Engine Tests of an Active PM Filter Regeneration System · Engine Tests of an Active PM Filter Regeneration System S. Nickolas and A. White Catalytica Energy Systems, Inc. ... materials

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Engine Tests of an Active PM Filter Regeneration System

S. Nickolas and A. WhiteCatalytica Energy Systems, Inc.

430 Ferguson Dr.Mountain View, California 94043

A. Kotrba and A. YetkinTenneco Automotive, Inc.

3901 Willis RoadGrass Lakes, Michigan 49240

Presented at DEER ConferenceChicago, Illinois

August 21-25, 2005


Abstract

Regulations for the 2007 model year diesel engines will almost universally require

Particulate Matter (PM) filters to achieve the required particulate emissions level.

For vehicle applications in which the exhaust temperature is low, significant

challenges occur in obtaining light-off temperatures of the Diesel Oxidation

Catalyst (DOC). Without this minimum temperature, filter regeneration cannot be

activated through post-injected fuel and systems face risk of becoming overloaded

with soot and eventually plugged.

An active PM filter regeneration technology has been developed in which diesel

fuel is oxidized in the presence of a proprietary catalyst system, regenerating the

PM filter in an efficient and controlled manner.


Abstract

Several important benefits for such a system include light off at low exhaust

temperatures, which allows active regeneration over a wide range of vehicle uses,

the ability to heat the PM filter uniformly without hot spots or uncontrolled

temperature extremes, lower backpressures and fuel penalty costs and a control

strategy disconnected from the engine management system.

The Xonon Fuel Combustor (XFC™) provides for active regeneration of the PM

filter at various vehicle loads and speeds. System attributes include operation at

engine exhaust temperatures as low as 220°C and an outlet temperature that can

be efficiently controlled over a wide range, as high as 700°C.


Abstract

The system is designed to produce a highly uniform outlet gas stream for

controlled regeneration of the PM filter. The integration of the XFC with a PM filter

potentially allows for use of uncatalyzed filter substrates and lower cost substrate

materials since the filter unit regeneration cycle can be carefully controlled and

managed. Engine tests over a wide exhaust flow rate range showing system

thermal response, PM filter regeneration and low temperature operation data is

presented.


OutlineThe Problem…Particulate Matter (PM) Emissions

Product Concept

Demonstration Program Objectives

System Features

Diesel GENSET Test Stand

Test Hardware

DPF Loading

Engine Test DataXFC™ Thermal Only (no DPF Installed)DPF Regeneration

Summary


PM Emissions Reduction

36281

36358

36435

36511

36588

36665

36742

36818

36895

36972

10.00

0.10

0.20

0.30

USJapan

0.00

0.05

0.10

0.15

0.20

0.25

0.30

1999

2001

2003

2005

2007

2009

2011

2013

PM

Em

issi

ons

(g/b

hp-h

r)

US EU Japan

In US, PM emission limits reduced by a factor of 10

from 2000 to 2010. 2007 and

beyond PM emission

limit=0.013 g/bHP-hr

(similarly for EU and Japan)


XFC™ Product Concept

Mixing Section

DPF FilterXFC

What does XFC bring to the party?PM filter regeneration through efficient and uniform thermal managementExtend PM filter lifeAbility to use Cordierite filters will result in cost benefitsActive at all engine loads

FuelInjector

DPF Filter

DemonstrationPrototype

CompactDesign

Exhaust

Exhaust

FuelInjector

XFC


Demonstration Program Objective

Demonstrate active regeneration of catalyzed or non-catalyzed OEM Diesel Particulate Filters (DPF) based on diesel fuel combustiontechnology in hand.

System FeaturesInjection and mixing system that provides uniform fuel air mixture to combustion catalyst.Catalytic combustion catalyst providing very uniform heated exhaust gas stream to the PM filter.Xonon Fuel Combustor (XFC) to provide the temperature required to initiate complete regeneration of the DPF. Prototype system based on developmental hardware scaled to 5.9 liter Cummins engine.


GENSET Test Stand

DPF

XFC™

MixingSection

Engine

8.3Liter Cummins Genset

M/N: 6CTA8.3-G2

Output=160kw

RPM=1800 rpm


Diesel Particulate Filter

Flow Direction

10 Liter, Non-catalyzed, Silicon Carbide


XFC™ Engine Testing: No DPF installed

Device out

EGT-4"

Device In

Fuel Flow (g/m)

260

300

340

380

420

460

500

540

580

620

660

14:24 14:26 14:28 14:30 14:32 14:34 14:36 14:38 14:40 14:42 14:44 14:46Time

XFC

Dev

ice

Gas

Tem

pera

ture

(°C

)

0

12

24

36

48

60

72

84

96

108

120

XFC

Fue

l Flo

w (g

/min

)

Dodge Ram 70mph: Controlled temperature rise to 650°C inlet to DPF at 270°C inlet to XFC.


XFC Engine Testing: No DPF installed


250

290

330

370

410

450

490

530

570

610

650

15:24 15:28 15:32 15:36 15:40 15:44 15:48Time

XFC

Dev

ice

Gas

Tem

pera

ture

(°C

)

0

8

16

24

32

40

48

56

64

72

80

XFC

Fue

l Flo

w (g

/min

)Fuel Flow

Device Out

EGT-4"

Device In




200

240

280

320

360

400

440

480

520

560

600

640

9:41 9:43 9:45 9:47 9:49 9:51 9:53 9:55 9:57 9:59 10:01Time

XFC

Dev

ice

Gas

Tem

pera

ture

(°C

)

0

8

16

24

32

40

48

56

64

72

80

88

XFC

Fue

l Flo

w (g

/min

)

Device Out

Fuel Flow (g/min)

EGT-4"

Device In



Load

160

200

240

280

320

360

400

440

480

520

560

600

640

10:38 10:42 10:46 10:50 10:54 10:58 11:02 11:06 11:10Time

XFC

Dev

ice

Gas

Tem

pera

ture

(°C

)

0

8

16

24

32

40

48

56

64

72

80

88

96

XFC

Fue

l Flo

w (g

/min

) or L

oad

(kw

)Device Out

Fuel Flow (g/min)

EGT-4"

Device In

XFC startup at engine exhaust temperatures above 220°C. Once started, ability to operate at exhaust temperatures as low as 180°C


XFC Engine Testing: DPF Loading

Loaded DPF with ~75 grams of soot

0

5

10

15

20

25

30

35

40

45

0 10 20 30 40 50 60 70 80 90 100DPF Loading (grams)

DPF

Pre

ssur

e D

rop

(in H

2O)

Removed DPF and weighedseveral times to determine

the mass of the accumulatedsoot vs. the target of 80grams.


050

100150200250300350400450500550600650700750

10:50 10:58 11:06 11:14 11:22 11:30 11:38 11:46 11:54 12:02 12:10Clock Time

Tem

pera

ture

(°C

)

051015202530354045505560657075

DPF

Inle

t Pre

ssur

e (in

H2O

) or C

O2

(%)

Rig In

DPF Inlet Pressure

XFC Out

DPF Out

XFC Engine Testing: DPF Regeneration

DPF regeneration initiated at 550°C and was complete at 600°C

Lower pressure drop after regeneration consistent with complete soot removal


250

300

350

400

450

500

550

600

650

700

750

11:22 11:26 11:30 11:34 11:38 11:42 11:46 11:50Clock Time

Tem

pera

ture

(°C

)

0

8

16

24

32

40

48

56

64

72

80

DPF

Inle

t Pre

ssur

e (in

H2O

)

Rig In

DPF Inlet Pressure

DPF InXFC Out

DPF Out

XFC Engine Testing: DPF Regeneration

Temperature rise across DPF: 100°C at 550°C and 50-60°C at 600°C

Controlled regeneration of DPF as illustrated by smooth exotherm


Summary

Successful demonstration of XFC™ technologyAbility to controllably produce the required temperature to regenerate a Diesel Particulate FilterBased on Gas Turbine catalyst development and design experience as applied to CESI’s Xonon Fuel Processor (XFP™) for Diesel NOx Emissions Reduction

Successful demonstration of DPF regenerationHighly controllable processUniform temperature field exiting XFC™ (+/-25°C) with lower variations entering DPFComplete removal of accumulated soot at average temperatures lower than typical with a non-catalyzed DPF – weight after regeneration equal to weight prior to

Identification of several value added system featuresAbility to use non-catalyzed or partially catalyzed DPFUse of lower cost substrates given the controlled and uniform exotherm in DPFActive regeneration (“on-demand”) within a large portion of the engine operating duty (at device inlet temperatures as low as 200-220°C)Minimal fuel penalty and hydrocarbon breakthrough


What’s Next?

System design for DPF regenerationFits into undercarriage spaceLow cost systemLow pressure drop

Transient operation

Control strategy

Vehicle demonstration/evaluation


Acknowledgments

David Ausley

Brian Berry

Ralph Dalla Betta

Sasha Guliaeff

William Holland

Ryan Kocher

Steve Lemons

Scott Magno

Jonathan Roberts

Arne Solberg


Thank YouContacts

Business: Jonathan Roberts

[email protected]

(630) 762-0902

Technical: Sarento Nickolas

[email protected]

(650) 940-6346

mailto:[email protected]

mailto:[email protected]

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Engine Tests of an Active PM Filter Regeneration System · Engine Tests of an Active PM Filter Regeneration System S. Nickolas and A. White Catalytica Energy Systems, Inc. ... materials