A New Urea Dosing System for Passenger Cars · A joint venture between Ashok Leyland and Alteams...

Dr. Georg Hüthwohl

A New Urea Dosing System for Passenger Cars

4th International Conference Selective Catalytic Reduction 2012 24 – 26 September 2012

1 STRICTLY CONFIDENTIAL | 9/28/2012 | 1 |

1

2

3

4

5

Introduction

Key requirements for AdBlue dosing

Results of catalyst efficiency with improved spray

System set up for passenger cars

Conclusion

Content

Hinduja Group India’s Premier Transnational Conglomerates

• Founded in 1914

• Headquartered in London

• Present in 10 business sectors

• Present in 35 countries

• Employs over 50,000 personnel

• Privately owned by the Hinduja Family

• Revenue of the Group is several billion dollars

Hinduja Automotive Ltd.


Automotive Energy & Chemicals Banking & Finance IT & ITES

Media & Entertainment Real Estate Luxury Lifestyle

A joint venture between Ashok Leyland and Continental AG

A joint venture between Ashok Leyland and Alteams Group

Nissan Ashok Leyland Vehicles Ltd.

Construction equipment Ashok Leyland John Deere

Construction Equipment Private Ltd.

Albonair Company Hinduja Group Active in various industries

http://www.defiance-tech.com/index.html

Major Centres and Establishments Europe : London, Paris, Geneva, Moscow United States : New York, Washington India : Mumbai, Delhi, Chennai, Bangalore, Hyderabad, Vizag Middle East : Dubai South East Asia : China, Philippines South America : Brazil Africa : Johannesburg, Cairo, Mauritius

Worldwide Locations


Hinduja Automotive Landscape

Foundry Business

Engines & Gensets

Transmissions

Engineering Manufacturing

and Enterprise Services

Exhaust System Technology

Auto Electronics M&HCV Defence Mobility Buses

LCVs Construction equipment

Trucks Bus


C:/Users/saurabh.jain2/Desktop/Defiance_Corporate_Presentation_June2011.pdf

Ashok Leyland - Single Page.pptx

Med. & Heavy Comm. Vehicles Second Largest CV Maker in India

• Market Leader in Bus Segment

• Significant Presence in Medium and Heavy Duty trucks

• 6 Manufacturing Plants in India

• 2 Overseas manufacturing operations

• Joint venture in Sri Lanka

• Capacity of over 150,000 vehicles


Company Profile - Bus

• Market Leader in Bus segment in India

• 2 dedicated Bus Manufacturing Plants

• Largest global fleet of CNG Buses in commercial operation


Manufacturing Footprint

• 6 Manufacturing Plants in India

• 2 Overseas manufacturing operations

• Joint Venture in Sri Lanka

• Capacity of over 150,000 vehicles and aggregates

Ennore

Hosur 2

Hosur 1

Bhandara

Alwar Pantnagar

State of the art facilities and a flexible supply chain



Detroit, USA » Testing facilities » Sales » Customer Service

Dortmund, Germany » Headquarter » R&D » Sales » Customer Service

Taicang, China » Urea Dosing System assembly line » Housing assembly line » Sales » Customer Service

Chennai, India » Urea Dosing Assembly Line » Housing Assembly Line » Sales » Customer Service

Albonair - Company Overview Global Presence


EURO 6 (e.g. Europe) EURO 4 (e.g. Emerging Markets)

Tier 4 Final (e.g. Off-Road vehicles) EURO 6 Passenger Car (e.g. Europe, USA)

Albonair Company Overview UREA Dosing Systems for Different Market Applications


1

2

3

4

5




Introduction

Conclusions

Content


System Spray Formation Characteristics

Pressure Atomizer (Airless)

» Energy for atomization from the liquid pressure

» Increase of pressure leads to improved spray quality

Twin Fluid Atomizer with internal mixing (Air Assisted)

» Energy for atomization from air pressure

» Typically high air consumption

Albonair’s Concept is based on: Twin Fluid Atomizer with external mixing (Air Assisted)

» Energy for atomization mainly from air pressure

» Low air consumption

» No contact between AdBlue and air in the dosing system / nozzle to avoid crystallization and deposits

Albonair UREA Dosing System Functional Advantages to competitors Spray Formation of Different AdBlue Dosing Systems


Main Requirements for a UREA Dosing System

Technical Requirements Fine Spray avoiding big droplets for fast evaporation Homogeneous distribution of the DEF in the exhaust Precise dosing of small amounts of DEF Small size of the nozzle for easy packaging High temperature resistance

Solution Air assisted dosing nozzle with very low air consumption Droplet Size of only 15 µm SMD Temperature resistant without cooling up to 800

C exhaust temperature

No electric parts in the Nozzle Suited for close coupled position of the DEF dosing nozzle Electric air compressor for air supply (30 W power consumption) Mixer only for DEF distribution, not for droplet decomposition

Ø20 mm


1

2

3

4

5




Introduction

Conclusions

Content


Ø16mm

Albonair UREA Dosing System Injector Types - Connectors for AdBlue and Air hose have to be routed out of hot areas (>120° C)


Packaging of the Dosing Nozzle in the Heavy Duty EURO 6 Exhaust System


@Exhaust velocity 50 m/s and Low temperature (300

C)

» Even at 300

C small droplets of SMD 15 µm evaporate completely within 600 mm

» Very poor evaporation for big droplets SMD 70 µm

Evaporation Rates for Different Droplet Distributions

Albonair UREA Dosing System Functional Advantages to competitors

Point of

Measurement


CFD-Analysis of the Spray Evaporation with the ALBONAIR Doser AdBlue is homogenously distributed and evaporates fast due to small droplet size

Conditions: Exhaust Gas Mass Flow: 170kg/h | Frequency: 2.1 Hz | Exhaust Gas Temperature: 260

C


0%

20%

40%

60%

80%

100%

100% 25% 50% 75%

0%

20%

40%

60%

80%

100%

100% 25% 50% 75%

Ad

Blu

e D

eco

mp

osi

tio

n

» Signifikant increase of AdBlue Hydrolysis » Better Nox-Conversion at the SCR

Catalyst » Less deposits in the exhaust system

@ engine medium speed

@ engine high speed

Airless: NH3

Airless: HNCO

Albonair: NH3

Albonair: HNCO

Test Conditions: »Measurement HNCO and NH3 using FTIR

NH3 and HNCO decomposition improve with Albonair UDS



30

40

50

60

70

80

90

100

175 195 215 235 255 275

NO

x-C

on

vers

ion

Rat

e (%

)

Temperature (°C)

Low Exhaust Mass Flow200 - 250 kg/h

Albonair

Airless

30

40

50

60

70

80

90

100

175 195 215 235 255 275

NO

x-C

on

vers

ion

Rat

e (%

)

Temperature (°C)

High Exhaust Mass Flow600 - 1000 kg/h

Albonair

Airless

Catalyst Efficiency improved at low Exhaust Mass Flow - Little NH3-Slip



First Test results from 3 different Passenger Car OEMs showed impressive NOx conversion results using Albonair’s System in comparison with BOSCH airless dosing system (Dated, 26.05.2012)

First evaluation Test results – Passenger Car apllication



1

2

3

4

5


Results of catalyst efficiency with improved spray System set up for passenger cars

Introduction

Conclusions

Content


UREA Dosing System

NOx sensor

Exhaust System

Nozzle

Temp. Sensor

Air

Urea Suction Line (heated)

Actuators

Air Pressure Line

Urea Pressure Line

Temp. Sensor

Exh. Temperature (Pre)

Urea level/temp

Urea Quality

Air pressure

Urea pressure

Urea temperature

Air Filter

Afterteatment Control

AdBlue Tank

Actuators (Heating)

Engine Control Unit

Exh. Temperature (Post)

NOx

Albonair UREA Dosing System Schematics


Tank System

Nozzle

Urea Dosing

System

Albonair UREA Dosing System System Overview - Schematics for Passenger Cars


Membrane

Airpump incl. Pressure sensor

AdBlue Dosing Pump

AdBlue IN SAE

AdBlue OUT SAE

Air Out

AdBlue Pressure/Temperature Sensor

Electronics “Dosing”

Albonair UREA Dosing System AdBlue Pump


122 mm 155 mm

115 m

m

Albonair UREA Dosing System Dimensions


1

2

3

4

5

Key requirements for AdBlue dosing Results of catalyst efficiency with improved spray System set up for passenger cars

Introduction

Conclusions

Content


Technical Aspects

» Optimized Distribution & Evaporation of AdBlue

» Fast evaporation of AdBlue droplets

» Improved catalyst efficiency especially at low temperatures

» No significant urea deposition in the system

Design Aspects

» Maintenance free – no service filters in the system

» Nozzle

» Compact design

» No mechanical parts

» No electrical parts

» High temperature resistant

» No possibility of congestion


A New Urea Dosing System for Passenger Cars · A joint venture between Ashok Leyland and Alteams...

Documents

Transcript of A New Urea Dosing System for Passenger Cars · A joint venture between Ashok Leyland and Alteams...