Scaling API-first – The story of a global engineering organization
Bio 3B: Biodiesel exhaust aftertreatment
1. Biodiesel
Technical
Training
Course
BIO3B:
Exhaust
A:er-‐
Treatment
and
Biodiesel
Presented by the
National Biodiesel Board
2. Today’s
Topics
• Changes
in
diesel
engine
emissions
regula4ons
• Basics
of
diesel
engine
emissions
– Changes
in
hardware
required
by
emissions
regula4ons
– Interac4ons
of
fuels
and
fuel
systems
• Methods
of
exhaust
a>ertreatment
• Exhaust
a>ertreatment
&
biodiesel
• Resources
3. Learning
Objec4ves
• Provide
access
to
industry
experts
for
more
detailed
ques4ons
and
answers
about
biodiesel
• Introduce
the
Na4onal
Biodiesel
Board’s
Diesel
Technician
Training
program
and
the
program
resources
to
the
audience
• Provide
quality
informa4on
about
biodiesel
and
diesel
emissions
• Provide
quality
informa4on
about
biodiesel
usage
and
today’s
diesel
exhaust
emissions
a>ertreatment
4. Learning
Outcomes
• Be able to answer general questions about biodiesel that
you may be asked as a technician
• Be able to answer questions about biodiesel emissions
• Be able to answer questions about biodiesel usage and
today’s diesel exhaust emissions aftertreatment
• Be able to make recommendations regarding biodiesel use
and vehicle maintenance
9. 2010
standards
• Introduction of ultra-low sulfur diesel fuel in October 2006
• EPA emissions standard for 2007:
• Diesel particle filters (DPF)
• Increased levels of exhaust gas recirculation (EGR) and higher fuel
injection pressures
• Full EPA emissions standard in 2010:
• DPF, EGR, high pressure fuel injection
• Exhaust catalysts for NOx reduction
• NOx adsorber catalysts, unburned diesel fuel for operation
• Selective catalytic reduction (SCR)
• Diesel Exhaust Fluid (DEF) needed for SCR operation
10. Diesel
Par4cle
Filters
• Exhaust
flows
through
porous
wall-‐flow
elements
– PM
is
trapped
on
the
walls
of
the
filter
• When
exhaust
temperature
is
high
enough,
PM
is
burned
off
– In
most
cases,
unburned
diesel
fuel
is
injected
to
accomplish
this
• Precious
metal
is
loaded
onto
filter
walls
to
lower
the
temperature
required
for
regenera4on
• Issues:
– Regenera4on
at
low
temperatures/duty
cycles
– Plugging
with
incombus4ble
materials
like
lube
oil
ash
11. Diesel
Par4culate
Filter
(DPF)
Maintenance
• Carbon
par?culates
are
burned
off
with
on-‐board
regenera?on
• Ash
remains
in
the
DPF
and
must
be
removed
periodically
– This
requires
removal
from
vehicle
12. Catalyzed
Diesel
Par4culate
Filter
(CDPFs)
Exhaust Gas
Platinum Catalyst Soot Filter
Converts NO2 Oxidizes Soot in Filter
NO 2NO2 2NO2 + C CO2 + 2NO
• Uses
chemicals
in
exhaust
to
con?nuously
burn
carbon
in
Soot
Filter
• Must
s?ll
be
removed
to
clean
ash
16. Biodiesel
Tes4ng
Cummins ISB 300
• 2002 Engine, 2004 Certification
• Cooled EGR, VGT
Johnson Matthey CCRT
• 12 Liter DPF
• Passively Regenerated System
• Pre Catalyst (NO2 Production)
• ReFUEL Test Facility
• 400 HP Dynamometer
• Transient & Steady State Testing
• Cummins
• Soot Characterization
• Significant financial support for testing
• Fuels: ULSD, B100, B20, B5
17. B20 Testing
B20 results in substantial PM reduction even with DPF
(data for 2003 Cummins ISB with Johnson Matthey CCRT on HD FTP)
Reduction with DPF ranges
from 20% to 70%, depending
on basefuel, test cycle, and
other factors
• Reduction in sulfate
emissions
• Increased PM reactivity
Williams, et al., “Effect of Biodiesel Blends on Diesel Particulate Filter
Performance” SAE 2006-01-3280
18. Superb Results
BPT • BPT is 40ºC lower for B20
ULSD 360ºC • Soot is more easily burned off of filter
B20 320ºC • B20 can be used for lower temperature duty cycle
B100 250ºC
• Regeneration rate increases with
increasing biodiesel content
• Even at 5%, biodiesel PM measurably
oxidizes more quickly
19. NOx
Adsorber
Technology
Diesel
Injector DOC LNA
Filter NOx
Sensor
DOC
Diesel Valves
Oxidation Bypass
Catalyst Reference: Volvo
• Filter
removes
par?cles
• LNA
absorbs
NOx
on
lean
opera?on
• Controls
switch
to
rich
opera?on
to
NOx
to
harmless
Nitrogen
• Filter
regenera?on
and
LNA
regenera?on
are
separate
• Complex;
costly;
&
fuel
economy
loss
21. NOx
Controls
• NOx
Adsorber
Catalyst/Lean
NOx
trap
– Catalyst
converts
all
NOx
to
NO2,
adsorbent
bed
“traps”
NO2
– When
bed
is
saturated,
exhaust
forced
rich
– NO2
is
released
and
converted
to
N2
– Bed
also
traps
SO2,
but
doesn’t
release
it
NOx adsorber catalyst (NAC) is also
• Near
sulfur
free
exhaust
is
needed
known as a lean-NOx trap (LNT)
• Higher
temps,
longer
4me
needed
to
release
sulfur
– 90%+
conversion
is
possible
NOx + NH3
• Selec4ve
Cataly4c
Reduc4on
(SCR)
Sensor
– Used
for
industrial
NOx
control
for
years
– Requires
a
supplemental
“reductant”
– Typically
ammonia,
derived
from
urea
SCR
• “Diesel
Exhaust
Fluid”
– 80-‐90%
reduc4on
efficiency
Injection
– Generally
sulfur
tolerant
Urea
22. Biodiesel
Tes4ng
with
LD
Emission
Systems
• Includes
two
emission
control
systems
and
two
fuel
blends
on
a
light-‐duty
placorm
– NAC/DPF
and
SCR/DPF
– 5%
and
20
%
biodiesel
blends
• Performance,
op4miza4on
and
durability
– Aging
to
represent
2100
hours
of
opera4on
(approximately
120,00
miles
or
full
useful
life)
for
B20
– Emissions
evalua4ons
over
UDDS,
US06,
and
HFET–
tes4ng
by
EPA
– Perform
engine
and
fuel
component
teardown
at
end
of
aging
Engine: DCX Vehicle: Mercedes
OM646 C200 CDI
23. ULSD vs B20 – SCR
No statistical difference in NOx Conversion with B20
24. Selec4ve-‐Catalysts
Reduc4on
(SCR)
Air Induction Aqueous
NO EGR Urea
Air to Air Cooler
Solution
Pump and Tank
Injector
1
Turbo-Charge
Atomized
2
Urea
C
Solution
3
T
4
5
6
Catalyzed SCR Catalyst Ammonia
Particulate Slip
Engine Filter Catalyst
Reference: DDC
25. Selec4ve-‐Catalysts
Reduc4on
(SCR)
• Uses
aqueous
Urea
instead
of
fuel
to
convert
NOx
to
Nitrogen
– Requires
extra
tank
etc.
– Must
add
Urea
distribu?on
system
to
supply
chain
• Reduced
EGR
or
no
EGR
• Fuel
economy
gains
compared
to
NOx
Adsorber
• Proven
durability
for
European
applica?ons
• Favored
by
some
for
large
truck
and
sta?onary
applica?ons
26. How
Does
Biodiesel
Effect
Emissions
&
A>ertreatment
?
• Fuel
System
– Concern
over
deposits
and
corrosion
– Addressed
by
ASTM
specifica?ons
• Engine
Emissions
– Lower
HC
and
Par?culate
– NOx
emissions
depend
on
duty
cycle
• A:ertreatment
hardware
/
durability
– Easier
DPF
regenera?on
– Studies
at
NREL
/
ORNL
show
no
adverse
effects
on
hardware
durability
27. What
Will
Be
in
the
Marketplace?
• All
of
the
above!
• Par?culate
Traps
(or
Soot
Filters)
were
across
the
board
in
2007
• NOx
Adsorbers
are
on
some
pick-‐up
truck
applica?ons
• SCR
is
favored
for
many
HD
truck
and
sta?onary
applica?ons
28. Biodiesel
and
A>ertreatment
Systems
Biodiesel
is
compa4ble
with
Diesel
Par4culate
Filters,
and
has
some
dis4nct
advantages:
• Lowers
regenera4on
temperatures
• Less
engine
out
par4culate
maher
• May
provide
increased
performance
and
decreased
maintenance
vs.
ULSD
alone
• May
provide
increased
fuel
economy
Regenera4on
mode
is
important
• Late
in-‐cylinder
injec4on
may
cause
increased
fuel
dilu4on
of
engine
oil
and
limit
the
level
of
biodiesel
that
can
be
used
(i.e.
B20
or
B5)
• Most
US
heavy
duty
applica4ons
use
exhaust
stream
fuel
injec4on
which
is
compa4ble
with
B20,
perhaps
higher
blends
• Some
light
duty
OEMs
recommend
max
B5
at
present
28
29. Conclusion
• NBB,
the
US
Department
of
Energy,
and
the
engine
and
vehicle
manufacturers
are
expending
significant
resources
to
understand
how
biodiesel
blends
interact
with
new
diesel
emission
controls
• Detailed
tes4ng
thus
far
indicates
B20
and
lower
blends
are
compa4ble
with
both
diesel
and
NOx
a>er
treatment
– Provides
benefits
in
some
cases
• B5
is
now
just
part
of
normal
D975
diesel
fuel
• Addi4onal
study
is
underway
– Quan4fy
long
term
benefits
of
biodiesel
blends
– Late
in-‐cylinder
injec4on
impact
on
fuel
dilu4on
– NBB
is
encouraging
OEM’s
to
publicly
support
B20
30. Biodiesel
Resources
www.biodiesel.org
• Biodiesel
Training
Toolkit
• News
Releases
&
Informa4on
Resources
• Technical
Library,
Spec
Sheets
&
Videos
• OEM
Warranty
Posi4ons
on
Biodiesel
•
U.S.
Diesel
Vehicle
List
www.BQ-‐9000.org
• Lis4ng
of
BQ-‐9000
Cer4fied
Companies
www.biotrucker.com
• Lis4ng
of
BioTrucker
retail
sites
www.biodieselautomo?ve.org
30
• Dedicated to information exchange for biodiesel & diesel
technicians
31. Thank You!
Questions…?
Rachel
Burton
Call
NBB
at
1-‐800-‐841-‐5849
OEM
Diesel
Technician
Training
Visit
www.biodiesel.org
Program
wrenchwench@blast.com
Tel:
919-‐444-‐3495
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