HDV Emissions Retrofit Kit - Nanoparticles

8. September 2007

HDV Emissions Retrofit Kit11th ETH-Conference on Combustion Generated Nanoparticles

Yves Hohl, Alois Amstutz

© ETH Zürich | Measurement and Control Laboratory

28. September 2007

Measurement and Control Laboratory

Outline of the presentation

Introduction and objectives of the project

The Heavy Duty Vehicle emissions retrofit kit

Phase 1: Investigation on the engine test bench

Phase 2: Field tests on the garbage truck

Field test results

38. September 2007

Measurement and Control Laboratory

Introduction

Community trucks have a life time between 10 to 20 yearsMany of them are EURO 3

48. September 2007

Measurement and Control Laboratory

Objective of the project

EGR

coo

ler

• 50% reduction of the NOX emissions• 99.5% reduction of the PM emissions• without producing secondary emissions as NO2

NOX (g/kWh)

1 765432 98

0.1

0.2

0.3

0.4PM (g/kWh)

EURO 11990

EURO 2

EURO 3

EURO 4EURO 5

EGR NO

X

Reduction > 50%DPF PM

Reduction > 99%

Trade-offPM - NOX

build a retrofit kit

Retrofit Kit

58. September 2007

Measurement and Control Laboratory

Objectives

(2006)(2009)

NOx-reduction by closed loop controlled EGR

Diesel particulate filter for PM reduction

DPF regeneration by thermodynamical means

68. September 2007

Measurement and Control Laboratory

Schematic representation of the kit

particulate trap

turbine

throttle „2"

intercooler

compressor

EGR

-coo

ler

EGR-valvewith

throttle „1"

λ-sensorNOX-sensor

rpm

timpim

pos. gas pedal

pb. comp.

tb. DPFta. DPF

pb. DPF pa. DPF

8. September 2007

Investigation on the engine test bench (phase 1)

88. September 2007

Measurement and Control Laboratory

Components and characteristics of the engine test bench

Mercedes OM 611

• 4 cylinders, 4 valves

• with turbocharger and Common-Rail

• 2150 cm3

• compression ratio 19:1

• 92 kW @ 4200 rpm

• 300 Nm from 1600 rpm to 2600 rpm

particulate trap

throttle „1“

EGR valve

EGR-cooler

NOX & Lambda-Sensor

turbocharger

98. September 2007

Measurement and Control Laboratory

EGR control system

PartikelfilterTurbine

Klappe „2"

Ladeluftkühler

Verdichter

AG

R-K

ühle

r

AGR-VentilMit

Klappe „1"

pin

pout

mA

GR

mLuft

mLuft + mAGR

λ-Sonde

108. September 2007

Measurement and Control Laboratory

EGR control system

Regelstrecke

AGR-Ventil Motor

Motortemp.,...

PI-Regler

Lambda-Sonde

Kennfeld Lambda Soll

VorsteuerungAGR-Ventil

• w: Führungsgrösse (Kennfeld Lambda)• e: Regelabweichung• u(R): Stellgrösse von Regler• u(0): Stellgrösse von Vorsteuerung• u: Stellgrösse• z: Störung (Motortemperatur, Ladedruck, Abgastemperatur, Genauigkeit von Klappe)• y: Regelgrösse (Lambda)

118. September 2007

Measurement and Control Laboratory

Control System for Regeneration

PartikelfilterTurbine

Klappe „2"

Ladeluftkühler

Verdichter

AG

R-K

ühle

r

AGR-VentilMit

Klappe „1"

mLuft

λ-Sonde

PI-Regler Klappe 2 Motor

u0 Kl 2

λsoll +

-+

+

λist

eKl 2

rpm

u GP

1.5

Regnerationsstrategie

Δp DPF

T vor DPF

mAbg

128. September 2007

Measurement and Control Laboratory

Regeneration control system

Regelstrecke

AGR-Ventil Motor

Motortemp.,...

PI-Regler

Lambda-Sonde

Lambda soll

• w: Führungsgrösse (Kennfeld Lambda)• e: Regelabweichung• u(R): Stellgrösse von Regler• u(0): Stellgrösse von Vorsteuerung• u: Stellgrösse• z: Störung (Motortemperatur, Ladedruck, Genauigkeit von Klappe)• y: Regelgrösse (Lambda)

Regenera-tions-strategie

138. September 2007

Measurement and Control Laboratory

Effect of the EGR and DPF

1000 1250 1500 1750 2000 2250 2500 2750 30000

2

4

6

8

10

12

14

16

18

engine speed [rpm]

pme

[bar

]

NOX reduction [%]

0

10

20

30

40

50

60

70

80

1000 1250 1500 1750 2000 2250 2500 2750 30000

2

4

6

8

10

12

14

16

18

engine speed [rpm]

pme

[bar

]

reduction of elementar carbon [%]

99

99.1

99.2

99.3

99.4

99.5

99.6

99.7

99.8

99.9

100

148. September 2007

Measurement and Control Laboratory

Effect of the throttling with throttle 2

1400 1600 1800 2000 2200 2400 26000

2

4

6

8

10

12

14

16

temperature before DPF without throttling [°C]

engine speed [rpm]

pme

[bar

]

200

220

240

260

280

300

320

340

360

380

1400 1600 1800 2000 2200 2400 26000

2

4

6

8

10

12

14

16

Lambda without throttling [-]

engine speed [rpm]

pme

[bar

]

1.5

2

2.5

3

3.5

1400 1600 1800 2000 2200 2400 26000

2

4

6

8

10

12

14

16

engine speed [rpm]

pme

[bar

]

temperature before DPF with throttling [°C]

360

380

400

420

440

460

480

500

520

1400 1600 1800 2000 2200 2400 26000

2

4

6

8

10

12

14

16

engine speed [rpm]

pme

[bar

]

Lambda with throttling [-]

1

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

2

158. September 2007

Measurement and Control Laboratory

Effect of the EGR during cycle 1

0 20 40 60 80 100 120 140 160 180 200 220 2401

2

3

4

NO

x [g

/kW

h]

original enginewith the kit with EGR

0 20 40 60 80 100 120 140 160 180 200 220 2400

20

40

60

redu

ctio

n of

NO

x [%

]

0 20 40 60 80 100 120 140 160 180 200 220 24005

1015202530

time [s]

engi

ne s

peed

[rpm

] p

me

[bar

]

engine speed/100pme

mean value during cycle 1

100 %

- 30 %

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

1

conc

entr

atio

n of

NO

X [g

/kW

h]

original engine with the kit with EGR

mean value during cycle 1

168. September 2007

Measurement and Control Laboratory

Effect of the DPF

0 20 40 60 80 100 120 140 160 180 200 220 2400

1

2

3

4

5

6

7

8

9

10

time [s]

elem

enta

r car

bon

[mg/

kWh]

with the kit with EGRwith the kit during the regeneration

Comparison w/wo regeneration

0 20 40 60 80 100 120 140 160 180 200 220 2400

20

40

60

80

100

120

140

160

180

200

220

240

260

time [s]

elem

enta

r car

bon

[mg/

kWh]

with the kit with EGRwith the kit during the regenerationoriginal engine

Comparison w/wo DPF

8. September 2007

Field test on the garbage truck (phase 2)

188. September 2007

Measurement and Control Laboratory

Field test: Vehicle

Hersteller: Mercedes-BenzTyp: Econic 2628-LMotor: OM 906 LA.III/4 (6-Zylinder)Abgas-Normen: Euro 3Leistung: 205 kW (280 PS) @ 2'200 rpmHubraum: 6'374 ccm

198. September 2007

Measurement and Control Laboratory

Implementation on the truck

208. September 2007

Measurement and Control Laboratory

Typical route of the waste collection (truck n° 64)

218. September 2007

Measurement and Control Laboratory

Week analysis, DPF data

228. September 2007

Measurement and Control Laboratory

Statistics on how the truck is used

65.2

14.7

13.0

2.7

0.1

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70

500 ≤ rpm < 1000

1000 ≤ rpm < 1500

1500 ≤ rpm < 2000

2000 ≤ rpm < 2500

2500 ≤ rpm

frequency [%]

73.3

5.0

5.9

3.7

12.2

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

0 ≤ GP < 20

20 ≤ GP < 40

40 ≤ GP < 60

60 ≤ GP < 80

80 ≤ GP < 100

frequency [%]

85.8

10.4

3.6

0.2

0.0

0 10 20 30 40 50 60 70 80 90 100

0 ≤ v truck < 20

20 ≤ v truck < 40

40 ≤ v truck < 60

60 ≤ v truck < 80

80 ≤ v truck < 100

freqeuncy [%]

engine speedgas pedal

truck speed

238. September 2007

Measurement and Control Laboratory

Statistics on how the truck is used

68.2

15.9

4.0

1.2

1.1

0.3

0.1

0.0

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75

0 ≤ p < 40

40 ≤ p < 80

80 ≤ p < 120

120 ≤ p < 160

200 ≤ p < 240

240 ≤ p < 280

320 ≤ p < 360

360 ≤ p

frequency [%]

3.5

14.6

52.6

19.4

5.4

0.7

0.2

0.1

0.1

0 5 10 15 20 25 30 35 40 45 50 55 60

100 ≤ T < 200

200 ≤ T < 250

250 ≤ T < 300

300 ≤ T < 350

350 ≤ T < 400

400 ≤ T < 450

450 ≤ T < 500

500 ≤ T < 550

550 ≤ T

frequency [%]

5.3

13.4

45.3

22.7

7.5

3.0

1.1

0.2

0.0

0 5 10 15 20 25 30 35 40 45 50

100 ≤ T < 200

200 ≤ T < 250

250 ≤ T < 300

300 ≤ T < 350

350 ≤ T < 400

400 ≤ T < 450

450 ≤ T < 500

500 ≤ T < 550

550 ≤ T

frequency [%]

temp. before DPF temp. after DPF

pressure diff. on DPF

248. September 2007

Measurement and Control Laboratory

Regeneration analysis

16.4 16.45 16.5 16.55 16.6 16.65 16.7 16.75 16.8 16.85 16.912345

time [h]

lam

bda

[-]

16.4 16.45 16.5 16.55 16.6 16.65 16.7 16.75 16.8 16.85 16.900.20.40.60.8

1

time [h]

th. 2

[-]

16.4 16.45 16.5 16.55 16.6 16.65 16.7 16.75 16.8 16.85 16.9100200300400500600

time [h]

tem

p. [°

C]

16.4 16.45 16.5 16.55 16.6 16.65 16.7 16.75 16.8 16.85 16.9050

100150200250300

time [h]

p D

PF [m

bar]

before DPF

after DPF

258. September 2007

Measurement and Control Laboratory

EGR analysisWithout EGR With EGR

8. September 2007

Exhaust gas measurements

278. September 2007

Measurement and Control Laboratory

Description of the stationary measurements

load

[%]

Modified ESC test cycle

288. September 2007

Measurement and Control Laboratory

Description of the dynamic measurements

Waste collection cycle City-cycle

298. September 2007

Measurement and Control Laboratory

Results of the gas analysis I

0

100

200

300

400

500

600

700

1 2 3 4 5 6 7 8 9 10 11 12 13

operating points [-]

NO

X [p

pm]

measurement 1 (before DPF, wo EGR)measurement 4 (after DPF, w EGR)

1 3 5 7 8 9 11 a b c d e f0

25

50

75

100

Load

[%]

Idle speed A B C46

70 65 53

50 50 50

0 0 0

0 0 0

1375 rpm 1750 rpm 2125 rpm600 rpm

75

67667562

47

NOX reduction [%] Comparison of NOX emissionswith/without the Kit

308. September 2007

Measurement and Control Laboratory

Results of the particle analysis

PM reduction [%]

0

25

50

75

100

Load

[%]

Idle speed A B C99

99 99 99

99 99 99

99 99 99

99 99 99

1375 rpm 1750 rpm 2125 rpm600 rpm

99

99999999

99

Size distribution and penetration

318. September 2007

Measurement and Control Laboratory

NO2/NOX ratio

05

101520253035404550

100 150 200 250 300 350 400 450 500 550exhaust gas temperature before DPF [°C]

NO

2/NO

X [%

]

sinter-metal DPF + FBC + EGRwo DPF, wo EGR, w FBC

328. September 2007

Measurement and Control Laboratory

Results of the gas analysis II

CO increasing [%]Comparison of CO emissionswith/without the Kit

0

25

50

75

100

Load

[%]

Idle speed A B C50

336 190

0 0 0

0 0 0

1375 rpm 1750 rpm 2125 rpm600 rpm

354

207

263218178173

133

200 200200

0200400600800

10001200140016001800

1 2 3 4 5 6 7 8 9 10 11 12 13

operating points [-]

CO

[ppm

]

measurement 4 (after DPF, w EGR)measurement 1 (before DPF, wo EGR)

1 3 5 7 8 9 11 a b c d e f

338. September 2007

Measurement and Control Laboratory

Waste collection cycle

0

10000

20000

30000

40000

50000

60000

0 10 20 30 40 50 60 70 80 90 100 110 120time [s]

PAS

2000

[μgE

C/m

3 ] before DPF

after DPF

-100%

-80%

-60%

-40%

-20%

0%

20%

NOx PM CO

effe

ct o

f the

HD

V Em

issi

ons

Ret

rofit

Kit,

w

aste

col

lect

ion

cycl

e

auxiliary drive system is turned on

348. September 2007

Measurement and Control Laboratory

City-cycle

-100%

-80%

-60%

-40%

-20%

0%

20%

40%

60%

NOx PM CO

effe

ct o

f the

HD

V Em

issi

ons

Ret

rofit

Kit,

city

-cy

cle

0 20 40 60 80 100 120 140 160 180 2000

100

200

300

400

500

600

700

800

900

1000

time [s]

NO

X [ppm

]

NOX wo EGR

NOX w EGR

358. September 2007

Measurement and Control Laboratory

ConclusionsHDV Emissions Retrofit Kit consisting of

- DPF- EGR system- Additive for regeneration

finds on a truck room to be installedproved to be very reliablecosts about 6000 CHF w/o DPFachieves

is a suitable solution for retrofitting heavy duty vehicles in communitiy applicationsProject should be extended to a bigger fleet

• 45% reduction of the NOX emissions• 99.5% reduction of the PM emissions• without producing secondary emissions

8. September 2007

HDV Emissions Retrofit Kit11th ETH-Conference on Combustion Generated Nanoparticles

Yves Hohl, Alois Amstutz

© ETH Zürich | Measurement and Control Laboratory

Thank you for your attention!

Andreas MayerThomas Lutz