Maxcat

Catagen’s Recirculating Gas Reactor – an optimisation and
calibration tool for automotive after-treatment systems
Dr Jonathan Stewart
1st June 2016
1
Real World Driving Emissions & Testing
1
Contents
• Overview
• Recirculating Gas Reactor (Maxcat)
• Specifications
• Capabilities
• Maxcat as a calibration tool – “Measuring the measurers”
• Case Study 1
• Maxcat as an optimisation tool
• Cast Study 2
• Questions
2
Overview
To investigate the use of a synthetic gas reactor as:
• An optimisation tool for exhaust gas after-treatment systems
• A calibration tool for exhaust gas after-treatment systems measuring devices e.g.
emissions analysers, Lambda sensors, thermocouples etc
3
Recirculating Gas Reactor – Maxcat specifications
Maxcat the most energy efficient & environmentally friendly full scale after-treatment
system testing equipment with the capability to reproduce any real world drive or
customer test cycle.
•
•
•
•
Gas flow rates from zero to 200g/s (10,000 LPM) (steady state +/- 1g/s)
Testing temperatures 25 to 1100°C (steady state +/- 1oC)
Precise control of gas composition
Heat Exchanger
More than 80% less energy
Control
Panel
Blower
Tank
consumed than dyno/burner
testing*.
Furnace
• Over 90% less CO2 produced
Sample Area
than dyno/burner testing*.
*Measurements and calculations performed for 4x2 Litre
catalysts at 50g/s/catalyst flow rate under RAT ageing conditions
Mop-up
Catalysts
4
Recirculating Gas Reactor – Maxcat capabilities
Flow Measurement
-
Controlled mass flow adjustments at set points 80, 100 and 60 g/s
-
Flow is to +/- 1 g/s at 100g/s
-
Measurement by a Venturi designed to BS 9300:2005
-
Verified by mols of chemical reactions
5
Bed Temp oC (Norm
Bed Temp oC (Norm
60
40
Recirculating Gas Reactor – Maxcat capabilities
20
0
18
Temperature Stability
Inlet Temp oC (Normalised to 0)
4 Hours Tes ng
(200 Cycles)
0
10
5
20
15
20
0
Time (s)
4 Hours Tes ng
(200 Cycles)
EngineTested
TestedCatalyst
Catalyst Inlet
Bed Temperature
Plot
SurfacePlot
TemperatureQuality
Engine
150
0
2
4
6
8
10
12
14
16
18
Time (s)
Maxcat
Plot
SurfacePlot
TemperatureSurface
InletTemperature
Catalyst Bed
Tested Catalyst
Maxcat Tested
Inlet Temp oC (Normalised to 0)
16
40
150
100
50
Mean
Data Spread ± 1.9oC
0
4 Hours Tes ng
(200 Cycles)
0
2
4
6
8
10
12
14
16
18
Time (s)
Engine Tested Catalyst Inlet Temperature Quality Plot
Mean
Data Spread ± 1.9oC
100
50
0
4 Hours Tes ng
(200 Cycles)
Mean
Data Spread ± 1.3oC
0
2
4
6
8
10
12
14
16
18
Time (s)
Maxcat Tested Catalyst Bed Temperature Surface Plot
Mean
Mean
Data Spread ±
oC
± 1on
Standard
Devia
= XX
Data
Spread
Graphs demonstrate controlled temperature response of Maxcat
6
Recirculating Gas Reactor – Maxcat capabilities
Gas Injection Response & Measurement
C3H8 Measured High Speed MFC Response & Catagen Quality
Measurement
12
Setpoint
Measured MFC Response
Flow Rate (l/min)
10
8
6
4
2
0
0
0.1
0.2
0.3
0.4
0.5
Characteristics
Data Sampled Every 37 Milliseconds
0 - 50% Scale in 0.11 Seconds
Stable After 0.14 Seconds
Measured Stability Data
STANDARD DEV = 0.007 (6 SIGMA Equivalent)
MEAN = 9.999 of 10.000 SP
MFC
Official Rated Tolerance = 0.1%
Measured Tolerance < 0.1%
0.6
0.7
0.8
0.9
1
Time (s)
7
Recirculating Gas Reactor – Maxcat capabilities
C3H8-1 MFC
Gas Injection Response & Measurement
4.00
Delivery
Set-point
3.50
Delivery (l/min)
3.00
C3H8 Set point and measured delivery
at 10Hz for two ranges and profiles.
2.50
2.00
1.50
1.00
0.50
0.00
600
620
640
660
680
700
720
740
760
780
800
780
800
Time(s)
Cycle to cycle standard deviation in
the range of 0.005-0.039
C3H8-Bal MFC
16.00
Delivery
Set-point
14.00
12.00
Delivery (l/min)
•
10.00
8.00
6.00
4.00
2.00
0.00
600
620
640
660
680
700
720
740
760
Time(s)
8
Recirculating Gas Reactor – Maxcat capabilities
Air-1 MFC
Gas Injection Response & Measurement
400
Set-point
Delivery
350
Delivery (l/min)
300
Air Set point and measured delivery at
10Hz for two ranges and profiles.
250
200
150
100
50
0
600
620
640
660
680
720
700
740
760
780
800
740
760
780
800
Time(s)
Cycle to cycle standard deviation in
the range of 0.417-2.632
Air-Bal MFC
400
Delivery
350
Set-point
300
Delivery (l/min)
•
250
200
150
100
50
0
600
620
640
660
680
700
720
Time(s)
9
Recirculating Gas Reactor – Maxcat capabilities
Gas Injection Response & Measurement
Graphs demonstrating integrated
maxcat gas delivery response to
HC set point (top) and
corresponding bench analyser
measurement (below)
10
Maxcat as a calibration tool – “Measuring the
measurers”
The accuracy of flow, temperature and emissions allows Maxcat to be used as a
calibration tool for various after-treatment measuring systems. Some examples
include:
Emission analysers, Lambda sensors and Thermocouples
What follows is a case study of an emission analyser used with the Maxcat system
11
“Measuring the measurers”- Case Study 1 Overview
Figure 1.
Example of O2
analyser response
to step change with
T10-90%
measurement
Gas species O2 conc. (Vol.%)
Case Study 1: This study focused on the performance of a O2 analyser to a step
change input held for a defined period for injections of Air and propane gas specimens in
to a standardized exhaust medium. Typical metrics are the timed responses (e.g. T1090%, T90-10%, settling time) and specimen quantity (see figure 1)
Fig 1. Sensor Response using T10-90%
12
“Measuring the measurers”- Case Study 1 Results
Results: The following plots show the response of the oxygen analyser when
the standardized gas has injections of 50, 75, 100, 150 and 200 l/min from the
Air MFC into an exhaust stream at 36g/s and 600 C
Calibration of
accuracy
technique in
representative
exhaust gas
conditions
A comparison of the amount of oxygen measured between what
the MFC delivers into a exhaust gas allows calibration to be
13
assessed
“Measuring the measurers”- Case Study 1 Results
Results: The following plots show the response of the oxygen analyser when
the standardized gas has three separate injections of 100 l/min from the Air MFC
into an exhaust stream at 36g/s and 600 C
Calibration
technique in
representative
exhaust gas
conditions
This test allows measurement manufacturers to assess the
repeatability of their equipment
14
“Measuring the measurers”- Case Study 1 Results
Results: The table below details T10-90 times and accuracy metrics for the oxygen
measurements taken
15
Maxcat as an optimisation tool
With the capabilities already presented Maxcat can reproduce real world drive
cycles delivering customer defined emissions to their after-treatment system of
choice. Numerous optimisation scenarios are therefore possible e.g. the effect of
varying engine out emissions on catalyst preformance, varying catalyst loading,
varying catalyst geometry etc.
The second case study looks at running a ULEV drive cycle on a Maxcat and
generating the correct engine out emissions at a catalyst.
16
Case Study 2 – Replicating the ULEV drive cycle on
Maxcat
Flow measurement
ULEV Drive Cycle Flow Rate Example at Catalyst Inlet
17
Case Study 2 – Replicating the ULEV drive cycle
on Maxcat
Transient Flow Control - Bridging the Gap between the Lab and Real
World
ULEV - Catalyst Inlet Temperature
700
Temperature (°C)
600
500
400
300
200
Catalyst Inlet - Engine
100
Catalyst - Inlet Maxcat
0
0
50
100
150
200
Time (s)
Company Confidential Do Not Reproduce
18
Case Study 2 – Replicating the ULEV drive cycle on
Maxcat
Gas Injection Response & Measurement
Mass Flow (g/s)
ULEV O2 Mass Flow Rate
0.50
0.45
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
O2-Maxcat
0
50
100
O2-Engine
150
200
Time (s)
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Findings
Catagen have highly efficient full scale precision testing equipment that
can replicate real world drive cycle conditions providing a unique
capability to develop new insights into automotive catalysis and aftertreatment system performance optimization.
Catagen’s Labcat and Maxcat can act as sophisticated translators
between laboratory testing and real world conditions. Precise and known
conditions such as flow rate, temperature and individual gas species can
be actuated at 10Hz creating any test condition.
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Summary & Discussion
Testing Capability:
Precision Controllability & Measurement, Flexibility, Repeatability &
Efficiency
Range of Test Types:
Testing for understanding, experimentation, ageing, development, durability,
sweep, screening, sensitivity & performance to virtually any condition
Range of Test Subjects:
Catalyst, after-treatment system, GPF, gas analysers, MFCs, Sensors
Your partner for Real World Testing
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Gas Usage & Efficiency Data
Transient/Drive Cycle Testing efficiencies*
95% less volume of gases used compared to standard gas bench
87% lower running costs than standard gas bench
80% less energy consumed than dyno engine testing
*Based on 2 Litre catalyst under ULEV drive cycle conditions
22
Transient Flow Control - Bridging the Gap between the
Lab and Real World
ULEV - Total Catalyst Inlet Flow Rate
80
Flow Rate (g/s)
Initial Results
FLOW
Engine Data
Averaged Total Flow
70
60
System Flow Rate
50
40
30
20
10
0
0
50
100
150
200
Time (s)
Company Confidential Do Not Reproduce
23
Transient Flow Control - Bridging the Gap between the
Lab and Real World
ULEV - Catalyst Inlet Temperature
700
TEMPERATUR
E
600
Temperature (°C)
Initial Results
500
400
300
200
Catalyst Inlet - Engine
100
Catalyst - Inlet Maxcat
0
0
50
100
150
200
Time (s)
Company Confidential Do Not Reproduce
24
Transient Flow Control - Bridging the Gap between the
Lab and Real World
ULEV O2 Mass Flow Rate
O2 Mass Flow
Mass Flow (g/s)
Initial Results
0.50
0.45
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
O2-Maxcat
0
50
100
O2-Engine
150
200
Time (s)
Company Confidential Do Not Reproduce
25
Transient Flow Control - Bridging the Gap between the
Lab and Real World
Initial Results
CO Mass Flow
Mass Flow (g/s)
ULEV CO Mass Flow Rate
0.50
0.45
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
1.4
CO-Maxcat
CO-Engine
1.2
1
0.8
0.6
0.4
0.2
0
0
50
100
150
200
Time (s)
Company Confidential Do Not Reproduce
26
Transient Flow Control - Bridging the Gap between the
Lab and Real World
ULEV THC Mass Flow Rate
0.09
THC Mass
Flow
Mass Flow (g/s)
Initial Results
0.08
THC-Maxcat
THC-Engine
0.07
0.06
0.05
0.04
0.03
0.02
0.01
0.00
0
50
100
150
200
Time (s)
Company Confidential Do Not Reproduce
27