Complete Stratus Presentation - Spinner II · STRATUS DIESEL PARTICULATE FILTERS. Diesel emissions and their hazardous pollutants. Diesel Emissions and Their Hazardous Pollutants

1

Exhaust Gas Aftertreatment Technologies

Part 1Diesel Emissions and Their Hazardous Pollutants

STRATUSSTRATUSDIESEL PARTICULATE FILTERSDIESEL PARTICULATE FILTERS

Diesel emissions and their hazardous pollutants

Diesel Emissions and Their Hazardous Pollutants Carbon Dioxide

• colourless• odourless• greenhouse gas

Water

• colourless • odourless • harmless

Nitrogen Oxides

• colourless � brown• acrid-smelling • greenhouse gas, acid rain

Particulate Matter (PM)

• gray or black cloud • burnt-smelling • greenhouse effect• carcinogenic

Carbon Monoxide• colourless • odourless• greenhouse gas • danger of suffocation

Hydrocarbon

• colourless • fuel-smelling• greenhouse gas• carcinogen

CO

CO2

NOx

PM

H2O

HC

DIESEL

Environmental Hazard

Toxic

Toxic

Very Toxic

Very Toxic

Diesel Particulate Filter

Diesel Exhaust Gas Aftertreatment Technologies – Overview

DieselEmissions

Particulate Matter(PM)

Hydrocarbon (HC)Carbon Monoxide (CO)

ExhaustTechnology

CRT + SCR = SCRT®

��

� �

��

�

� > 95 % Reduction of HC and CO

� > 99 % Reduction of PM

� up to 90% Reduction of NOx

CRT System Stage 1 SCR System Stage 2

Stufe 1Stage 1

Stage 2

Nitrogen Oxides(NOx)

Selective Catalytic Reduction (SCR)

Diesel-Oxidation-Catalyst(DOC)

What is Particulate Matter (PM)?� The term particulate matter (PM) is used to

describe airborne solid particles and/or droplets. The particles vary in size, composition & origin.

� The definition was established by the US Environmental Protection Agency (EPA) in 1987: “National Air Quality”-Standard for PM.

Electron micrograph of PM sampled on a filter near a street; diesel soot (small grey spheres) dominates the sample

Source: World Health Organization (WHO): “Health Aspects of Air Pollution – Results from the WHO Project “Systematic Review of Health Aspects of Air Pollution in Europe” / Federal Environment Agency (C. Trimbacher), Vienna

Salt

Minerals

Gey area diesel soot:

Minerals

Particles fromcombustion

1st scope: PM10 (coarse & fine particles)� PM10 => Basis for EC limit values (since 01.01.05) � Used for description of particles with aerodynamic

diameter < 10 m� PM10-sized particles may reach the upper part of the

airways and lung

2nd scope: PM2.5 (fine particles)� Smaller particles penetrate more deeply into the lung� Alveolar

Fuel, unburned6%

Sulfates12%

Ash10% Other

5%

Oil, unburned23% Carbon

44%

Typical Soot Composition:

The composition depends on:- Operating conditions - Fuel (S)- Lubricating oil

Chemical Composition of Diesel Particles

Effects of Particulate Matters on Climate and Health

• Diesel particulate matter is one contributor to global warming

• Diesel exhaust gases are carcinogenic (WHO 06/12)

Consequences:

• Regulations to limit emissions• Europe: Low emission zones• Activities to improve working

conditions

Irritation of mucous membrandes

Ultrafine particles

Enter the circulatory system

(Higher risk of cancer)

Damage to alveoli

Constriction of bronchial tubes

Lungs‘ capacity for

self-cleaning is impaired

Parts of the body attacked Particle sizeNose and pharynx 5 – 10 m

Airways 3 – 5 m

Bronchial tubes 2 – 3 m

Bronchioles 1 – 2 m

Alveoli 0,1 – 1 m

Negative Health Effects Caused By The Pollutant - PM

Effects related to short-term exposure Effects related to long-term exposure

Lung inflammatory reactions Increase in lower respiratory symptoms

Respiratory symptoms Reduction in lung function in children

Adverse effects on the cardiovascular system Increase in chronic obstructive pulmonary disease

Increase in medication usage Reduction in lung function in adults

Increase in hospital admissions �Reduction in life expectancy, owing mainly to cardiopulmonary mortality and probably to lungcancer (2 % caused by air polution)

� Increase in mortality � Increase in mortality WHO: 2,4 Mio. death rate / year)

Source: World Health Organization (WHO): “Health Aspects of Air Pollution “ – Results from the WHO Project “Systematic Review of Health Aspects of Air Pollution in Europe” / Federal Environment Agency (C. Trimbacher), Vienna

Diesel exhaust gases are definitely carcinogenic.

They are as hazardous as arsenic, asbestos and mustard gas.

Now it is clear that exhaust gases from diesel engines causes cancer.

(Scientists from the WHO in June 2012)

Publication in June 2012

Particulate Matter

(PM)

DieselEmissions

Hydrocarbon /Carbon Monoxide

(HC / CO)

Nitrogen Oxides

(NOx)

ExhaustTechnology


(DPF)

Selective CatalyticReduction

(SCR)

Diesel-Oxidation-Catalyst

(DOC)

Reduction of Soot Particles

Diesel Pollutants and Exhaust Technologies


DieselEmissions




ExhaustTechnology

CRT SCR

CRT + SCR = SCRT®

��

��

� �

�


� > 95 % Reduction of HC + CO

� Up to 90% Reduction of NOx

CRT System Stage 1Stufe 2SCR System Stage 2

Stage 1

Stage 2




Diesel Particulate Filters – Applications

Diesel Particulate Filters

Wall flow filter(closed system)

Partial flow filter(open system)

Regeneration

Filtration Efficiency Efficiency: 90 - 99,9 %

Description

Efficiency: Ø 50 %

Active Regeneration-Supporting measures:

• post-injection (engine modifications)

• Fuel-borne catalyst (Addition of additive)

• Heating elements• Catalytic coating• Diesel oxidation catalyst (DOC)• Continuously Regeneration

Technology = CRT

• Continuously RegenerationTechnology = CRT

• Catalytic Regeneration• No intervention in

engine management system• No sensors

CRT-System

City-Filter®

Wall Flow Filters and TheirPhenomenoly of Soot Loading• Ceramic• SMF® - Sintered Metal Filter

Phenomenology of Soot Loading – Ceramic versus SMF®

Sieving effect 2: Filter cake tends to clueing and blocking. This may lead to back pressure. Therefore regeneration is strictly required (Burn-off soot).

Sieving effect 1: Filter cake is still porous. This effect can especially be detected with ash loading. Less back pressure drop for ash accumulation .

Sieving effect 3: Larger particles stick to narrow parts of pore channels. Larger soot agglomerates may be filtered this way. Regeneration also burns those off.

Adsorption: Particles that are not kept back by the sieving effects, adhere to the surfaces of the pore channels. This mechanism mostly affects particles < 1 µm. This causes high efficiency - even for new filters!

The porous medium works as a surface filter

Capability to deep filtration increases filter performance – especially in case of “clean filters”

5 Min

10 Min

60 Min

First areas are covered within 5 min. Mostly found on the surface ( p �).

After 10 min a nearly complete closed soot cake can be detected ( p �).Filter efficiency reaches final value. Pores in soot layer are very small.

Phenomenology of Soot Loading – Ceramic versus SMF®

Examples of Closed Systems

Emission Technology

Range of Application:LDV, Bus, Non-road Machinery

Regeneration:- AR- FBC- CRTType of Filter: Sintered Metal

SCRT® System

General System Description of Sintered Metal Filter -Open Design

The exhaust from the engine passes the porous sintered metal and soot particles are retained by the filter media. By installing an overflow area (bypass) the filter efficiencycan be adjusted between 30 and 80 %.

Porous Sintered Metal

Bypass: Adjustable between 30 - 80% filtration efficiency at constant backpressure

Engine exhaust gas Cleaned exhaust gas

Materials for Filtration:- Ceramic � Cordierite for Example

Materials for Soot Filtration

� SiC: Wall flow filter silicon carbide

� Cor.: Wall flow Cordierite

� SMF®: Sintered metal filter

SMF® SiC Cor.

Ceramic filter

SMF® Cordierite SiC% 48 50 50μm 15 20 12

g/cm³ 4.2 1.3 1.5

ppm/K 17 1 4W/m/K 15 1.8 100

J/cm³/K 4.2 2,8 3.6J/cm³/K 2.2 1.4 1.8

Heat Capacity, system, 500 °C J/l/K 550 540 630

Heat Capacity, dense, 500 °CHeat Capacity, porous, 500 °C

PorosityMean Pore Size (Mercury)

Density, porous

Thermal ExpansionThermal Conductivity, dense

Application AdvantagesComparing Material Properties:

0,5 mm

Micrograph, Cordierite

Micrograph, SiC

Micrograph, SMF

Application Advantages

Cordierite, Flow in / Flow out side Cordierite, Flow in side on top

Application AdvantagesDifferent Porous Structures:


Part 2Diesel Emissions a Hazardous Pollutant


SiC, Flow in / Flow outside SiC, Flow inside on top

Application Advantages and Range of Applications

Different Porous Structures:

CRT System with ceramic filter � Cordierite

Particulate filter

Engine exhaust gas

Cleaned exhaust gas

Particle reduced exhaust gas

Engine exhaust gas

Particle reduced exhaust gas

Cordierite Filter Construction

1

2

4

3

5

Engine exhaust gas

Cleaned exhaust gas

Filter plug

Retained particles + ash

Filter wall

Blockage of Cordierite Channels / SiC-Monoliths by Ash Accumulation

• High increase of backpressure due to narrowed ducts by ash accumulation.

• Duct diameter works with power of 4 for the partlypressure drop.

• Reduced filtration area.

Materials for Filtration:– Sintered Metal Filter SMF®

SMF® – Sintered Metal Filter

Step 1: For further processing the high alloy metal powder is mixed with a binder

Step 2: The pourable powder mix is applied to reinforcing expanded metal

Step 3: After the sintering process the powder particles are bonded with each other and the expanded metal

Step 4: Sheets are punched out of the porosemetal foil and reinforced with a hem band

Step 5: A spacer is inserted into the filter pocket for stabilization purposes

Step 6: After welding the individual filter pockets to a filter module, the module is inserted into the a housing and complemented with further components to a particulate filter system (e.g. pipes, conuses)

Filter box Original-DPF City-Filter®

Satellite-filter

Filter element

SMF® Sintered Metal Filter - Various Designs

Filter Material: Process Steps

Expanded Metal

Coating

Sintering

Filter Pocket Assembly Product

Mixing

Metal Powder Binder Additives

Due to heat and presure the metal powder is strongly fixed on the Expanded Metal

Surface of Sintered Metal SMF®

SEM-Picture, Detail

SEM-Picture, Surface - Flow inside

Materials for Filtration:– Coated Sintered Metal Filter CSMF®

Application Areas and Regeneration Technologies

Arbeitsbereiche verschiedener Regenerationstechnologien

0 100 200 300 400 500 600 700

Nacheinspritzung (OE-Systeme)

Thermoelektrische Regeneration

CRT®-System

Katalytisch beschichteter Filter

Additiv-Systeme

Ruß ohne Regenerationshilfe

Abgastemperatur [°C]

Zusatznutzen CSF Arbeitsbereich

Passive Regeneration

Additive-System

Catalytic coated SMF®

SMF® -AR System

Post-Injection (OE-Systems)

Application areaAdditional value CSMF®

Application Areas and Regeneration Technologies

Exhaust gas temperature (oC)

CRT-

Without DOC and NO2� O2-Reg.

Without DOC � NO2-+ O2-Reg.

With DOC � NO2-Reg.

Catalytic Coated SMF® FilterBenefits:

• Coating was a special development for HJS‘s sintered metal filters

• Coating based on new nano-technologies

• Coating is done with complete filter after welding with a dip-coating

• No increasing of pressure drop after coating – coating is <1 µm thin

• Pressure drop improvement in CCRT® application due to soot free pores

• Further improvement of corrosion behavior after coating

• 20 g/cft Pt for optimum CCRT® functionality

• Thermal durability equal to other coatings

• Short delivery time, due to in-house coating

Catalytic Coated SMF® - Sintered MetalNearly noblockingof poresafter nano-coating

SEM-Picture, Surface – flow inside

Materials for Filtration – Benchmark:- Ceramic � Cordierite- Sintered Metal Filter SMF®

SMF® Filter Ceramic Filter� Cordierite

Ceramic filter with ash loading

SMF®-Filter: Lower Risk of BlockageHigher ash storage capacity � low-maintenance � Cost savings

SMF® – ash storage capacity is three to four times higher than ceramic wall flow

Application Advantages and Range of ApplicationsAsh Distribution Model:

parallel(soot)

parallel(soot)

bottomto top

bottomto top

Ash

Ash

Access for Ash Storage and CleaningSMF® 100 cpsi

Cleaning from ash sideand from clean side

Cleaning from clean side – losingpressure due to filter media

6 mm2 mm

AshFilter

AshFilter

Water

Particulate Matter

(PM)

DieselEmissions


(HC / CO)

Nitrogen Oxides

(NOx)

ExhaustTechnology

Diesel ParticulateFilter

(DPF)


(SCR)


Reduction of HC + CO

Diesel Pollutants and Exhaust Gas Aftertreatment Technologies


DieselEmissions




ExhaustTechnology

CRT SCR

CRT + SCR = SCRT®

��

��

� �

�


� > 95 % Reduction of HC + CO


CRT System Stage 1Stufe 2

SCR - System Stage 2

Stage 1

Stage 2




SCR System Stage 2

Cordierit substrate

Wash coat

Catalytic activeprecious metal

(Platinum Pt)

Diesel-Oxidation-Catalyst (DOC) � Construction

Cordierite substrate: - Porous material with a huge surface

Wash coat: - For increasing the surface 1 Gramm = 100 m2

- Carrier of precious metal

Transformation of: � Cabon monoxide (CO) in carbon dioxide (CO2)

� Hydrocarbon (HC) in water (H2O)

Additional functions:

� Transformation of nitrogen monoxide (NO) in Nitrogen dioxide (NO2)

� Nitrogen dioxide (NO2) is needed for the continuously soot oxidation � CRT Principle

Diesel-Oxidation-Catalyst (DOC)

2 CO + O2 � 2 CO2

2 NO + O2 � 2 NO2

4 HC + 5 O2 � 4 CO2 + 2 H2O

Carbon Dioxide


Water


Nitrogen oxides



• gray or black cloud • burnt-smelling • greenhouse effect• carcinogen � ?


Hydrocarbon


CO

CO2

NOx

PM

H2O

HC

DIESEL


Toxic

Toxic

Very Toxic

Very Toxic

Diesel Emissions and TheirHazardous Pollutants � The Results of

the DOC

X X


Part 3Diesel emissions and their hazardous pollutants


CRT System� Continuously Regeneration Technology

Reduction of:- Carbon monoxide- Hydrocarbon- Particulate matter

� Passive Regeneration

Particulate Matter

(PM)Diesel

Emissions


(HC / CO)

Nitrogen Oxides

(NOx)

ExhaustTechnology


(DPF)


(SCR)


Reduction of Soot Particles + HC + CO



Diesel Exhaust Technologies – Overview

DieselEmissions



ExhaustTechnology

CRT + SCR = SCRT®

��

� �

��

�





Stufe 1Stage 1

Stage 2



Diesel-Oxidation-Catalyst (DOC)

Oxidation cat

• of carbon monoxide (CO) and uncombusted hydrocarbons (HC)to form water (H2O) and carbon dioxide (CO2)

• of nitrogen monoxide (NO) to form nitrogen dioxide (NO2)

• Particulate matter (PM) is trapped by the filter material

• Nitrogen dioxide (NO2) generated in the oxi-cat continuously oxidizes the accumulated PM = CRT® Principle

SMF® particulate filter

CRT® System

Oxidation PM reduction

Inlet Outlet

CRT® Continuously Regenerating Technology

Design and Operating Principle

The Modular CRT System � (Continuously Regeneration Technology)

Output Module Input ModuleSilencer

Particulate Filter Oxidation-Catalyst

SMF® CRT System (Continuously Regeneration Technology)

1. > 95% Reduction of HC + CO 2. > 99% Reduction of PM (In number)

Passive Regeneration�Continuously Regeneration > 260 C

Filter System for

HDV & Bus ApplicationsOxi-CatInput Module

Output ModuleCRT System

12

12 SMF® Particulate Filter

Diesel Oxidation Catalyst SMF® Sintered Metal Filter

CRT Description of Function (Continuously Regeneration Technology)

4HC + 5O2 � 4CO2+2H2O 2NO2 + C � 2NO + CO2

2CO + O2 � 2CO2

2NO + O2 � 2NO2

Engine exhaust gas Cleaned exhaust gas

Carbon Dioxide


Water


Nitrogen Oxides

• colourless � brown• acrid smelling • greenhouse gas, acid rain




Hydrocarbon


CO

CO2

NOx

PM

H2O

HC

DIESEL


Toxic

Toxic

Very Toxic

Very Toxic


the CRT System

X XX

Fuel Borne Catalyst (FBC)

Fuel additive assisted regeneration� Passive Regeneration

Fuel Borne Catalyst (fuel additive assisted regeneration)

How It Works

- A dosing system is used to add an additive to the diesel fuel combusted in the engine. The combusted additive is deposited on the particulate filter together with the particulate matter (PM).

- This reduces the ignition temperature of the PM on the filter from normally 600 – 650 Cto 380 – 400 C and the system is able to regenerate itself periodically or intermittently by means of the exhaust gas temperature of the engine.

- The sintered metal particulate filter, SMF®, traps approx. 99% of the particulate matter.

- Advantages: NO2 neutral, suitable for low exhaust gas temperatures

- Disadvantages: FBC ash deposited in filter in addition to oil ash also has to be cleaned out

- Applications: commercial vehicles, buses, construction machinery, mining equipment

Fuel-borne catalyst (FBC) – Fuel Additive Assisted Regeneration

SCRT® System�Selective Catalytic Reduction Technology

Reduction of:- Carbon monoxide- Hydrocarbon- Particulate matters- Nitrogen oxides

� Passive Regeneration

Particulate Matter

(PM)Diesel

Emissions


(HC / CO)

Nitrogen Oxides

(NOx)

ExhaustTechnology


(DPF)


(SCR)


Reduction of NOx



Diesel Exhaust Technologies – Overview

DieselEmissions



ExhaustTechnology

CRT + SCR = SCRT®

��

� �

��

�





Stufe 1Stage 1

Stage 2


Selective Catalytic Reduction(SCR)


SCRT® System (= SCR + CRT®)

Urea (AdBlue®) Doser

SMF® Sintered Metal Filter Oxi-Cat

SCR Catalyst

SCRT® SystemCRT System Stage 1

SCR System Stage 2

&AmmoniaSlip Catalyst

Soot

Nitrogen Oxidesfree

free

SCR – Selective Catalytic Reduction

Urea Dosing SCR CatalystHydrolysis of Urea

NOX Reduction by ammonia (NH3) under oxidizing conditions

SCR Transformations: 4 NO + 4 NH3 + O2 � 4 N2 + 6 H2O2 NH3 + NO + NO2 � 2 N2 + 3 H2O6 NO2 + 8 NH3 � 7 N2 + 12 H2O

SCR System Stage 2

AdBlue® Drops NOx ReductionAmmonia Production

In Out

Engineering – SCRT® (Technology for PC and CV Applications)

Engineering – SCRT® (Technology for PC and CV Applications)

Carbon Dioxide


Water


Nitrogen Oxides





Hydrocarbon


CO

CO2

NOx

PM

H2O

HC

DIESEL


Toxic

Toxic

Very Toxic

Very Toxic


the SCRT® System

X XX

X

Active RegenerationThe SMF®-AR

SMF®-AR 100% Diesel Particulate Filter(SMF®– Technology for Light CV and Non-Road Applications, e.g.)

General Description of Function- The SMF®-AR system is comprised of a sintered metal filter with a fully automatic

regeneration unit (AR).

- This is capable of regenerating the soot accumulated in the filter, in any engine operating states, without any support from the engine and without intervention by the driver. For regeneration a upstream catalyst is not necessary.

- The sintered metal filter retains particles produced while the engine is running with an efficiency factor of almost 100%.

- The sensors mounted on the filter constantly monitor the exhaust temperature and exhaust back pressure in the filter. This determines the increasing quantity of soot in thefilter as the engine time lengthens.

- When sufficient soot has accumulated in the filter, the control unit automatically triggers a regeneration.

- In this case, the electrical heater elements are switched on for approximately two minutes.

- In order for all the soot to burn-off in a short time leaving practically no residue, an additive is added automatically to the diesel fuel by the dosing system which lowers theignition temperature of the soot and increases the burn-off speed.

SMF®-AR

SMF®-AR 100% Sintered Metal Filter – Active Regeneration

� Suitable for OE applications and retrofitting � > 99% reduction of soot particles incl. fine particles � Suitable for urban traffic („Stop-and-go“) � Automatic � active regeneration � Modular system � Reliable system and low maintenance

Filter System forLDV + Non-Road

Applications

71

T.F. Hudgins, Incorporated

Phone 713-682-3651Fax 713-682-1109

Email: [email protected]: www.spinnerii.com

Thank You

Documents

Complete Stratus Presentation - Spinner II · STRATUS DIESEL PARTICULATE FILTERS. Diesel emissions and their hazardous pollutants. Diesel Emissions and Their Hazardous Pollutants