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Stratus DPF Overview - Spinner II® Products
STRATUS DIESEL PARTICULATE FILTERS Exhaust Gas Aftertreatment Technologies Part 1 Diesel Emissions and Their Hazardous Pollutants 1 Diesel emissions and their hazardous pollutants Diesel Emissions and Their Hazardous Pollutants Carbon Dioxide • colourless • odourless • greenhouse gas Water Environmental Hazard Nitrogen Oxides • colourless • odourless • harmless Very Toxic CO2 H 2O NOx DIESEL Carbon Monoxide • • • • colourless Toxic odourless greenhouse gas danger of suffocation Hydrocarbon HC CO • colourless Î brown • acrid-smelling • greenhouse gas, acid rain PM • • • • colourless fuel-smelling greenhouse gas carcinogen Particulate Matter (PM) • • • • gray or black cloud burnt-smelling greenhouse effect carcinogenic Very Toxic Toxic Diesel Exhaust Gas Aftertreatment Technologies – Overview Diesel Emissions Diesel-Oxidation-Catalyst Exhaust Technology (DOC) c Diesel Particulate Filter Selective Catalytic Reduction (SCR) Stage 1 c > 95 % Reduction of HC and CO d > 99 % Reduction of PM e up to 90% Reduction of NOx e d c CRT System Nitrogen Oxides (NOx) Particulate Matter (PM) Hydrocarbon (HC) Carbon Monoxide (CO) d SCR System CRT + SCR = SCRT® Stage 1Stufe 1 d c e Stage 2 Stage 2 What is Particulate Matter (PM)? Particles from combustion Gey area diesel soot: 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. Minerals 1st scope: PM10 (coarse & fine particles) Salt Minerals Electron micrograph of PM sampled on a filter near a street; diesel soot (small grey spheres) dominates the sample PM10 => Basis for EC limit values (since 01.01.05) Used for description of particles with aerodynamic diameter < 10 䃛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 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 Chemical Composition of Diesel Particles Typical Soot Composition: Sulfates 12% Ash 10% Oil, unburned 23% Fuel, unburned 6% The composition depends on: - Operating conditions - Fuel (S) - Lubricating oil Other 5% Carbon 44% 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 Constriction of bronchial tubes Ultrafine particles Enter the circulatory system Lungs‘ capacity for (Higher risk of cancer) Damage to alveoli self-cleaning is impaired Parts of the body attacked Particle size Nose and pharynx 5 – 10 䃛m Airways 3– 5 䃛m Bronchial tubes 2– 3 䃛m Bronchioles 1– 2 䃛m Alveoli 0,1 – 1 䃛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 ÎReduction in life expectancy, owing mainly to cardiopulmonary mortality and probably to lung cancer (2 % caused by air polution) Î Increase in mortality Î 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 Publication in June 2012 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) Diesel Pollutants and Exhaust Technologies Diesel Emissions Exhaust Technology Particulate Matter Hydrocarbon / Carbon Monoxide (PM) (HC / CO) Diesel Particulate Filter Diesel-OxidationCatalyst (DPF) (DOC) Reduction of Soot Particles Nitrogen Oxides (NOx) Selective Catalytic Reduction (SCR) Diesel Exhaust Gas Aftertreatment Technologies – Overview Diesel Emissions Exhaust Technology Particulate Matter (PM) Hydrocarbon (HC) Carbon Monoxide (CO) Nitrogen Oxides (NOx) Diesel Particulate Filter Diesel-Oxidation-Catalyst Selective Catalytic Reduction (DOC) c (SCR) e d CRT CRT System Stage 1 c > 99 % Reduction of PM d > 95 % Reduction of HC + CO e Up to 90% Reduction of NOx d SCR c SCR System CRT + SCR = SCRT® c d Stage 1 e Stage 2 Stufe 2 Stage 2 Diesel Particulate Filters – Applications City-Filter® CRT-System Diesel Particulate Filters Description Filtration Efficiency Regeneration Wall flow filter (closed system) Partial flow filter (open system) Efficiency: 90 - 99,9 % Efficiency: Ø 50 % Active RegenerationSupporting measures: • post-injection (engine modifications) • Fuel-borne catalyst (Addition of additive) • Heating elements • Catalytic coating • Diesel oxidation catalyst (DOC) • Continuously Regeneration Technology = CRT • Continuously Regeneration Technology = CRT • Catalytic Regeneration • No intervention in engine management system • No sensors Wall Flow Filters and Their Phenomenoly of Soot Loading • Ceramic • SMF® - Sintered Metal Filter Phenomenology of Soot Loading – Ceramic versus SMF® The porous medium works as a surface filter 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 2: Filter cake tends to clueing and blocking. This may lead to back pressure. Therefore regeneration is strictly required (Burn-off soot). Capability to deep filtration increases filter performance – especially in case of “clean filters” 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! Phenomenology of Soot Loading – Ceramic versus SMF® 60 Min 10 Min 5 Min First areas are covered within 5 min. Mostly found on the surface (䂴p Ï). After 10 min a nearly complete closed soot cake can be detected (䂴p Ï). Filter efficiency reaches final value. Pores in soot layer are very small. Examples of Closed Systems Emission Technology Range of Application: LDV, Bus, Non-road Machinery Regeneration: - AR - FBC - CRT Type of Filter: Sintered Metal SCRT® System General System Description of Sintered Metal Filter Open Design Porous Sintered Metal Bypass: Adjustable between 30 - 80% filtration efficiency at constant backpressure Engine exhaust gas Cleaned exhaust gas 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 efficiency can be adjusted between 30 and 80 %. Materials for Filtration: - Ceramic Î Cordierite for Example Materials for Soot Filtration SiC: Wall flow filter silicon carbide Ceramic filter Cor.: Wall flow Cordierite SMF®: Sintered metal filter SMF® SiC Cor. Application Advantages Comparing Material Properties: % μm SMF® 48 15 Cordierite 50 20 SiC 50 12 Density, porous g/cm³ 4.2 1.3 1.5 Thermal Expansion Thermal Conductivity, dense ppm/K W/m/K 17 15 1 1.8 4 100 Heat Capacity, dense, 500 °C J/cm³/K Heat Capacity, porous, 500 °C J/cm³/K Heat Capacity, system, 500 °C J/l/K 4.2 2.2 2,8 1.4 3.6 1.8 550 540 630 Porosity Mean Pore Size (Mercury) Application Advantages Micrograph, SMF Micrograph, SiC Micrograph, Cordierite 0,5 mm Application Advantages Different Porous Structures: Cordierite, Flow in / Flow out side Cordierite, Flow in side on top STRATUS DIESEL PARTICULATE FILTERS Exhaust Gas Aftertreatment Technologies Part 2 Diesel Emissions a Hazardous Pollutant Application Advantages and Range of Applications Different Porous Structures: SiC, Flow in / Flow outside SiC, Flow inside on top CRT System with ceramic filter Î Cordierite Particle reduced exhaust gas Engine exhaust gas Particle reduced exhaust gas Particulate filter Engine exhaust gas Cleaned exhaust gas Cordierite Filter Construction 1 Engine exhaust gas 2 Cleaned exhaust gas 3 Filter plug 4 Retained particles + ash 5 Filter wall Blockage of Cordierite Channels / SiC-Monoliths by Ash Accumulation • High increase of back pressure due to narrowed ducts by ash accumulation. • Duct diameter works with power of 4 for the partly pressure 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 porose metal 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) SMF® Sintered Metal Filter - Various Designs Filter box Original-DPF City-Filter® Satellite-filter Filter element Filter Material: Process Steps Expanded Metal Filter Pocket Additives Mixing Coating Sintering Binder Metal Powder Due to heat and presure the metal powder is strongly fixed on the Expanded Metal Assembly Product 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 Application Areas and Regeneration Technologies Arbeitsbereiche verschiedener Regenerationstechnologien Passive Regeneration Ruß ohne Regenerationshilfe Without DOC and NO2 Î O2-Reg. Additive-System Additiv-Systeme Without DOC Î NO2-+ O2-Reg. Catalytic coated SMF® Katalytisch beschichteter Filter With DOC Î NO2-Reg. CRT®-System CRTThermoelektrische Regeneration SMF® -AR System Nacheinspritzung (OE-Systeme) Post-Injection (OE-Systems) 0 100 200 300 400 500 600 Exhaust gas temperature (oC) Abgastemperatur [°C] Additional value CSMF® CSF Application area Zusatznutzen Arbeitsbereich 700 Catalytic Coated SMF® Filter Benefits: • 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 Metal Nearly no blocking of pores after nanocoating SEM-Picture, Surface – flow inside Materials for Filtration – Benchmark: - Ceramic Î Cordierite - Sintered Metal Filter SMF® SMF® – ash storage capacity is three to four times higher than ceramic wall flow SMF® Filter Ceramic Filter Î Cordierite Ceramic filter with ash loading SMF®-Filter: Lower Risk of Blockage Higher ash storage capacity Î low-maintenance Î Cost savings Application Advantages and Range of Applications Ash Distribution Model: Ash parallel (soot) bottom to top parallel (soot) Ash bottom to top Access for Ash Storage and Cleaning SMF® 100 cpsi 6 mm 2 mm Water Cleaning from ash side and from clean side Ash Ash Filter Filter Cleaning from clean side – losing pressure due to filter media Diesel Pollutants and Exhaust Gas Aftertreatment Technologies Diesel Emissions Exhaust Technology Particulate Matter (PM) Hydrocarbon / Carbon Monoxide Nitrogen Oxides (NOx) (HC / CO) Diesel Particulate Filter Diesel-OxidationCatalyst (DPF) (DOC) Selective Catalytic Reduction Reduction of HC + CO (SCR) Diesel Exhaust Gas Aftertreatment Technologies – Overview Diesel Emissions Particulate Matter (PM) Diesel Particulate Filter Exhaust Technology Nitrogen Oxides (NOx) Hydrocarbon (HC) Carbon Monoxide (CO) Diesel-Oxidation-Catalyst Selective Catalytic Reduction (DOC) c (SCR) e d CRT CRT System SCR Stufe 2 Stage 1 c > 99 % Reduction of PM d > 95 % Reduction of HC + CO e up to 90% Reduction of NOx d c SCR SCR -System System CRT + SCR = SCRT® c d Stage 1 e Stage 2 Stage Stage 22 Diesel-Oxidation-Catalyst (DOC) Î Construction Cordierit substrate Wash coat Catalytic active precious metal (Platinum Pt) Cordierite substrate: - Porous material with a huge surface Wash coat: - For increasing the surface 1 Gramm = 100 m2 - Carrier of precious metal Diesel-Oxidation-Catalyst (DOC) 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 Î CRT Principle 2 CO + O2 Æ 2 CO2 2 NO + O2 Æ 2 NO2 4 HC + 5 O2 Æ 4 CO2 + 2 H2O Diesel Emissions and Their Hazardous Pollutants Carbon Dioxide • colourless • odourless • greenhouse gas Î The Results of the DOC Environmental Hazard Nitrogen oxides Water Very Toxic CO2 • colourless • odourless • harmless H2O NOx DIESEL Carbon Monoxide • • • • X colourless Toxic odourless greenhouse gas danger of suffocation Hydrocarbon HC CO • colourless Î brown • acrid-smelling • greenhouse gas, acid rain PM • • • • Particulate Matter (PM) • • • • gray or black cloud burnt-smelling greenhouse effect carcinogen Î ? X colourless fuel-smelling greenhouse gas carcinogen Very Toxic Toxic STRATUS DIESEL PARTICULATE FILTERS Exhaust Gas Aftertreatment Technologies Part 3 Diesel emissions and their hazardous pollutants CRT System Î Continuously Regeneration Technology Reduction of: - Carbon monoxide - Hydrocarbon - Particulate matter Î Passive Regeneration Diesel Pollutants and Exhaust Technologies Diesel Emissions Exhaust Technology Particulate Matter (PM) Hydrocarbon / Carbon Monoxide Nitrogen Oxides (NOx) (HC / CO) Diesel Particulate Filter Diesel-OxidationCatalyst (DPF) (DOC) Selective Catalytic Reduction Reduction of Soot Particles + HC + CO (SCR) Diesel Exhaust Technologies – Overview Diesel Emissions Exhaust Technology Diesel-OxidationCatalyst (DOC) c Diesel Particulate Filter Selective Catalytic Reduction (SCR) Stage 1 c > 95 % Reduction of HC and CO d > 99 % Reduction of PM e up to 90% Reduction of NOx e d c CRT System Nitrogen Oxides (NOx) Particulate Matter (PM) Hydrocarbon (HC) Carbon Monoxide (CO) d SCR System CRT + SCR = SCRT® Stage 1Stufe 1 d c e Stage 2 Stage 2 Design and Operating Principle CRT® Continuously Regenerating Technology CRT® System SMF® particulate filter Oxidation cat Inlet Outlet PM reduction Oxidation • • 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 The Modular CRT System Î (Continuously Regeneration Technology) Particulate Filter Output Module Silencer Oxidation-Catalyst Input Module SMF® CRT System (Continuously Regeneration Technology) Filter System for Oxi-Cat HDV & Bus Applications Input Module 1 2 CRT System 11. 22. > 95% Reduction of HC + CO > 99% Reduction of PM (In number) Passive Regeneration ÎContinuously Regeneration > 260 㼻 C Output Module SMF® Particulate Filter CRT Description of Function (Continuously Regeneration Technology) Diesel Oxidation Catalyst SMF® Sintered Metal Filter Engine exhaust gas Cleaned exhaust gas 4HC + 5O2 Î 4CO2+2H2O 2CO + O2 Î 2CO2 2NO + O2 Î 2NO2 2NO2 + C Î 2NO + CO2 Diesel Emissions and Their Hazardous Pollutants Carbon Dioxide • colourless Î The Results of • odourless the CRT System • greenhouse gas Environmental Hazard Nitrogen Oxides Water Very Toxic CO2 • colourless • odourless • harmless H2O NOx DIESEL Carbon Monoxide • • • • X colourless Toxic odourless greenhouse gas danger of suffocation Hydrocarbon HC CO • colourless Î brown • acrid smelling • greenhouse gas, acid rain PM • • • • Particulate Matter (PM) • • • • X gray or black cloud burnt-smelling greenhouse effect carcinogen Î ? X colourless fuel-smelling greenhouse gas carcinogen Very Toxic Toxic Fuel Borne Catalyst (FBC) Fuel additive assisted regeneration Î Passive Regeneration Fuel Borne Catalyst (fuel additive assisted regeneration) Fuel-borne catalyst (FBC) – 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㼻C to 380 – 400㼻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 SCRT® System ÎSelective Catalytic Reduction Technology Reduction of: - Carbon monoxide - Hydrocarbon - Particulate matters - Nitrogen oxides Î Passive Regeneration Diesel Pollutants and Exhaust Technologies Diesel Emissions Exhaust Technology Hydrocarbon / Carbon Monoxide Nitrogen Oxides (HC / CO) (NOx) Diesel Particulate Filter Diesel-OxidationCatalyst Selective Catalytic Reduction (DPF) (DOC) (SCR) Particulate Matter (PM) Reduction of NOx Diesel Exhaust Technologies – Overview Diesel Emissions Hydrocarbon (HC) Carbon Monoxide (CO) Nitrogen Oxides (NOx) Particulate Matter (PM) Diesel-Oxidation-Catalyst Diesel Particulate Filter Selective Catalytic Reduction Exhaust Technology CRT System (DOC) c d c Stage 1 c > 95 % Reduction of HC and CO d > 99 % Reduction of PM e up to 90% Reduction of NOx (SCR) e d SCR System CRT + SCR = SCRT® Stage 1Stufe 1 d c e Stage 2 Stage 2 SCRT® System (= SCR + CRT®) SMF® Sintered Metal Filter Oxi-Cat CRT System Stage 1 SCRT® System SCR System Stage 2 Soot Urea (AdBlue®) Doser SCR Catalyst Ammonia Slip Catalyst free & Nitrogen Oxides free SCR – Selective Catalytic Reduction SCR System Urea Dosing Stage 2 Hydrolysis of Urea SCR Catalyst In Out AdBlue® Drops SCR Transformations: Ammonia Production 4 NO + 4 NH3 + O2 2 NH3 + NO + NO2 6 NO2 + 8 NH3 NOx Reduction 4 N2 + 6 H2O 2 N2 + 3 H2O 7 N2 + 12 H2O NOX Reduction by ammonia (NH3) under oxidizing conditions Engineering – SCRT® (Technology for PC and CV Applications) Engineering – SCRT® (Technology for PC and CV Applications) Diesel Emissions and Their Hazardous Pollutants Carbon Dioxide • colourless Î The Results of • odourless the SCRT® System • greenhouse gas Environmental Hazard Nitrogen Oxides Water CO2 • colourless • odourless • harmless H2O NOx DIESEL Carbon Monoxide • • • • X colourless Toxic odourless greenhouse gas danger of suffocation Hydrocarbon HC CO X PM • • • • X gray or black cloud burnt-smelling greenhouse effect carcinogen Î ? X colourless fuel-smelling greenhouse gas carcinogen Particulate Matter (PM) • • • • Very Toxic • colourless Î brown • acrid-smelling • greenhouse gas, acid rain Very Toxic Toxic Active Regeneration The 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 the filter 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 the ignition temperature of the soot and increases the burn-off speed. SMF®-AR 100% Sintered Metal Filter – Active Regeneration Filter System for LDV + Non-Road Applications SMF®-AR Suitable for OE applications and retrofitting > 99% reduction of soot particles incl. fine particles Suitable for urban traffic („Stop-and-go“) Automatic Î active regeneration Modular system Reliable system and low maintenance Thank You T.F. Hudgins, Incorporated Phone Fax 713-682-3651 713-682-1109 Email: [email protected] Internet: www.spinnerii.com 71
