Alfred Reck Guixia Ba Development of Diesel …Development of Diesel Catalysts for Today´s and...

Vertraulich / ConfidentialCopying of this document and giving it to others is strictly forbidden without express authority of Emitec!

Development of Diesel Catalysts for Today´s and Tomorrow´s

Diesel Engines

AVECC 2004, Beijing, April 27th- 29th

Alfred Reck

Guixia Ba


§Introduction

§Structured Foils

ØPErforated Foil

ØLS-Foil

§Hybrid Catalyst

§Compact Catalyst

§Pre-Turbo-Catalyst

§PM-Filter Cat

§Summary

Content of Presentation


Gas Flow and Mass Transfer Coefficient; Laminar and Turbulent ConditionsBasis: Cell Density 800 cpsi, T = 600°C

0

0,5

1

1,5

2

2,5

0 100 200 300 400 500 600 700 800Strömungsgeschwindigkeit [m/s]

Sto

fftr

ansp

ort

ß [m

/s]

PE - Struktur

Reynolds

Mas

s T

ran

sfer

ß


§Introduction

§Structured Foils

ØPErforated Foil

ØLS-Foil

§Hybrid Catalyst

§Compact Catalyst


§PM-Filter Cat

§Summary



PE Stucture: Improvement of Efficiency and Flow Distribution

PErforated Foil

Radial flow vector in the area of the hole

Properties:

•Cross Flow

•Reduced Heat Capacity

•Reduced Back Pressure

•Improved Efficiency


Measurement of Flow Distribution

Standard Substrate

Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4

Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4

PE-Substrate


Comparison of Light Off Behaviour, Standard and PE SubstrateØ 118 x 74,5 mm / 400 cpsi / 50 µm ( FTP-Cycle )

0

50

100

150

200

250

300

350

400

450

0 4 8 12 16 20

Standard SubstratePE-Substrate

25mm

Temperature [ °C ]

Time [ sec ]

3 sec


0

5

10

15

20

25

30

35

40

45

50 150 250 350

400cpsi/40µ600cpsi/30µ900cpsi/25µ 900 PE

600 PE

Comparison of Back Pressure between Standard and Perforated FoilsFlow test bench: substrate Ø 98,4 x 101,5 mm, temperature 100°C


NOx [g/km]

0

0,005

0,01

0,015

0,02

0,025

0,03

0,035

0,04Bag 3

Bag 2

Bag 1

Ø80x50,8mm/600cpsi+

Ø98,4x58mm/1200cpsi

Ø95x101,5mm1200cpsi/PE

(Zone Coating)

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8Bag 3

Bag 2

Bag 1

CO [g/km]




(Zone Coating)

0

0,005

0,01

0,015

0,02

0,025

0,03

0,035Bag 3

Bag 2

Bag 1

HC [g/km]




(Zone Coating)

Emission Test ProgramCascade System / PE Single Brick


§Introduction

§Structured Foils

ØPErforated Foil

ØLS-Foil

§Hybrid Catalyst

§Compact Catalyst


§PM-Filter Cat

§Summary



Improved Mass Transfer, è Turbulence, Higher Efficiency

Reduction of thermal Massè Improved Light Off

Reduction of Materialè Reduction of Cost

Properties of „LS“ Longitudinal Structure

Laminar200cpsi200cpsi

400cpsi

LS Structure


Back Pressure Ø90x120 mm, 40 µm, Winding S/3, uncoated

LS Standard

0

5

10

15

20

25

30

Bac

k pr

essu

re[m

bar]

L=150 kg/h 3,82 4,6 5,47 6,5 7,03 8,24 12,28

L=350 kg/h 10,1 10,27 13,57 14,29 18,46 18,3 27,18

LS 200/400cpsi

Standard 400cpsi

LS 300/600cpsi

Standard 600cpsi

LS 400/800cpsi

Standard 800cpsi

Standard 1000cpsi


LS-Catalyst; Catalytic EfficiencyAverage FTP Results

0

0,02

0,04

0,06

0,08

0,1H

C, N

Ox,

CO

/10

[g/m

i] W

eigh

ted

HC NOx CO

LS200/400 400 cpsi

Stand.

400 cpsi

Stand.400 cpsi

Stand.LS200/400

LS200/400


§Introduction

§Structured Foils

ØPErforated Foil

ØLS-Foil

§Hybrid Catalyst

§Compact Catalyst


§PM-Filter Cat

§Summary



Vertraulich / ConfidentialCopying of this document and giving it to others are forbidden without express authority!

Construction Principle of the Hybrid Catalyst

1. Brick with low thermal mass

Early Light-Off

2. Brick with high thermal mass

Good Heat-Storage

Exhaust Gas


Exhaust Gas TemperaturesMVEG Test Cycle

0

100

200

300

400

500

0 200 400 600 800 1000Time [s]

Tem

pera

ture

[°C

]

in front of Turbocharger behind Turbochargerin front of CCC in front of UFC

CCC

UFC

T6

T1

T2

T3

T4 T5

GE_L2GE_L1

GE_L3

CVS


125

100

75

50

25

00 200 400 600 800 1000 1200

500

400

300

200

100

0

Temperatur [°C]

SerieHybrid

100

80

60

40

20

0

Effizienz %125

100

75

50

25

00 200 400 600 800 1000 1200

SerieHybrid

Efficiency of Hybrid Catalyst


§Introduction

§Structured Foils

ØPErforated Foil

ØLS-Foil

§Hybrid Catalyst

§Compact Catalyst


§PM-Filter Cat

§Summary



New Compact Canning Design with Twin Cat and Single Cat

Inlet

Outlet

Hybrid - Matrix


Back-Pressure MeasurementProduction Catalyst / New Canning Design

0

10

20

30

40

50

60

70

80

90

0 50 100 150 200 250 300 350Massflow [kg/h]

Pre

ssu

red

rop

[m

bar

]

Production System: A = 8362 mm2

New Canning Design with Hybrid Catalyst: A = 7605 mm2

PTC: Ø 39 x 19 mm / 200 cpsi / 80 µmHybrid: Ø 98.4 x 40 mm / 400 cpsi / 30 µm +

95 mm / 400 cpsi / 80 µm

Hybridkat

∆pPTC

CCC: 135.8 x 78.4 x 124 / 400 / 4milUFC: 152.4 x 101.6 x 152.4 / 400 / 6.5 mil

CCC

∆p

UFC


0

0,02

0,04

0,06

0,08

0,1

0,12

0,14

0,16

HC CO PM

Bag

Res

ult

s [g

/km

]

Production CatalystCompact Catalyst

Efficiency of Compac Catalyst

Emission Test on Roller Test Bench, 1,9 lTDI, MVEG


§Introduction

§Structured Foils

ØPErforated Foil

ØLS-Foil

§Hybrid Catalyst

§Compact Catalyst


§PM-Filter Cat

§Summary



Preturbo-Catalysts, Turbulent Catalysts

Cylinderhead

PTC-C

Manifold

PTC-Ms PTC-Mr

Preturbo

PTC-T

Efficiency appr. 60 % appr70 % appr 50 % appr30 %

1 Turbocharger

per

Bank


Pre Turbo Catalysts, Turbulent Applications


Space Velocity [h-1]

PTC Ø 40 x 74,5 mm; 200 cpsiSpace Velocity at Different Engine Operation Points


PTC Ø 40 x 74,5 mm; 200 cpsiHC Conversion Efficiency

HC Conversion Rate [%]


Influence of various PTCs on Torque at full load in a Truckapplication

150

170

190

210

230

250

270

290

310

330

800 1300 1800 2300 2800 3300 3800 4300

Revolutions [U/min]

Torq

ue[N

m]

Series System

PTC 200 cpsi short

PTC 200 cpsi lang


§Introduction

§Structured Foils

ØPErforated Foil

ØLS-Foil

§Hybrid Catalyst

§Compact Catalyst


§PM-Filter Cat

§Summary



Principle


Session 6

4:15 Uwe Israel, Twin Tec

Retrofit Catalyst Systems for Diesel Engines

Further Details to PM-Filter Cat


§Introduction

§Structured Foils

ØPErforated Foil

ØLS-Foil

§Hybrid Catalyst

§Compact Catalyst


§PM-Filter Cat

§Summary



Summary

•Structured Foil Material will allow turbulent Catalyst Application

èHigh Efficiency, Low Cost, Low Volume

• Hybrid Catalyst gives improved thermal Management

è Early Light off, High Efficiency

•Compact Canning allows improved thermal Management and saves Space

•Preturbo-Catalysts are turbulent and show high Efficincy at low Cost

•PM-Filter Cat with Efficency of appr. 40- 50 % is suited for OEM and

Retrofit Application

•Combination of different Techniques is possible and provides most

advanced Technology


Thank you for

Your

Attention

Alfred Reck Guixia Ba Development of Diesel …Development of Diesel Catalysts for Today´s and...

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