24Aug2006
European Experience and Case study of SCR Passenger Car Integration
JJ Van Schaftingen
Inergy Research
24Aug2006
Program
SCR system overview
Focus on some functions Storage Filling Venting Heating Injection Control
Case studies: system integration examples
24Aug2006
SCR Technology : System Overview
Urea (NH2)2CO
1
Exhaust gas
Exhaust gas + water + ammonia
2
3
4
56
7 8
9
SCR Catalyst
Engine
hydrolysis
NO NO2 NH3 N2 H2O
NOx Reduction Reaction :
1 Urea solution tank 2 Temperature sensor 3 Level sensor 4 Supply module 5 ECU 6 Injector 7 Exhaust-gas
temperature sensor 8 Exhaust-gas sensor 9 Treated exhaust gas
24Aug2006
Program
SCR system overview
Focus on some functions Storage Venting Heating Filling Injection Control
Case studies: system integration examples
24Aug2006
SCR-System : AdBlue® tank
Consumption : approximately 1 l/1000 km for a Passenger Car (depending on Engine NOx generation, injection/dosing quality, etc.)
Integration into the vehicle.
Adblue® volume
1.5 l
Filling frequency
Filling at each fuel refill
Filling every 3 fuel refills
Filling at oil service
5 l
>18l
Integration possibilities
Tank in Mudguard
Tank along filler pipe
5 000 km1 000 km 25 000 km
1.5 l
Fillingfrequency
Filling ateach fuel refill
Filling every3 fuel refills
Filling atoil service
5 l
>18l
Tank in trunk area, under chassis, …
5 000 km1 000 km 25 000 km
24Aug2006
Inergy SCR system : system integration – Filling, Storage, Venting
Inergy concept with tank in trunk Refilling at trap Poke-Yoke function
Advantage : all functions in 1 concept
Cap with integrated OPR
Venting to the outside required
Over Pressure Relief valve (200-450 mbar +/- 50 mbar)
24Aug2006
Ammonia release + AdBlue® concentration evolution
Ammonia release Tank initially filled with 10 l Adblue®
80 °C constant temperature Over Pressure Relief opening pressure : 450 mbar
Measurement over 10 days
With Over Pressure Relief, 50 % more ammonia stays in solution and can be injected in the exhaust line
2% change in concentration with OPR compared to 4% without OPR after extreme/exagerated ageing phase
0 200 400 600 800
1000 1200
0 5 10
Wei
ght l
oss
(g) without OPR (B)
with OPR (A)
0
20
40
60
80
100
0 5 10
Am
mon
iaco
ncen
tratio
n (g
/l) without OPR (B) with OPR (A)
24Aug2006
Ammonia release + AdBlue concentration evolution
Monitoring the ammonia amount
potentially released by venting and wall permeation
Tank installed in a chamberof a known volume
Sampling the chamber atmosphere
at regular time interval
Use of an ammonia reactive cartridge
(lowest sensitivity range : 0.25 – 3 ppm)to measure ammonia concentration
Example of results : Car trunk internal volume : 0.35 m³ (estimation)
After 40 hours at continuous 40°C : no detection of any trace of ammonia vapour. < 3 ppm of ammonia vapour
24Aug2006
SCR-System : Heating system
Experiments : Heater in swirl pot.
Initial temperature T = -40°C
Heater power (electrical power) P = 100 W
Heating time t = 8 minutes (for measurement equipment)
Volume molten and ready for supply 150 ml
INERGY proposes an electrical heater with a power below 200 W (to include also preheating of pump and lines)
24Aug2006
Injector : Performance factors and integration
Injector performance : Droplet size and speed
(Spray measurement 50% on-time) 5 cm
5 cm
-2 +20
5 cm
5 cm
-2 +20
Droplet size and Mean speed
0
10
20
30
40
50
60
70
80
-2,5 -2 -1,5 -1 -0,5 0 0,5 1 1,5 2 2,5 3
Radial position (cm)
SMD
(µm
)
0
1
2
3
4
5
6
7
8
9
Ave
rage
spe
ed (m
/s)
Vmean D32
Overall droplet size : 54,6 µm Overall average speed : 7,0 m/s
Spray distribution : Interaction between droplets, gas flow and pipe wall
PowerSupply
24Aug2006
Inergy Electrical Control unit
At the centre of the SCR system
CPU
Pump
Injector
Purge valve
Pressure Sensor
Level sensor
Temperature Sensor
Actuators Sensors
Heating relay 1
Heating relay 2
Heating 1 (8.5A)
Heating 2 (8.5A)
Power Supply
Vbat GND CANH CANL
Engine or exhaust sensor data
Optional
Outputs :
•Dosing control •Spray quality control •Tank/lines heating •Tank/lines purging
Inputs :
•System pressure •Tank level signal •Tank temperature signal •Exhaust system sensor data •Engine control data
24Aug2006
Program
SCR system overview
Focus on some functions Storage Filling Venting Heating Injection Control
Case studies: system integration examples
24Aug2006
Case 1: Passenger Car tested in hot conditions
Personal car equipped with Dinox system Tank inside of trunk
Purge valve, filter and pump in trunk
Injector mounted on exhaust line
PA Lines: Starting from trunk
Going below car body to injector and back to trunk
Urea flow rate: 12kg/h (controlled by flowmeter)
Urea Tank Purge valve Filter Pump
Injector
Air
Exhaust pipe
(206)
(205)(207)T T
T
T (212)
24Aug2006
Case 1: Passenger Car tested in hot conditions (Pico Veleta test drive) Warm up drive Uphill drive Downhill drive
70Critical test conditions: very small Urea temperatures
urea volume in tank (3l) 65
60
55
In tank urea temperature exceeds [°C
]
50
hardly 50°C Confirmed by test started at 50°C by
artificial heating: reached only 54°C at mountain top.
With average urea volume (10l), urea temperature in tank hardly reached 43°C (with same test protocol)
45
40
35
30 0 1000
450
400
350
300
250
205(C) Urea temperature after pump (°C)206(C) Urea temperature after injector (°C)207(C) Urea temperature in return line close to tank (°C)212(C) Urea temperature in tank - bottom (°C)
2000 3000 4000 5000 6000
time [s]
Exhaust temperatures
[°C
]
200
150
Î limited generation of ammonia inside tank
100
203(C) Exhaust wall temperature at injector (°C)50 204(C) Exhaust gasses temperature before SCR catalyst (°C)
0 0 1000 3000 5000 2000 4000
time [s] 6000
24Aug2006
Case 2: Light Duty Truck
24Aug2006
Case 2: LDT Underside
Diesel Tank
Urea Tank
SCR Catalyst
24Aug2006
Case 2: Filler Pocket (Diesel & Urea Station Filling)
Diesel Fill Cap
Urea Fill Cap (w/ integrated overpressure relief valve)
24Aug2006
Case 2: Filler Pocket (Underside) & Fill Pipes
Diesel Fill
Urea Fill Tube
24Aug2006
Case 2: Station Fill Spud Option
Urea Fill Tube
Urea Fill Spud
Urea Storage Tank
24Aug2006
Conclusion
OEMs strategies and requirements can be met, i.e. volume of SCR tanks depending upon driving range and refilling intervals
Plastics offer flexible integration solutions in view of spatial and operational constraints
Global optimization of the system is essential in tight passenger car environment
With its longtime experience of fuel systems and diesel emissions reductions, Inergy is offering complete design, development and validation of SCR systems for passenger cars and light duty vehicles, from tank to injector
24Aug2006
Contact
www.inergyautomotive.com
Thank you!
Op de Beeck, Joël
Urea-SCR project manager Inergy Automotive Systems
rue de Ransbeek 310
B-1120 Bruxelles
Belgique
tel : (+32) 2 / 264 21 09
fax : (+32) 2 / 264 30 75
E-mail : [email protected]
Top Related