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

Powertrain

Parts

Technology

Business Units Business Logistics

Information Technology

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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

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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

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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]

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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

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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

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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.

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The selected solution UREA SCR

• Oxidation catalyst upstream (NO2 production)

• Cleanup catalyst for removal of NH3 slip

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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

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SCR – Muffler and AdBlue injection

Inlet Temp sensor

Inlet

AdBlue Injection nozzle

Outlet NOx sensor

Pre catalyst AdBlue injection nozzle

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SCR installation on Volvo B7R/RLE

AdBlue pump and dosing unit

Lefthand side variant AdBlue tank

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SCR system weight SCR installation on Volvo B7R/RLE between100 -125 kg

Temp. sensor

SCR muffler

AdBlue injector NOx sensor

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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

Filling neck insert drawing. B = 43.5 -/+0.1 mm C = > 26.8 mm C

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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

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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

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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)

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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

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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 Æ 2N2 + 3H2O fast ammonia to avoid •4NO + 4NH3 + O2 Æ 4N2 + 6H2O intermediate smell

•2NO2 + 4NH3 + O2 Æ 3N2 + 6H2O slow

⇒ NO/NO2 = 1/1 is best Temperature > 200°C needed

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Temperature in exhaust system

600 SCRT (DPF+SCR) 500 Before system

400

300

200 US kall After system US varmvarm 100 ETC ESC (tidsupp) 0 0 300600 900 1200 15001800

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Active temperature range for SCR catalysts

0.50 1.0 ETC Present SCR

0.40 0.8

0.30 0.6 US warm ESC

0.20 0.4 NOx conversion Frequency of given temperature Frequency 0.10 0.2 US cold Route 85 0.00 0.0 50 150 250 350 450 550 650 Temp °C

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Urea Dosing strategy tests for low temperature operation such as route 85

• Three different engine maps were tested using several different urea injection timing strategies and dosing amounts • Simulated city bus route cycle for low temperature operation (like route 85) • Monitoring of both gas phase compounds and particulate matter formation with both FTIR and a state-of-the-art particulate matter measurement

• Balance between NOx conversion and NH3 slip and production of cyanuric acid at too high dosing rates.

Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /32 Urea SCR- The Volvo Way Nitrous oxide N2O 3000 40 NOx 37% NOx conv. Ammonia NH3 30 HNCO 2500 20

10 2000

1500 -10

-20

1000 Concentration (ppm) -30

-40

500 (ppm) HNCO concentration NH3 and

-50

0 -60 15:38:53 15:41:46 15:44:38 15:47:31 15:50:24 15:53:17 15:56:10 15:59:02 16:01:55 dN/dlogDp /cc

1000 500

8.00E+06 200 7.00E+06 100 50 6.00E+06 (nm)

5.00E+06 20 10 4.00E+06 Particle diameter 5 3.00E+06

1 201 401 601 801 1001 1201 1401 2.00E+06

1.00E+06

0.00E+00

Dp (nm) 1.E+3 1.E+4 1.E+5 1.E+6 1.E+7 1.E+8 dN/dlogdp /cc Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /33 1.00 10.0 100 1000 Urea SCR- The Volvo Way Nitrous oxide N2O NOx 2000 60 Ammonia NH3 77% NOx conv HNCO 40

1500

1000 0

-20 Concentration (ppm)

500

-40 NH3and HNCO concentration(ppm)

0 -60 16:33:36 16:40:48 16:48:00 16:55:12 dN/dlogDp /cc 17:02:24 Time 1000 500

200 8.00E+06

100 7.00E+06 50 (nm) 6.00E+06

20 5.00E+06 10 4.00E+06 Particle diameter 5 3.00E+06 1 201 401 601 801 1001 1201 1401 2.00E+06

1.00E+06

0.00E+00 1.E+3 1.E+4 1.E+5 1.E+6 1.E+7 1.E+8 Dp (nm) dN/dlogdp /cc Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /34 1.00 10.0 100 1000 70

60 2500 50 Urea SCR- The Volvo Way test 07-03-13, II serie 40 2000 Carbon monoxide CO NOx Nitrous oxide N2O Ammonia NH3 30 HNCO

1500 20 ) (ppm )

10 2O (ppm O 3 and N x, C H ; N

NO 1000 11:49:00 11:51:53 11:54:46 11:57:38 12:00:31 12:03:24 12:06:17 12:09:10 0

Time HNCO

500 -10

0 -20 Start of urea 1.00E+00 1.E+3 1.E+4 1.E+5 1.E+6 1.E+7 1.E+8 9.00E-01 dN/dlogdp /cc 8.00E-01 injection 3.00E+08 Idling 7.00E-01 1000 40.00 6.00E-01 500

r 5.00E-01 ete

) 200 4.00E-01

2.50E+08 d

35.00 (nm 11:49:00 11:50:26 11:51:52 11:53:19 11:54:45 11:56:12 11:57:38 11:59:04 12:00:31 12:01:57 12:03:24 12:04:50 12:06:16 12:07:43 12:09:09 3.00E-01 100 spee

Part i cl e di am 2.00E-01 50 1.00E-01 30.00 20 2.00E+08 0.00E+00 dN/dlogDp /cc 10 Start25.00 of Cycle 5 6.00E+06 drive from 11:50 - 12:10 on 070313 1.50E+08 Ammonia NH3 5.00E+06 20.00 HNCO 800 820 840 86030 - 300 nm 880 900 920 940 960 980 1000 5 - 30 nm Time (sec) 4.00E+06 1.00E+08 15.00 m p 3.00E+06 r p o c /c N 10.00 5.00E+072.00E+06 5.00

1.00E+06

0.00 0.00E+00

0.00E+00 1.00 10.0 100 1000 Dp (nm) Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /35 Urea SCR- The Volvo Way

Four year durability study of a combined SCR + DPF

Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /36 Urea SCR- The Volvo Way

Outlet SCRT System Inlet

Urea Fuel tank tank Front SCRT™ wheel

Urea dosing system

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•Multi-year gas phase emission testing of a fleet of 23 vehicles •Both engine out and tailpipe measurements using mobile FTIR

•Engine Volvo D12C 12 liter 465 hp @1300 rpm •Total 71.5 liter aftertreatment unit (DPF + SCR) •18-mile simulated distribution route:

vehicle speed (km/h) 120

110

100

0 0 200 400 600 800 1000 1200 1400 1600 time (sec)

Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /38 Urea SCR- The Volvo Way

FTIR results from on-road tests on the 18-mile route Truck B228. Tailpipe emissions upstream and downstream of the CEATS system

Carbon monoxide CO B228 before Water vapor H2O Nitrogen monoxide NO B228 before Nitrogen dioxide NO2 1200 70 Carbon dioxide NOx 10 CO2 1100 Nitrous oxide N2O 9 1000 Ammonia NH3 60 8 900 50 7 800 700 6 40 600 5 500 30 4 400 20 3 (ppm) Concentration 300 2 200 CO2, H2O concentration (%) concentration H2O CO2,

10 (ppm) concentration NH3 N2O, 1 100 0 0 0 0 200 400 600 800 1000 1200 1400 1600 0 200 400 600 800 1000 1200 1400 1600 Time (sec) Time (sec)

B228 after Carbon monoxide CO B228 after Water vapor H2O Nitrogen monoxide NO 12 Nitrogen dioxide NO2 1000 70 Carbon dioxide NOx CO2 900 Nitrous oxide N2O 10 Ammonia NH3 60 800

8 700 50 600 40 6 500 30 400 4 300 20 Concentration (ppm)

CO2 , H2O concentration (%) concentration , H2O CO2 2 200

10 NH3, N2O concentration (ppm) 100 0 0 0 0 200 400 600 800 1000 1200 1400 1600 1800 0 200 400 600 800 1000 1200 1400 1600 1800 Time (sec) Time (sec)

Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /39 Urea SCR- The Volvo Way

Summary of Emission Results

US07 NTE Average NOx compliance Year NH slip conversion 3 within fleet (cold) October 2004 75 +/- 6% 20 ppm 91 % 73 +/- 8% June 2005 28 ppm 91 %

61 +/- 12% June 2006 30 ppm 70%

Overall durability is very good— Truck mileage varies +/- 150,000 miles Some trucks have driven over 350,000 miles

Volvo Technology Corporation 6130./ Ann W Grant / 5/10/2007 /40 Urea SCR- The Volvo Way Summary

• Optimized engine with SCR for Euro VI and EuroV • Infrastructure availability and refilling of Urea • Onboard diagnostics • More work needed for low temperature applications • Durability, field tests with total 700 000 km driving without major problems • NOx reduction >75% possible

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Special thanks to:

•Volvo Bus Corporation •Patrik Klintbom •Jonas Edvardsson •Miroslawa Abul-Mihl •Lennart Andersson •Lennart Cider •Heije Westberg

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