9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Mansour Masoudi Bosch Corporation Farmington Hills, Michigan

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Outline

Introduction

Drivers for Exhaust Aftertreatment Technologies

Bosch Denoxtronic Urea Dosing Systems

Exhaust System Optimization at Bosch

Achievements, Current and Future Challenges, Approaches Conclusions

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 2 disposal such as copying and passing on to third parties. The Bosch Group - Company Founder

Robert Bosch (1861 - 1942) Founded by Robert Bosch, 1886, “Workshop for Precision Mechanics and Electrical ” in ,

Company logo: First automotive product, the , an ignition device

Robert Bosch Foundation

Established in 1964, 92% holding (capital stock)

Since 1964, EUR 737 M spent on charity

Dedicated to promoting public health care, international understanding, social work, education, the arts and culture, the humanities, and social and natural sciences

Sponsors annual fellowship work-and-study programs in Germany for young American professionals

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Bosch Group Sales: 41.5 billion euros Associates on Jan. 1, 2006: 251,000

Automotive Industrial Consumer Goods & Technology Technology Building Technology Sales: 26.3 billion euros Sales: 5.2 billion euros Sales: 10 billion euros

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Gasoline Systems Car Multimedia1)

Diesel Systems Automotive Electronics

Chassis Systems Brakes Automotive Aftermarket

Chassis Systems Control Steering Systems2)

Energy and Body Systems Bosch Engineering GmbH3)

1) GmbH (100% Bosch-owned) 2) ZF Lenksysteme GmbH (50% Bosch-owned) 3) Development services in the field of electronic vehicle systems

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Anderson, SC Broadview, IL Electronics & Sensors Aftermarket Sales and Service Center

Headquarters Development

Manufacturing Charleston, SC Juarez, Mexico Systems Truck HD 1) Aftermarket Engine Control Unit Unit Injector Truck HD 1)

1) PC…passenger car; LD…light duty; MD…medium duty; HD…heavy duty

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Outline

Introduction

Drivers for Exhaust Aftertreatment Technologies

Bosch Denoxtronic Urea Dosing Systems

Exhaust System Optimization at Bosch

Achievements, Current and Future Challenges, Approaches Conclusions

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 7 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006 Solutions meeting upcoming Emission Legislations

EU5 US T2B5

To achieve T2B5 it is necessary to… • Combine lowest engine out emissions with high performance after.tr. system • Use of an advanced combustion strategy will be mandatory

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 8 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006 The Tier 2 BIN5 Challenge

MUST: Reduction of NOx raw emission levels

Tier2 BIN5 requires NOx raw emission levels of << 0.30 g/mi over FTP75 (based on current technology assessment) MUST: “Rapid Heat-up"

Engine-based

Post engine measures PLUS: Optimization of exhaust system ‘hardware’

Low light-off temperature

Hydrolysis catalyst

NO2-optimized DOC ….

Only a ‘combination’ of aforementioned measures will be successful

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Exhaust Gas Aftertreatment System Application & Optimization

Example -- SCR technology: NOx conversion is the product of many affecting parameters which need be “simultaneously” optimized! SCR catalyst DOC fuel, lube catalyst position

exhaust gas flow pattern NOx Conversion temperature

dosing space velocity strategy BOSCH reductant Core Expertise spray pattern mass flow

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Outline

Introduction

Drivers for Exhaust Aftertreatment Technologies

Bosch Denoxtronic Urea Dosing Systems

Exhaust System Optimization at Bosch

Achievements, Current and Future Challenges, Approaches Conclusions

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 11 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006 DENOXTRONIC 1 -- for HD With Air-Support AdBlue - tank Supply Module Air pressure Temp.- Filter sensor AdBlue AdBlue Dosing level Compressor sensor Dosing Control module Unit

In series production Actuators Sensors since 2004 Engine CAN Diagn. CAN Temp.- Temp.- Exhaust sensor Atomizer sensor gas sensor

OXI - cat SCR - cat Slip - cat

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nd AdBlue - tank 2 Generation Supply module DENOXTRONIC2 Not Air-Assisted

Temp.- sensor Filter AdBlue level sensor Dosing DCU control Bosch unit

Sensors Actuators Engine CAN Diagn. CAN Temp.- Temp.- Exhaust sensor AdBlue Dosing Module sensor gas sensor

OXI - cat SCR - cat Slip - cat

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DNOX PC - LD Level- sensor

AdBlue- Tank

Engine Control Unit Supply Module on including Functional Unit incl. Splashing SCR- (optional) functions Measures, Heating and Temp. Sensor Actuators Sensors Actuators Sensors

Pressure Sensor AdBlue Temp.- Dosing NOx- Sensor Module Sensor Bosch

DPF Mixer SCR-Catalyst

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PC-LD B1-Sample Design Supply Module PC/LD: Hardware Components Functional unit

Dosing Module with passive cooling

Standard AdBlue Tank Exhaust Tube (20 – 25 l)

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Thawing of limited volume to reach dosing mode within 30 minutes

Integration of Supply Module on top of tank

2-Pin-Sensor for level detection (continuous level sensor as back-up)

Splashing measures inside the tank implemented

Customized tank shape possible

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engine control unit*

tank with supply module

AdBlue dosing pipe module ECU control line *DCU functions integrated, separate DCU available

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3 Companies provide AdBlue through their filling station networks

At present:

~ 260 filling stations with pumps

~ 2600 filling stations offer canisters Various companies offer the distribution of:

• On-site tanks and pumps

• Bulk loads AdBlue Prices per liter range from €0.65 – €0.82

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Outline

Introduction

Drivers for Exhaust Aftertreatment Technologies

Bosch Denoxtronic Urea Dosing Systems

Exhaust System Optimization at Bosch

Achievements, Current and Future Challenges, Approaches Conclusions

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 19 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006 BOSCH Exhaust Gas Treatment Product Portfolio

Filters

*

* HCI: HydroCarbon Injection

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 20 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006 SCR – System Considerations (Example: Passenger Car) SCR system controller & software “Rapid heat-up“ strategy Thermally optimized exhaust manifold • Dosing strategy AdBlue canister

Emissions-optimized SCR catalyst engine • Light-off temperature/ time • Formulation

DOC, DPF • Location • NO2-optimized DOC Sensors • Temperature • NOx • sensor(s) location Dosing system • ‘Is it NOx or Ammonia?’ Thermally-optimized • Dosing module temperature exhaust pipes (must be < ~ 120 C) – (DPF regen, Reductant distribution in exhaust gas mountain drives, summer trips, …) • Dosing module location • Thawing strategy • Spray quality • Purging strategy to eliminate risk of • Distribution quality (uniformity) of Ammonia damage in freezing conditions • Use of mixer? • .… • Exhaust system design (geometry) • Simulation-based investigations •….

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 21 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006 ‘Classic’ Arrangement: (C)DPF followed by SCR

TF IC TC

AMS EGR

C DO

PF CD SCR

AdBlue Dosing Module

☺ close-coupled DOC + CDPF ease of CDPF active regeneration

☺ passive (C)DPF regeneration (NO2 effect) can be more effectively utilized ☺ allows most compact system SCR in underfloor position temperature management means most likely required

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TF IC TC

AMS EGR

C DO Hydrocarbon Injection (HCI) Module

AdBlue Dosing Module SCR DOC DPF

☺ rapid light-off of SCR converter passive (C)DPF regeneration less effective SCR-friendly DPF regeneration difficult supporting measures like HCI might be required! bulky system (2nd DOC, mixing length for both AdBlue and HC, …) system complexity

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 23 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006 SCR – System Considerations (Example PC) SCR system controller & software “Rapid heat-up“ strategy Thermally optimized exhaust manifold • Dosing strategy AdBlue canister

Emissions-optimized SCR catalyst engine • Light-off temperature/ time • Formulation

DOC+DPF • Location Sensors • NO2-optimized DOC • Temperature • NOx • sensor(s) location Dosing system • ‘Is it NOx or Ammonia?’ Thermally-optimized • Dosing module temperature Reductant distribution in exhaust gas exhaust pipes (must be < ~ 120 C) – (DPF regen, mountain drives, summer trips, …) • Dosing module location • Thawing strategy • Spray quality • Distribution quality (uniformity) of Ammonia • Purging strategy to eliminate risk of • Use of mixer? damage in freezing conditions • Exhaust system design (geometry) • .… • Simulation-based investigations • …

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Mixers – Effect on spray

xis y A ra Sp

xis y A ra Air flow Sp Mixer Wall wetting

Air flow

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low load medium load high load

60 11 60 46 60 28

40 low13 conversion 40 65 40 48

20 20 20

18 71 22 70 73 43 58 72 38 0 0 0

-20 -20 -20 NOx_Koordinate_y [-] NOx_Koordinate_y

high72 74 74 -40 conversion -40 -40 19 61 13 without mixer -60 Ui = 0.66 -60 Ui = 0.92 -60 Ui = 0.81

-60 -40 -20 0 20 40 60 -60 -40 -20 0 20 40 60 -60 -40 -20 0 20 40 60 NOx_Koordinate_x [-] NOx_Koordinate_x [-] NOx_Koordinate_x [-] 60 61 60 69 60 68

40 65 40 69 40 69

20 20 20

58 70 68 69 73 67 66 74 68 0 0 0

-20 -20 -20 NOx_Koordinate_y [-] NOx_Koordinate_y NOx_Koordinate_y [-] NOx_Koordinate_y

63 68 63

-40 -40 -40 with mixer 53 68 60 -60 Ui = 0.96 -60 Ui = 0.99 -60 Ui = 0.98 -60 -40 -20 0 20 40 60 -60 -40 -20 0 20 40 60 -60 -40 -20 0 20 40 60 NOx_Koordinate_x [-] NOx_Koordinate_x [-] NOx_Koordinate_x [-]

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 26 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006 Computational Fluid Dynamic (CFD) at Bosch – CFD as a Rapid Prototyping Tool

Why CFD? Use in Bosch dosing system • visualization of processes inside development exhaust gas systems • CFD coupled with experimental • optimization of injection, mixing validation and chemical conversion • prediction of major processes in SCR- • supporting geometrical SCR based deNOx-systems catalyst design with focus on • spray - gas interactions homogeneous reductant agent • spray-wall interaction/ film formation distribution • homogeneous gas phase reaction (urea to • establishing a tool for internal NH3 ) / predicting SCR catalyst reactions and external customer support • pressure loss of SCR catalyst • ….

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SCR Catalyst

Urea-Water-Solution tafter SOI = 10ms Spray

Thermolysis/Hydrolysis Mixer

Deposition of AdBlue

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Experience shows customers expect more than "just" components and software / calibration customers expect total system solutions and "emissions concept engineering" support

Example: exhaust system optimization by means of CFD as a "total system" optimization tool.

Layout 1 Layout 2 Layout 3

∆P =190 mbar ∆P =210 mbar sim,full load sim,full load ∆Psim,full load =160 mbar before optimization: After optimization: poor homogeneity better homogeneity good homogeneity ∆T = 35 K ∆T = 25 K ∆T = 10 K

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Simulation as a Means of SCR System Optimization 600 FTP75 NOx Raw Emission LDT3 Class Vehicle (4.750 lbs) Theoretical rapid heat-up Theoretical rapid heat-up result assumes a 70 % CC-DOC + CSF, UF-SCR result assumes a 70 % 500 NOx reduction in FTP75 Bosch DNOX-PC/LD A0-System NOx reduction in FTP75 phase 1 which would phase 1 which would Reductant: AdBlue require a SCR catalyst require a SCR catalyst light off after 120 sec. 400 light off after 120 sec. Today, catalyst light-off is Today, catalyst light-off is reached after approx. 250 reached after approx. 250 sec. leading to a ≈ 40 % 300 sec. leading to a ≈ 40 % NOx reduction on FTP75 NOx reduction on FTP75 phase 1. 79 % reduction phase 1. 88 % reduction

200 ≈ ≈ Please keep in mind, that 94 % reduction

91 % reduction Please keep in mind, that NOx raw emission level ≈

≈ NOx raw emission level given here is too high for

FTP75 Tailpipe NOx [mg/mi] 100 115 given here is too high for a series production a series production 65 Tier2/BIN5 application! 50 Tier2/BIN5 application! 0 35 beforebefore flow exhaust optimization after flowafter optimizationexhaustwith rapidplus rapid heat-up heat-upwith theo. rapidplus heat-uprapid heat-up STATUS system optimization system optimization (THEORY) (STATUS)

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NOx-Conversion NOx-Conversion

NOx-Conversion NOx-Conversion

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 31 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006 Simulation of Various Species spray evaporation wall film danger of fouling Catalyst

thermolysis/hydrolysis

Spray vapor Mass Fraction [-] Injection of AdBlue 0 5e-3 1e-2 1.5e-2 2e-2 valve location at the bottom Mole fraction H2O [-] SCR reactions

Mole fraction NH3 [-] Hydrolysis in the catalyst

Mole fraction HNCO [-] NH3-Oxidation in the catalyst

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 32 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006 Simulation Close-Coupled with Experiments

reductant distribution gas flow distribution (test) (simulation)

overlapping (schematic) Re w d lo uc F tan as t F G low

Improvement in SCR catalyst performance due to enhanced flow-spray-NH3 mixing

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 33 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006 SCR – System Considerations (Example PC)

Thermally optimized SCR system controller & software “Rapid heat-up“ strategy • Dosing strategy exhaust manifold AdBlue canister

Emissions-optimized SCR catalyst engine • Light-off temperature/ time • Formulation

DOC+DPF • Location Sensors • NO2-optimized DOC • Temperature • NOx • sensor(s) location Dosing system • ‘Is it NOx or Ammonia?’ Thermally-optimized • Dosing module temperature Reductant distribution in exhaust gas (must be < ~ 120 C) – (DPF regen, exhaust pipes • Dosing module location mountain drives, summer trips, …) • Spray quality • Thawing strategy • Distribution quality (uniformity) of Ammonia • Purging strategy to eliminate risk of • Use of mixer? damage in freezing conditions • Exhaust system design (geometry) • .… • Simulation-based investigations • ….

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FUL: Full Useful Life = 120k mi SCR Light-off during FTP75 HUL: Half Useful Life = 50k mi 100 80 60 40 20 NOx raw emission NOx Conversion [%] Conversion NOx 0

NOx (not phase-weighted!): 400 before SCR Converter Temperature [°C] NOx after SCR ≈ after SCR Converter 4 300 Tier2/BIN5 FUL

200 2

Cumulated NOx [g] 100 Virtually no NOx target: Tier2/BIN5 conversion for 200s0 0 HUL – 30 % Cold start management0 200 400 600 800 1000 1200 1400 1600 1800 2000 (corresponding to is required. a > 90 % NOx Elapsed Time of Cycle [sec] con-version target)

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 35 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006 SCR – System Considerations (Example PC)

Thermally optimized SCR system controller & software “Rapid heat-up“ strategy • Dosing strategy exhaust manifold AdBlue canister

Emissions-optimized SCR catalyst engine • Light-off temperature/ time • Formulation

DOC+DPF • Location Sensors • NO2-optimized DOC • Temperature • NOx • sensor(s) location Dosing system • ‘Is it NOx or Ammonia?’ Thermally-optimized • Dosing module temperature Reductant distribution in exhaust gas (must be < ~ 120 C) – (DPF regen, exhaust pipes Dosing module location mountain drives, summer trips, …) • • Spray quality • Thawing strategy • Distribution quality (uniformity) of Ammonia • Purging strategy to eliminate risk of • Use of mixer? damage in freezing conditions • Exhaust system design (geometry) • .… • Simulation-based investigations • ….

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 36 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006 Structure of SCR-software Dosing strategy SCR system OBD Calculation of required AdBlue quantity Monitoring of •NOx-raw emission model •SCR-catalyst •SCR-catalyst model •NOx-sensor •adaptation •temperature sensor (exhaust gas)

Dosing system control Dosing system OBD Monitoring of Monitoring of •injection of requested AdBlue quantity •dosing valve •anti-freeze •pump •protection of components •temperature- and pressure-sensors

Additional SCR relevant SW (under development) •Catalyst heating, requires interventions in engine management •Interaction SCR ↔ DPF (No dosing during DPF-regeneration

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 37 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006 SCR – System Considerations (Example PC)

Thermally optimized SCR system controller & software “Rapid heat-up“ strategy • Dosing strategy exhaust manifold AdBlue canister t! an ific Emissions-optimized ign y! SCR catalyst s s log engine ty i no • Light-off temperature/ time exi ch • Formulation pl y’ te com pla m d- te -an sys ug DOC+DPF R ‘pl • Location SC t a Sensors tal no • Temperature • NO2-optimized DOC To is CR • NOx S • sensor(s) location Dosing system • ‘Is it NOx or Ammonia?’ Thermally-optimized • Dosing module temperature Reductant distribution in exhaust gas exhaust pipes (must be < ~ 120 C) – (DPF regen, • Dosing module location mountain drives, summer trips, …) • Spray quality • Thawing strategy • Distribution quality (uniformity) of Ammonia • Purging strategy to eliminate risk of • Use of mixer? damage in freezing conditions • Exhaust system design (geometry) • .… • Simulation-based investigations • ….

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 38 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006 SCR Technology Challenges

Challenges: Approaches: minimization of ammonia slip closed-looped control, whilst maximizing NOx conversion exhaust system optimization minimization of reductant minimization of NOx raw consumption emissions minimization of reductant tank see above volume (mass) cold climate operability system heating, non-solidifying (below - 11°C) reductant low exhaust gas temperature "rapid-heat up", advanced catalyst performance improvement technologies maximization of NOx reduction ultra-low quantity dosing systems modified injectors, high precision dosing quantity control

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conclusions Pressure Sensor

DPF

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For European cycles similar to NEDC --

Key Challenge: Limited NOx conversion at low temperatures which require ‘counter measures’ (e.g. rapid heat up via engine)

Counter measures possibly not necessary for moderate NOx conversion rates

For US test cycle conditions --

US06 compliance is currently considered not a major challenge

US FTP75 lifetime compliance a challenge.

Lower raw NOx raw emissions (< 0.3 g/mi)

"Rapid heat-up" expected to be required

Progress is being made in reducing overall complexity of SCR technology

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Conclusions -- SCR Technology Outlook

SCR currently is the preferred technology to meet highest NOx conversion requirements over lifetime for HD / OHW applications and passenger car/ light duty applications (e.g. US Tier2/BIN5).

Advanced FIE / combustion systems are vital for meeting TIER2, EURO5 and beyond

Bosch's philosophy: Customers expect ‘total system knowledge’ -- emission concepts engineering, i.e. significantly more than components, systems and calibration!

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Bosch’s Achievements / Contributions:

Proven technology for on-road HD vehicle application (series introduction since late 2004) Successful demonstration of Denox PC/LD applications in various programs for all types of emission test cycles

Bosch’s expertise in systems and after-treatment technologies (specifically urea dosing systems) combined with its ‘total systems solutions’ approach provide the needed know-how and products to meet future, stringent emissions requirements

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 43 disposal such as copying and passing on to third parties. 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of 44 disposal such as copying and passing on to third parties.