alfred reck guixia ba development of diesel …development of diesel catalysts for today´s and...
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Development of Diesel Catalysts for Today´s and Tomorrow´s
Diesel Engines
AVECC 2004, Beijing, April 27th- 29th
Alfred Reck
Guixia Ba
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§Introduction
§Structured Foils
ØPErforated Foil
ØLS-Foil
§Hybrid Catalyst
§Compact Catalyst
§Pre-Turbo-Catalyst
§PM-Filter Cat
§Summary
Content of Presentation
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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
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§Introduction
§Structured Foils
ØPErforated Foil
ØLS-Foil
§Hybrid Catalyst
§Compact Catalyst
§Pre-Turbo-Catalyst
§PM-Filter Cat
§Summary
Content of Presentation
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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
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Measurement of Flow Distribution
Standard Substrate
Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4
Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4
PE-Substrate
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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
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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
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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]
Ø80x50,8mm/600cpsi+
Ø98,4x58mm/1200cpsi
Ø95x101,5mm1200cpsi/PE
(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]
Ø80x50,8mm/600cpsi+
Ø98,4x58mm/1200cpsi
Ø95x101,5mm1200cpsi/PE
(Zone Coating)
Emission Test ProgramCascade System / PE Single Brick
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§Introduction
§Structured Foils
ØPErforated Foil
ØLS-Foil
§Hybrid Catalyst
§Compact Catalyst
§Pre-Turbo-Catalyst
§PM-Filter Cat
§Summary
Content of Presentation
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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
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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
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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
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§Introduction
§Structured Foils
ØPErforated Foil
ØLS-Foil
§Hybrid Catalyst
§Compact Catalyst
§Pre-Turbo-Catalyst
§PM-Filter Cat
§Summary
Content of Presentation
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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
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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
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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
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§Introduction
§Structured Foils
ØPErforated Foil
ØLS-Foil
§Hybrid Catalyst
§Compact Catalyst
§Pre-Turbo-Catalyst
§PM-Filter Cat
§Summary
Content of Presentation
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New Compact Canning Design with Twin Cat and Single Cat
Inlet
Outlet
Hybrid - Matrix
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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
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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
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§Introduction
§Structured Foils
ØPErforated Foil
ØLS-Foil
§Hybrid Catalyst
§Compact Catalyst
§Pre-Turbo-Catalyst
§PM-Filter Cat
§Summary
Content of Presentation
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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
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Pre Turbo Catalysts, Turbulent Applications
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Space Velocity [h-1]
PTC Ø 40 x 74,5 mm; 200 cpsiSpace Velocity at Different Engine Operation Points
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PTC Ø 40 x 74,5 mm; 200 cpsiHC Conversion Efficiency
HC Conversion Rate [%]
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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
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§Introduction
§Structured Foils
ØPErforated Foil
ØLS-Foil
§Hybrid Catalyst
§Compact Catalyst
§Pre-Turbo-Catalyst
§PM-Filter Cat
§Summary
Content of Presentation
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Principle
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Session 6
4:15 Uwe Israel, Twin Tec
Retrofit Catalyst Systems for Diesel Engines
Further Details to PM-Filter Cat
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§Introduction
§Structured Foils
ØPErforated Foil
ØLS-Foil
§Hybrid Catalyst
§Compact Catalyst
§Pre-Turbo-Catalyst
§PM-Filter Cat
§Summary
Content of Presentation
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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
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Thank you for
Your
Attention
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