Eminox Technology Experience of Particulate Trap Retrofit

Transcription

Eminox Technology
Experience of Particulate Trap Retrofit
Programmes in Europe
Mike Galey, Eminox Limited
MoVE 2006, Hong Kong
Eminox – A Hexadex Company
Outline

Introduction to Eminox, our Products and Markets

Our CRT Retrofit Experience

The Key to Successful CRT Operation

The FBC System

SCRT – The Next Generation

The Case for Retrofit
9701
Eminox
– A Hexadex Company
4
Our Business
Designers, developers and manufacturers of
stainless steel exhaust and emission control systems for
trucks, buses and off-highway applications
Eminox Today

Turnover around £30 million (€45m)

More than 200 employees

Main manufacturing plant in UK

R&D and Product Development in UK and Scandinavia

Active in UK, Scandinavia, Europe, South America & Hong Kong

Customer Service Centres in UK, Sweden, France and Italy
Our Market Sectors
OE-Option Fit
Retrofit
Off-road
On-road
Bus
Rail
Coach
Offhighway
Truck
Special
Apps
OEM Customer Base

Truck –
Volvo, Scania, DAF, Iveco, Dennis Eagle

Bus –
Volvo, Alexander Dennis, Scania, VDL Bus, Iris Bus, MAN

Rail –
Bombardier and Alstom

SEM (Special Equipment Manufacturers) –
Caterpillar, Liebherr, Terex-Demag
Our Current Products
Traditional Products

Stainless Steel Silencers
Stainless Steel Spark Arrestors
First Generation Emissions Products

Diesel Oxidation Catalysts
Gas Catalysts
Second Generation Emissions Products
CRT® - Continuously Regenerating Trap
CCRT® - Catalysed CRT
FBC – Fuel Borne Catalyst (OctimaxTM)
Partial filtration products

CRT® and CCRT® are registered trademarks of Johnson Matthey
CRT® - Continuously Regenerating Trap
FILTER
module
CATALYST
module
Inlet
Outlet
Port for measuring opacity and
back pressure
CRT Emissions Reductions
Autobus, Gothenburg
4.57 g/km
0.56 g/km
14.9 g/km
0.72 g/km
100
90
80
70
60
ULSD
ULSD/CRT
50
40
30
20
10
0
CO
HC
NO x
PM
CRT Effect on Nanoparticles
100
.
80
10% load
PM Conversion (% )
50% load
60
100% load
40
20
0
0
50
100
150
Particle Size (nm)
200
250
Retrofit Market Drivers - Europe

Emissions regulations (Air Quality Directive ….)

Low Emission Zones (Sweden, Denmark, UK ….)

Inter-city competition and image (Tourism ….)

Large national events (Olympics ….)

National Incentives & Grants

Contract Conditions – ‘Best Available Technology’
Eminox CRT Population by Application
No. of Units
35000
Over 40,000 Eminox CRTs sold since 1994
30000
25000
20000
15000
10000
5000
0
Bus
Truck
Other
CRT Bus Retrofit Experience

London, TfL franchised operators (8,000 systems)

RATP, Paris (3,000 systems)

GVB, Amsterdam

Swebus, Gothenburg

De Lijn, Brussels
…. and many more
London Air Quality
Air quality modelling shows that
PM10 and NO2 air quality
standards will be exceeded in
London and other city centres
17%
41%
11%
Studies highlight the
significance of buses and
trucks for city centre
12%
PM10
Source: Westminster Study, city centre PM10
19%
M&HGV
Buses
Taxis
LGV
Cars
Millbrook London Transport Bus Cycle
MLTB
Cycle
Time
Average Idle Time
Speed
(minutes) (km/h)
(%)
15
10
37
Inner
23
17
27
Outer
Combined
38
14
31
Engine Torque (Nm)
900
Torque Curve
500
40% at Idle
100
600
1000
1400
Engine Speed (rpm)
1800
2200
Effect of CRT Fitment on London Buses
London Bus Fleet Growth
Partículate Emissions
9000
600.0
8000
7000
500.0
6000
5000
4000
400.0
3000
2000
200.0
1000
0
100.0
300.0
1998
2000
Fleet size
2002
Passenger-km (millions)
2004
0.0
1998
Tonnes
2000
2002
2004
kg/million passenger-km (x10)
Filter Durability
CRT after 111,000 km – Without Maintenance!
FILTER inlet
FILTER outlet
Key to Successful CRT Operation

Appraisal
Fuel Sulphur level / Total sulphur load
Good NOx : PM ratio
Good duty cycle – sufficient exhaust temperatures for regeneration

Application
Correct CRT sizing
Good installation, maximising temperature at catalyst face etc

Operation
Correct fuelling
Good engine maintenance
Low oil consumption
Monitoring of back-pressure warning light
Prompt filter cleaning / ash removal
CRT Inlet Temperatures
350
Temperature
ºC
250
150
0%
0
25
NO conversion (%)
Catalyst performance
(field aged)
50
0
25%
50%
75%
50
100%
100
% time above temperature
Typical city bus temperatures
(excluding idle)
Engine Issues

Good engine maintenance
Injectors, Fuel pump, Air filter
Checks on opacity as indicator of high particulate
Regular checks for early detection of problems masked by CRT

Low oil consumption
1.0 litre per 1,000 km max
0.7% S max, 1.2% max sulphated ash
Avoids risk of catalyst poisoning / filter blocking with ash

Correct fuelling
50 ppm S max
Avoids risk of catalyst poisoning
CRT Performance related to Opacity
All the above results are from Euro2 RENAULT buses
ESI (Electronic Service Indicator)
Control lights
GREEN ORANGE RED
Digital display
Connection
for remote
lights
Back
pressure
sensor
Connection to
CRT®
ESI Experience – Volvo B7TL, London
Amber Lamp Triggered
& Filter Cleaned
Max pressures
180
160
PVL139
PVL144
140
PVL96
PVL100
PVL154
Pressure (mb)
120
100
80
60
40
20
0
27/02/2003
18/04/2003
07/06/2003
27/07/2003
Date
15/09/2003
Filter Cleaning

Filter removable due to CRT modular construction

Allows clean exchange filter to be immediately inserted

Provides time for cleaning operation

Two requirements for successful cleaning

Heat
High pressure air
Soot & Ash Removal
100
90
80
70
60
50
40
30
20
10
0
% soot & ash
removed
Cold blow only
Heat & Blow
Eminox Cleaning Centre
Factors for Successful CRT Applications
Use of ESI
To predict
service needs
Maintain
Engine
4
Operating Temp
2
(insulation)
Successful
CRT
1
Low
Sulphur
fuel
3
Satisfactory
NOx/PM ratio
FBC System Overview
OctimaxTM
additive
tank
Level sensor
Filter
Pump control
Dosing pump
Diesel
tank
Fuel feed
Engine
Fuel return
Stainless steel
exhaust system
ECU
SiC
filter
Back Pressure feedback
In-cab
warning
light
Silicon Carbide Wall Flow Filter

High durability

High heat conductivity

Suppresses temperature peaks,
hot spots and ash sintering
FBC System – Main Features
Fuel-borne catalyst lowers the soot combustion temperature
from 600oC to around 400oC
a typical exhaust gas temperature

Temperature ‘spike’ promotes regeneration

Sulphur tolerant - does not require ULSD

Compatible with bio-diesel and water-fuel emulsions
Filter Regeneration
The Eminox FBC system can regenerate the filter with only
occasional short temperature peaks of 400°C
Regeneration
temperature
Engine back
pressure
FBC System Applications

Vehicles working on light duty cycles

Smaller HDD engines

Engines with high particulate emissions

Older pre-Euro and Euro 1 engines
Off-highway vehicles

Vehicles that do not run on ULSD

Where there is limited space to fit a CRT system
The SCRT® system – SCR + CRT

Third Generation Emissions Product
Removal of HC, CO, PM and NOx
Close Coupled
Compact Drum
In-Line
SCRT® and EGRT® are registered trademarks of Johnson Matthey
SCRT Schematic
Exhaust
SCR
CRT
ox
min
E
4
00
©2
Ltd
Inlet
Urea injection
18
SCRT

SCRT is supplied to Iris Bus as OEM option
Meets Euro 4, Euro 5 and EEV standards

Retrofit SCR is in an advanced state of development

Joint development with Johnson Matthey plc

Extensive customer trials on buses in the field
London
Paris
Belgium

Commercially available 2006
SCRT Development Vehicle
SCR+ CRT (SCRT) Testing

SCRT equipped vehicles tested on
several ‘Real-World’ Driving Cycles
MLTB (London) Cycle
UTAC (RATP) Cycle
TNO (Dutch) Cycle
Results show SCRT
retrofit system meets
Euro 5 and beyond
Typical ‘Real-World’ Emission Test Results
Emission
Reduction
PM
90%
CO
95%
HC
98%
NOx
85%
The Economic Case for Retrofit
Conclusion

Cities across the World have the same problems
with diesel vehicle emissions

Eminox has been able to provide solutions,
primarily with the CRT system, that have achieved real
reductions in harmful emissions

The Eminox CRT systems now fitted save Europe’s cities from
around one ton of diesel soot every day

The clear interest in the technology requires
the support of local and national administrations
Thank you for your attention