AdBlue Technology

By Dr Mark Cook Technical Manager Allen Group Limited

NH2

AdBlue what is it ?

| C=0 | NH2

A compound manufactured by combining Ammonia (NH3) with Carbon Dioxide (CO2) under high pressure and used traditionally as a fertiliser. Urea solution 32.5% urea / 67.5% water.

Marketed as AdBlue and conforms to DIN V70070

History
Abstract
- Emissions of Diesel engines contain some hazardous components - Particulate and NOx-emissions can be reduced by the SCR technology (Selective Catalytic Reduction) - A reduction agent has to be injected into the exhaust upstream of a catalyst

Truck Market
- SCR technology was used with Diesel engines since mid-80s - 1991 : joint development between DaimlerChrysler, MAN, Iveco and Siemens to use this technology on Heavy Duty Trucks (HDT) - SCR technology is meeting Euro 4 and Euro 5 European Regulations - SCR technology is now used by all main truck makers : Mercedes-Benz, MAN, Volvo, Renault, Mack, Iveco, DAF, except Scania - SCR technology: key players are Bosch and Cummins Emissions Solutions (part of Cummins)

Reduction agent
- Aqueous solution of Urea : commercial name is AdBlue TM conforms to DIN V70070 - AdBlue is a non toxic and non smelling liquid - The AdBlue consumption is about 5% of the Diesel fuel consumption

Cleaner Products Environmental Challenge

1996

PM (Particulate Matter) [g/kWh]

0.14 0.12 0.1 0.08 0.06 0.04

Euro 2 US 02 Euro 3

US 10

Euro 5 US 07
0.5 1 1.5 2 2.5

Euro 4 NOx [g/kWh]

3 3.5 4 4.5 5 5.5 6 6.5 7 7.5

0.02 0
2010

Basic Principle of Selective Catalytic Reduction (SCR)

SCR system for trucks Additional equipment located close to the Fuel Diesel tank

Typical AdBlue pipe dimensions AdBlue tank - pump feed: 8x1mm AdBlue tank pump return: 8x1mm Pump injector: 5x1mm

Woking principle - injection of AdBlue inside exhaust upstream - NOx is reduced into N2 (Nitrogen) and H2O (water) - Spray of AdBlue in the exhaust : less than 0.1 second dwell time

AdBlue Hose Assemblies - Unheated

The technology is based on Cummins Emissions Solutions SCR system Grundfos AdBlue pump (air activated) SAE quick connector ports as specified by Allen Group
Easy to install, no leak

6.30mm used on injection lines / 5x1mm tubing 7.89 or 9.49mm used on feed / return lines (poke yoke) / 8x1mm tubing Injection line is fluoropolymer lined for low friction (Allen design) Minimize AdBlue crystallization

Validated by Cummins Emission Solution Europe

Existing customers
6 customers to date (including Leyland Trucks)

Injection Line (self purging, always unheated)

5x1mm tube

6.30mm SAE fitting

Injection nozzle

Exhaust with catalyst

Unheated Feed and Return Lines

8x1mm tubing 7.89 / 9.49mm SAE fittings Poke Yoked for installation

Pump side

AdBlue tank side (with level sensor)

AdBlue Hose Assemblies - Heated

Key features
Proprietary design High bend radius small envelope PA12 core tube Proprietary conductive polymer formulation Insulating sheath to provide isolation from the vehicle AdBlue resistant SAE J2044 quick fit connectors Standard 2 pole / 4 pole electrical connectors Water ingress resistant to IP67 Thermostatic control Constant temperature sensing - reduced energy input via control box Allen designed control box Power input of 20W/m Validation to Allen specification and customer standards Developments with 5 OE customers

AdBlue Hose Assembly - Heated

CORRUGATED HOSE

PROPRIETARY CONSTRUCTION

QUICK CONNECTOR
ELECTICAL CONNECTION

AdBlue Hose Assembly - Heated

Technical data At a power input of 20W/m down to an ambient temperature of -38C, the hoses are capable of melting frozen urea from within the tubes to enable dosing by the SCR system within 30 minutes of activation of the system by the operator.
Temperature data for heated AdBlue hose (Power = 20 W/m)
0

0
-5 -10 -15 -20 -25 -30 -35 -40

10

15

20

25

30

35

Temperature (C)

23C -40C -36C -30C

-45

Time (minutes)

Advantages over competition (1)

Methods of heating AdBlue Hoses Electrical heating Nissan Diesel, Volvo 3P, Leyland Trucks Coolant water heating Scania
Differences in the heating methods Electrical heating 1. AdBlue heating achieved by electrical power in a cable 2. Consistent and rapid heating 3. Will achieve emission regulations for Euro 6 engines

Coolant water heating 1. AdBlue heating achieved by hot coolant water in double skin hos 2. Inconsistent and slow heating, 3. Will not achieve emission regulations for Euro 6 engines

Advantages over competition (2)

Competitors ContiTech / SAE fittings: Bosch DINOX 2 Electrical: Volvo ContiTech / Voss fittings: Bosch DINOX 1 Coolant: Scania Nitta Moore / Voss 246 fittings: Bosch DINOX 1 Electrical: Nissan Advantages of Allen System over competition 1. Compact hose design (less weight, high bend radius) 2. SAE fittings (easy to install, disconnect, no leakage) 3. Compatible with Bosch DINOX 2 and Cummins SCR system 4. Lowest energy consumption of all electrically heated hoses 5. Controlled heating, via control box 6. IP67 rated 7. EMC tested