LDV Diesel SCR on DPF Technology to meet tighter NOx and PN emission in RDE condition

Transcription

1 ECT-2018 BSVI and Real Driving Emissions. Path Forward October 25-26, 2018 Hotel Hyatt Regency, Nagar Road, Pune, India LDV Diesel SCR on DPF Technology to meet tighter NOx and PN emission in RDE condition T. Ogata, Y. Aoki, M. Yamashita, M. Makino / NGK Insulators Ltd. K. Sugimoto, A. Gopalkrishna NGK Technologies India Pvt. Ltd. SCR: Selective Catalytic Reduction DPF: Diesel Particulate Filter RDE: Real Driving Emission NGK Product Engineering Department Engineering Division Slide1

2 1. System Trend to Meet Tighter NOx and PN Regulation 2. SCR on DPF Technology 3. Investigation of PN Emission in RDE condition Future Development Summary NGK Product Engineering Department Engineering Division Slide2

3 1. System Trend to Meet Tighter NOx and PN Regulation 2. SCR on DPF Technology 3. Investigation of PN Emission in RDE condition Future Development Summary NGK Product Engineering Department Engineering Division Slide3

4 Indian Diesel Regulation India Now NGK Product Engineering Department Engineering Division Regulation BSIV BSVI Stage I BSVI Stage II Cycle NOx [mg/km] MIDC RDE monitor RDE + MIDC Wide driving range Tighter NOx and PN 80+ RDE CF? PN [#/km] 6x RDE monitor 6x RDE CF? CO 2 [g/km] MIDC : Modified Indian Driving Cycle RDE : Real Driving Emissions PN : Particle Number CF : Conformity Factor Tighter regulation for NOx and PN with Real Driving Emission from Lower CO 2 Slide4

5 Technique to Meet Tighter NOx emission in RDE How to accomplish high NOx conversion in RDE? RDE Wide driving range Wide range of exhaust temperature At low exhaust temperature At high exhaust temp. Apply LNT Improve light off of SCR Increase SCR volume SCR in Close Coupled Space Constraint in Underfloor Only LNT will be not enough. Apply SCR on DPF in Close Coupled UF : Under Floor DOC : Diesel Oxidation Catalyst LNT: Lean NOx Trip SCR : Selective Catalytic Reduction ASC : Ammonia Slip Catalyst SCR on DPF will be a mainstream in RDE implementation. Slide5

6 NOx Conversion (%) Schematic consideration of NOx Conversion Assumption in NGK understanding City Rural Area Highway Uphill Driving Impact of SCR in Close Coupled Faster light off LNT+SCR on DPF+SCR (as system) LNT LNT+SCR SCR Impact of More SCR catalyst Higher NOx conversion Exhaust Temperature C SCR on DPF system will cover wide range of exhaust temp. Slide6

7 Diesel System Layout Consideration BSVI stage I (RDE monitoring) BSVI stageii (RDE implementation) DOC CSF SCR/ASC DOC SCR on DPF SCR/ASC LNT CSF SCR/ASC Urea Tighter NOx regulation Urea LNT SCR on DPF SCR/ASC DOC Urea SCR on DPF Mainstream Urea SCR catalyst loading on DPF achieved compact system Could be fit to Indian market Before RDE implementation, both CSF and SCR on DPF can be applied. SCR DOC CSF: Catalyzed Soot Filter (Oxidation catalyst coating) SCR on DPF SCR on DPF will be required from RDE implementation. Source: Automobile and Engine Technology 2015, Daimler Slide7

8 1. System Trend to Meet Tighter NOx and PN Regulation 2. SCR on DPF Technology 3. Investigation of PN Emission in RDE condition Future Development Summary NGK Product Engineering Department Engineering Division Slide8

9 NGK s developed DPF to Meet Requirement BSVI NGK Product Engineering Department Engineering Division Market Needs Higher NOx Conversion Lower CO2 Lower PN Key requirement to DPF Higher Catalyst Loading Lower Pressure drop Higher Filtration Efficiency NGK s Technologies Higher Porosity Optimized Pore Size Distribution NGK developed SiC-DPF with both high porosity and optimized pore size distribution Slide9

10 Pore volume Optimized Pore Size Distribution for high Porosity SiC-DPF Material pore size distribution material Standard material pore High max. Pore volume Developed material (more uniform) catalyst Reduce Small pore Lower pressure drop Reduce big pore Higher filtration Small Pore diameter Large Developed material reduced small pore size and big pore size achieved lower pressure drop and higher filtration Slide10

11 Basic SCR on DPF Performance NOx conversion PN filtration Pressure drop Max DPF Temperature at uncontrollable regeneration Drop to Idle (DTI) test procedure Slide11

12 NOx [mg/km] Particle Number [#/km] NOx/PN Emission by Vehicle on the Market in EU6 cycle as basic performance Test condition Vehicle on the Market: 2.0L Diesel engine with 3ltr round DPF, System layout: DOC+SCR on DPF+SCR NOx emission EU6 Limit 80mg/km 1.0E+12 NGK Product Engineering Department Engineering Division PN emission EU6 Limit 6.0 x /km E E+10 NEDC WLTC NEDC WLTC NEDC : New European Driving Cycle WLTP : World harmonized Light-duty Test Procedure SCR on DPF with high porosity SiC-DPF meets NOx/PN regulation in EU6 cycle. Slide12

13 Bare CSF (Coated) Bare Pressure drop [kpa] SCR on DPF (Coated) Pressure drop [mbar] Pressure Drop [mbar] Pressure Drop Comparison with Conventional CSF System Cold flow bench Test condition Device: NGK cold flow bench DPF: 3ltr round, Gas flow: 10m3/min, Temperature: RT NGK Product Engineering Department Engineering Division, Engine (Full PD_EKM load [hpa] step up) SCR on DPF 250 CSF CSF with NGK dense material SCR on DPF with NGK High porosity material Test condition Device: 2.0L, Euro4 engine DPF: 3ltr round, coated Full load step up: 3min/step Time [sec] Time [sec] Similar pressure drop was confirmed although SCR on DPF was coated by much higher catalyst loading than CSF. Slide13

14 DPF Max Temperature [deg.c] DTI Test Result with Conventional CSF System NGK Product Engineering Department Engineering Division 1,400 1,300 Crack area 1,200 CSF(coated) 1,100 1,000 SCR on DPF(coated) Test condition Device: 2.0L Euro5 engine, CC DOC+DPF DTI condition: MSC-2SR (CSF EU5) C1 MSC-2SR (CSF EU5) C4 2,000rpm, SC Nm (SCR_High) 1,000rpm, S3 0Nm Inlet Gas SC-18 temp. (SCR_High) at DTI: 640deg.C S5 (Post injection: ca sec) DPF: 3ltr round Soot loading [g/l] Loaded Soot [g/l] Max DPF temperature behavior with different soot loading was similar between SCR on DPF and CSF in DTI test. Slide14

15 Basic Performance Test Results for SCR on DPF DPF performance NOx conversion* PN filtration* Pressure drop* (compared with conventional CSF system) Temperature behavior at DPF regeneration* (compared with conventional CSF system) Result Potential to achieve NOx limit with EU6 cycle Potential to achieve PN limit with EU6 cycle Equivalent with CSF Equivalent with CSF *All performance results are catalyzed DPF NGK high porosity SiC-DPF has at per performance as SCR on DPF. As further investigation, NGK confirmed PN emission in RDE as filter responsible performance Next section NOx emission is not focused because not only DPF but also vehicle calibration, catalyst etc. influence NOx. Slide15

16 1. System Trend to Meet Tighter NOx and PN Regulation 2. SCR on DPF Technology 3. Investigation of PN Emission in RDE condition Future Development Summary NGK Product Engineering Department Engineering Division Slide16

17 PN Measurement in RDE Condition on the Road Limburg an der Lahn Motivation / Aim for RDE Tests - (EU6) Class E Vehicle L 4-Cyl. (140 kw) 3.0L SCR on DPF with NGK high porosity SiC-DPF - Include Cold Start / high speed Bad Camberg - Include DPF regeneration - Commercial PEMS equipment Urban Rural Motorway Idstein RDE testing with vehicle was conducted on the EU road Slide17

18 PN emission [#/km] Include filter regeneration PN Emission Results in RDE PN emission data (weighted by EMROAD) Test condition : 2.0L 4-Cyl. EU6 Vehicle with 3ltr round SCR on DPF with NGK high porosity SiC-DPF Before PN measurement, the vehicle ran the RDE route to check equipment. 1.0E E E E E+10 EU Not To Exceed limit (CF=1.0 case) Regulated for Full RDE Cycle and Urban. Full RDE Cycle Urban 1.0E E+08 RDE#2.2 RDE#2.3 RDE#2.4 RDE#2.5 1st test 2nd test 3rd test 4th test PN is affected by soot loading and regeneration events. PN is under NTE limit even when active regeneration occurred. PN in the urban section remains under NTE limit also after filter regeneration. Slide18

19 1. System Trend to Meet Tighter NOx and PN Regulation 2. SCR on DPF Technology 3. Investigation of PN Emission in RDE condition Future Development Summary NGK Product Engineering Department Engineering Division Slide19

20 Future Development BSVI NGK high porosity SiC-DPF for SCR on DPF - Well Established and Ready for Mass Production - Market experience (11 OEMs globally) Tighter regulation Future NGK Continues to develop DPF for SCR on DPF!! Further Design Optimization of Balanced Performance to meet Future RDE Slide20

21 Summary NGK Product Engineering Department Engineering Division SCR on DPF will be required from the timing of RDE implementation. NGK high porosity SiC-DPF has at per performance as SCR on DPF. NGK high porosity SiC-DPF shows possibility to meet PN limit with RDE. Slide21

22 NGK Product Engineering Department Engineering Division Thank you for your attention! DIESEL PARTICULATE FILTER HONEYCERAM LARGE SIZE MONOLITH HONEYCOMB Slide22