen, Netherlands Netherlands Total amounts in kilotons 750 000 t/yr 390 000 t/yr Austria 380 France 443 Germany 2116 Norsk Hydro Italy 440 Brunsbüttel, Germany Netherlands 1140 Norsk Hydro 530 000 t/yr Portugal 80 Le Havre, France Spain 385 333 000 t/yr SKW Piesteritz, Germany Total 4984 1 041 000 t/yr Grande Paroisse Oissel, France BASF 120 000 t/yr Ludwigshafen, Germany Adubos 545 000 t/yr Lavradio, Portugal 80 000 t/yr Agrolinz Linz, Austria 380 000 t/yr Norsk Hydro Fertiberia Fertiberia Ferrara, Italy Puertollano, 440 000 t/yr Huelva, Spain Spain 250 000 t/yr 135 000 t/yr Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /26 Urea SCR- The Volvo Way Automotive urea demand estimation • Estimations of automotive urea consumption up till 2012 has been reported by ACEA • Annual production of urea in 2002 was approximately 5 million tons. Corresponds to approximately 15 million tons of automotive grade urea. • Automotive grade urea demand in 2012 is estimated to be approximately 3.5 million tons (20% increase in urea-demand) Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /27 Urea SCR- The Volvo Way Some issues in Urea SCR: Mobile measurements and Ad-blue dosing strategies for low temperature performance • Dosing strategy test to define the best dosing strategy for ad-blue for vehicles operating at low temperatures • 23 vehicle multiyear durability study of a combined DPF/SCR system in the US using mobile measurements Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /28 Urea SCR- The Volvo Way Basic Chemistry of the SCR system (Selective Catalytic Reduction) Urea ((NH2)2CO) decomposes to ammonia (NH3) and CO2 in hot exhaust gas (>130 °C) through an HNCO intermediate (thermolysis and hydrolysis) SCR catalyst Clean-up catalyst NO , NH NO , NH x 3 Vanadium x 3 NOx oxide Platinum Clean up catalyst Ammonia reduces NO in the SCR catalyst: x remove surplus •NO2 + NO + 2NH3
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