Fresh ldea3 - Cleaner Future

E.c.o,c'TXt-

lbonair

Emission Techniques and Related SCR Systems by Ecocat and Albonair

I
Silke Jrgens, Albonair Toni Kinnunen, Ecocat Teuvo Maunula, Ecocat 25.5.2012
*fs-

WWWECOCAT.COM WWW.ALBONAIR-COM

Gontents

o Ecocat and Albonair collaboration

o V-SCR catalyst

o Urea dosing technology o Optional elements o Hydrolizing catalyst o Ammonia slip catalyst o Summary

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Ecocat in Brief
Overview

Ecocat Oy ("Ecocat") is a leading emission technology company operating in the growing

market for catalytic convefters

r r

Leading industry pioneer with market presence since 1985

Ecocat is 150-T516949 and ISO14001 ceftified.

Broad range of application areas in the global markets for r Passenger & light commercial vehicles

r r r

Heavy commercial vehicles (trucks, busses)

Off-road (agricultural, rail, marine) Industry (stationary engines, VOC incinerators)

Capabilities for complete delivery of catalytic convelters from substrate to canning r In-house manufacturing of durable metallic
substrates

Coating expeftise for both metallic and ceramic substrates Canning capabilities for different catalyst types

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Ecocat Group

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nland Finland

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h

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-/2^ -Tt/

-)
$

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Nizhniy

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Ghina

ng

Italy - Genoa
0

lran - Teh ran

- Faridabad

JU

' '

Approximately 290 employees in five countries Sales agents close to customers

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Ecocat's Products are Organized Around Four Business Areas

Passenger and Light Gommercial Vehicles

lndustry

Heavy Commercial Vehicles

Off-Road

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Albonair - Company Overview

Development of Albonair

2007

2008

2009

20'10

2012

Albonair is founded as part of Hinduja's Automotive Sector 100% privately owned by Hinduja Group

Albonair delivers first prototypes of SCR-Systems to customers

Albonair India is founded to set up a production facility for a local customer

SOP of exhaust aftertreatment solutons for the lndian market Albonair moves into a new headquafter in Dortmund, Germany

SOP of EURO Vl-UDS for an European OEM

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bonair

Albonair - Company Overview

Global Presence

Dortmund, Germany
Headqua rter R&D
Sales
Ej

Customer Service

Detroit, USA
Testing facilities
Sales

Customer Service

Taicang, China

Chennai, lndia
Urea Dosing Assembly Line Housing Assembly Line
Sales

Urea Dosing System assembly line Housing assembly line

Sales

Customer Service

Customer Service

ECOCrlf

bonair

E.g,o,C'l,,jf
Fast growing European company, OEM supplier status

bonair
,/ ,/ ,/ ,/ ,/ ,/

,/ ,/ ,/ ,/ ,/ ,/ ,/

High-class technology for diesel exhaust aftertreatment Flexibility and intimacy to solve customers' challenges Focusing on the key projects Global presence with covering customer interface Localized production sites and competence centers to serve customers All the catalytic elements available, substrates and coatings together with canning All the SCR urea dosing system dosing components and system integration know-how available

r/

Two companies matching perfectly to enhance own success together by provdng complete customized and well-integrated solutions

ECACIIT

bonair

Complete diesel aftertreatment system

_>

DOC
co
co2
Hydrocarbons NO)NO2

SCR
U

DPF
NH3

CO2 and HrO

Urea

NH3

NOx

N,

N2

Paicle mass

CO2

INJECTION

Based on application, normally only some of above are needed

Ecocat has the whole range of catalysts n portfolio; substrates and coatngs
Together with partners, the complete systems tailored to fulfill customers requirements

E,COCIIT

bonair

Fresh ldea3 - Cleaner Fulute

ECOCIIT

lbonair

WWW.ECOCAT.COM WIA'W.ALBONAIR.COM

Reactions in SCR systems

PreOxicat Hydrolysis
SCR catalyst
standard

NO+O,
CO(f{Hr)rCO + HrO

2NH 3

CO,

SCR

4 NO +

Oz4Nr+6HrO
NH3
3

fast SCR

NO

4Nr+3H2O

N02-SCR

4I\H 3

3.5 N, *

6Id.zO

PostOxicat

+ 3Or+2Nr*6H2O

Optimization of DOG together with H-kat and SCR needed: NO, formation, backpressure, temperatures and costs

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SCR activity by engne experiments

Criteria NO* conversion at 280"C

100

s c.9 g. o-

80

A I a !

g z z

94

60 40 20
0

NHr slip <20 ppm

--> 98o/o NO'

conversion

0.7

0.8

0.9

1.1

1.2

Nominal NH3/NOx

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SCR activity by engine experiments Engine 6.9 L; Catalyst 12.8L,500 cpsi

NOx conversion curve 100

28.000 h-1 465 ppm NO,
51.OOO
h-1

e^
ctr ocL ' cL
F

61 . OOO h-1

57. OOO

h-1

80

1170 ppm

990 ppm NO,

60

R trV
fJ= -

16.500 h-1 1420 ppm NO,

930 ppm NO*

O(

40
20
0

200
,c.oc,rlf

250

300 350 400 oC

Temperature,

450

500

550

Effect of NH3 slip criteria limit

UreaCR engine results- MAN 6.9L, 15 h aged KSCR2,500 cpsi,'12.7L

100

E90 80
CL

s70
60

s!

eo.ooo h4
SI.OO

trr

st.ooo

ha

s8.ooo trr

$9'o
(! ' o,

230
20
10

az 840 x

tS.SO0

trr

KSCR2, 20 ppm NH3 <-KSCR2, l0 ppm NH3

200

250

300

350

400
oC

450

500

5s0

Temperature,

) )
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No significant changes in performance without any additional NH3 slip catalyst

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Effect of cell density (surface area)

Ecocat 500 cpsi 100 90

Target conversions
Euro 6/tTS20l0 Euro 5 Euro 4

i80 170

Extruded ref
Ecocat 220 cpsi

gR'40 Ev 30 20 oro
0

Go

so

Ecocat 350 cpsi

3o.ooo n"
16.S00

tr"

s1.ooo h"

61.ooo

n'

58.ooo n"

200 250

300

350

400
oG

450 500

550

Temperature,

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Ecocat SCR: the frst EPA and CARB approval for V-SCR (off-road)
r,

srn

",

PROTECTION AGENCY UNITED STATES W OFFICE OF TRANSPORTATION AND AIR QUALITY .WASHINGTONDC 20460

EO Sra 6."

z fJ q

CERTIFICATE OF CONFORMITY 2OIO MODEL YEAR

Manufacrer: Engrae Farnily:

.{O

SIS[, PO\\IER

I]iC.

-{sil)L08.4H6jl'

IR RESOURCES BOARD
MODEL YEAR ENGINE FATILY

Acco stsu DIESEL lilc.

(libn)
FUEL TYPE

I
Ner Off-Road

Com pression-lgnition Engines

DISPL.ACEIUEilT

USEFUL LIFE (hours)

2010

ASIDLO8.4H6A

8.4 & 9.8

Diesel
TYPICAL EQUIPiIETTT APPUCATION

8000

SPECIAL FEATURES & EIU]SSION COHTROL SYSTEHS

Direct E
,c.o,g.I\T

Cooler, ter,

ractor

High-Temp SCR
The reasons to develope improved V-SCR for high-temperature applications
a

The SCR chemistry need to be durable for high-temp applications, too . Of-road full-load drivings . Need to be applicable for the usage together with DPF (Euro5 and beyond) . Cu-zeolite limitations (NrO formation, sulphur sensitivity, NO, sensitivity)

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Laboratory results
a

a a

HT700/20h lnlet: NO 1000 ppm, NO, 0 ppm, NH3 1000 ppm,Or10 600 cpsi, SV = 50 000 h-1
100 90 s 80 70 60 ,9 g, 50 o 40 tr o o 30 x o 20 z 10
0

o/o,

H2O

I %, N, bal.

HT700"Ct20h 1000 oom NO

\.

\ \

+ Thermally sta ble VSCR-wl +Std V-SGR-w1249 REF

-10 -20

150 200 250 300 350 400 450 500 550 oC

Temperature,

600

Ec,o,C,/X

bonair

Laboratory results
a a
a

HT700/20h lnlet: NO 600 ppm, NO2 400 ppm, NH3 1000 ppm, Or10 600 cpsi, SV = 50 000 h-1
100 90 80 70 60 50 40 30 20 10
0 -10

o/o,

H2O 8 %, N, bal

s
.9
g,

o
tr o ()
x

HT700'C l20h 600 ppm NO 400 ppm NO,

+ +
-I

hermally sta ble V-SC R-w1241

! I

Std V-SCR-w1249 REF

\
600 Temperature, "C

-20

150 200 250 300 350 400 450 500 550

E.co,c'tNf

Fre3h ldeas - Gleaner FuluTo

Eco,C,lxf

lbonair

WWW.ECOCAT.COM WIIVW.ALBONAIR.COM

AI bonai

r Prod uct Portfol io

Selective Catalytic Reduction System Urea Tank
ACU & UDS

Diesel Particulate Filter Diesel Oxidation Catalyst

DPF

DOC

SCR-Muffler & Nozzle

q..

t
C

,)

Albonair offers complete exhaust aftertreatment systems

bonair

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Urea Dosing Units for Different Markets

EURO 4 (e.g. Emerging Markets) EURO 6 (e.9. Europe)

@
o

Tier 4 Final (e.g. Off-Road

vehicles)

EURO 6 Passenger Car (e.9. Europe' USA)

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Products & Technology

Location of Products

ru
,--

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'tt
UR=q
5
T

.:A

llli

5CF
STE
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r- -n .1,-

ir

5lll:i

F.'lUFFLER

I'I'ST

Eh"I

n JTE P ATI EI

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-------- ---.-17

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Concept of Albonair's SCR System

Schematics
Urea level Urea temperature

Air pressure
Urea pressure CAN Urea temperature

Engine
ECU

Dosing System

Electronics (ACU)
Actuators

AdBlue Tank sil-. \-,-5T

Engine Coolant

Urea
Air Air
Sensors

ine Coolant

Urea
SCR

Air Supply (vehicle

air or electrical air
pr

Muffler with lnjection Nozzle

Nozzle

Temp Exhaust stream

NOx

Temp. Sensor

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ir

Goncept of Albonair's SCR System

s ra Formation of Different AdBlue Dosin

tems
Characteristics

System

Spray Formation
Hot
Exhaust

> >

Pressure Atomizer (Airless)

Energy for atomization from the liquid pressure

lncrease of pressure leads to improved spray quality

Hot

Twin Fluid Atomizer with internal mixing (Air Assisted)

AdBlue

Exhaust
Gas
-}l

...

> Energy for atomization

from air pressure

o o'3 aa

*
-+

o'r
aa

Air

.:

> Typically high air consumption

>
Hot

Energy for atomization mainly from air pressure

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

Exha ust

Air
AdB

Gas
iE a'.

ue

II

l-r .'.'. '.' o;..::.'.'..: .r e

o r ..'.'1.. ' . '
i

..a'- t' "-

> Low air consumption > No contact between AdBlue

Air +

and air in the dosing system / nozzle to avoid crystallization and deposits

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Technical Background
Evaporation Rates for Different Droplet Distributions

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

> .: c (u
E
f

Air.less Doslng

o
-o

System

i5

Albonair Air-Assisted
Dosing System

Even at 300 "C small

200
300

100

Particle Size [pm]

80

(u

.
G G

60

c o o
40
o-

droplets of SMD 2t tm eva porate com pletely within 600 mm Very poor evaporation for big droplets SMD 96 pm

20

96

100

200

300 400 500

Evaporation Length [mm]

600

700

800

,c.(),C,IIT

bonair

Technical Background
NH, and HNCO decomposition improve with Albonair UDS

100o/o

80o/o

60%

t-]

40o/o

Test Conditions: HD Dieselengine L2l, Hydrolyse Tube 600mm, Measurement HNCO and NHt using FTIR

c o
'6 o
E
CL

2 0o/o
to 0 o/ 10Oo/o

o o

75o/o

@1200 minr

50o/o

25o/o

o
t

o'1 00o/o

i"tfl

o
80%

'l

Albonair: NH. Albonair: HNCO

60%
40%

r-l

ffi

Airless: NH.

Airless:

HNCO

Significant increase of AdBlue Hydrolysis Better Nox-Conversion at the SCR Catalyst Less deposits in the exhaust system

20o/o

Oo/o

10Oo/o

75o/o
bonair

@2000 minr

50%

25%

,COC,IT

Gatalyst Effciency improved at low Exhaust Mass Flow

Little NH.-Slip
Low Exhaust Mass Flow 200 - 250 kelh
100 100

High Exhaust Mass Flow 500 - 1000 kelh

90

90

80

80

oc'
c
o
I

s
70

o o

'
tr
lrt

o o

70

o o o (, I x o

o
r.,

860
50

E60
50

* o

40

40

.#Albonair

*Albonair

{-Airless
30
30

*Airless
275 175
195

775

19s

2r5

235

255

215

235

255

275

Temperature ('C)

Temperature ('C)

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The importance of proper urea distribution

AdBlue Concefitrtol

(normolhcdl
4.00

3.r0
3.60
3.10

3.20 3.00 2 r') 2.0 2.40

2.0

2.00

t.80
1.60

t..0
t.20 t.00
0.E0

Proper design is an essential part of SCR technology to ensure that urea is well distributed and decomposed to ammonia before SCR catalyst

0.60 0.40 0.20 0.00

Ad8luc Concmm

(nomlBcd)
4.00
3.E0

3.60

3.{0
3.20

l.o0

2O
2.60

.10
2.20 2.00 1,80 1.60

1a0

r20

to0
0,r0
0.60 0.40 0,20 0.00

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ir

FTesh ldeas - Cleaner Fulurc

ECOClIT

lbonair

WWW.ECOCAT.COM WWW.ALBONAIR.COM

Urea hydrolysis

Thermal or catalytic hydrolysis of urea important in the limited space of exhaust lines at Iow temperatures (NH z)zCO >
thermolysis

HNCO +

HzO

>

hydrolysis

+ enhancement with EcoXcell mixers in particular at low temperatures + possible to have good mixing, urea nozzle near to SCR
and combinatory properties

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ir

Metallic substrate for mixers and H-catalysts

EcoXcell@ . Welded, mixer-type structure for coated catalysts having efficient 3D mass and heat transfer . EcoXcell 20" for SCR applications

+ Hydrolysis catalyst coating + SCR catalyst coating

fm 3^-ll

ECO,llT

C,I
Velocity
(Ve<tor
1)

}G'

.. 104.5

69.7

34.8

0.0
[m s^-

l]

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How to utilize H-cat in SCR?

1) Combination of SCR catalyst coated EcoXcell mixer-catalyst and SCR catalyst mixing and total SCR catalyst amount
Exhaust gas

*Urea

2) Small EcoXcell substrat e (25 cpsi) as urea dosing mixer: to enhance hydrolysis catalyst reactions to avoid any urea accumulation

Exhaust +Urea

ga5+

Note: also inlet tube (and cone) surfaces can be coated by H-Cat, to avoid any accumulation and coffosion
Eq.o,c'ttT
bonair

H cat only laboratory experiments

Product distribution with blanco substrate Nominal inlet: 1000 ppm NO, no NOrr 500 ppm Urea, SV = 100 000 h-l

l0'/'

O2r8 o H2O, N2 balance

Urea hydrolysis products- blanco substrate

ooooooaolooaoo
unreacted urea

1200
1

-25 % of urea unreacted, o additional NHt

600 400
E
CL CL

n NOx

200
0
1

r HNCO r NH3

80

205

230 260

300

350

450

Temperature before cat, oC

E,c,o,C,tNf

H cat only laboratory experiments

Product distribution with HT700 KHI.1+KH2.2 (good adhesion/improved selectivity) Nominal inle 1000 ppm NO, no NO2,500 ppm Urea, l0 o/o O2r8 "/" H2O, N2 balance SV = 100 000 h-l

Urea hydrolysis products- KHl .1+KH2.2 (w8090-200 cps) HT700 aged

ooaoolooaoaao
unreacted urea

ot

1200
1

000

800

z
E
CL

!
I

N20

Almost only NH3!! no by-products

600 400

tr NOx

r HNCO r NH3

200
0
1

80

205

230 260

300
oC

350

450

Temperature before cat,

,g.Q,c,llT

The enhancing effect of H-kat at low temperature

NOx conv.To NH3 slip <20ppm
100

90 80 70 60 50 40 30 20

T
r
NOx conv.To NH3 slp <20ppm

l0
0
1500 mm no (245 deg

C)

H-kat

'1500 mm no

(285 deg

C)

H-kat

550 mm with Hkat (245 deg C)

550 mm with Hkat (285 deg C)

550 mm no H-kat 550 mm no H-kat (285 deg C) (245 deg

C)

Significant effect on SCR acitivity by utilising H-kat in front of SCR obtained Studied by 4.9 lengine (H-kat size D105 x L 100 mm)

,COCI\T

bonair

The role of ASC, NH3 slip control

of AS c
100
E

98

98

98

99

98 88

90 80 70 60
50

o N

CL CL

79 66

77

77

s i
.9
g.

310'C 260'C t g.ooo n-t

230"C 2o.ooo h-t 3.ooo n-t

400'c
48.ooo h-t

c
x

o (J

40
30

z (
'tr

N Pt-DOC+KSCR2-300 cpsi FRESH

o +,

20
10
0

r Pt-DOC+KSGR2

300 cpsi - Burner aged 570'C/100h

480'C

Pt-DOC+KSGR2-300cpsi+4PUASC- Burner aged 570'C/100h

st.ooo n-t

MODE 10

(230.C)

MODE 9

(260"C)

MODE3

(310"C)

MODE2

(400'C) MODEI(480'C)

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SUMMARY
o

Ecocat-Albonair combination provides uniqu, one source solution

All the elements available for meeting Euro6 requirements

SCR chemistry proven to be extremely durable

Gompetitive and cost-efficient urea dosing systems

Glear technical benefits for NOx performance
H-CAT and ASC elements available for the most challenging targets

Ec.(',C,,\T