Cummins/ORNL-FEERC CRADA: NOx Control & Measurement ...€¦ · Cummins/ORNL-FEERC CRADA: NOx Control & Measurement Technology for Heavy-Duty Diesel Engines Author: Bill Partridge,

W.P. Partridge (PI), J.-S. Choi, J.E. Parks, L.A. KranendonkOak Ridge National Laboratory

N. Currier (PI), R. Shute (PI), A. Yezerets, M. Cunningham, M. Ruth, K. Kamasamudram Cummins Inc.

Presenter: Bill [email protected]

U.S. DOE Program Management Team:Ken Howden, Gurpreet Singh, Steve Goguen

Cummins/ORNL-FEERC CRADA: NOx Control & Measurement Technology

for Heavy-Duty Diesel Engines

2010 Vehicle Technologies Program Annual Merit ReviewJune 10, 2010, Washington, DC

This presentation does not contain any proprietary, confidential, or otherwise restricted information.

Project ID: ACE032

2 Managed by UT-Battellefor the Department of Energy

Overview

Timeline• Start: FY1998• Major Revisions: 2001, 03, 06, 10• Current is 2010-’12 revision• Finish: September 2012• % Complete: ~17%

Budget• Total project budget since 1998

– DOE share: $4,950k– Contractor share: $4,950k

• Funding received in FY09– $400k

• Funding for FY10– $400k

Barriers• Engine combustion

– Combustion uniformity

• Emissions controls– Catalyst fundamentals, design &

control, (& efficiency)

• Engine controls– Variability & diagnostics– Fast PM & species diagnostics

• Durability– Fuel dilution of oil, (& efficiency)

Partners• ORNL & Cummins Inc.• Informal coordination with

CLEERS, U.Houston & MI Tech. ACEC (Adv. Comb. & Emiss. Control)

3 Managed by UT-Battellefor the Department of Energy

Objectives

Combustion Uniformity:• Measure cylinder H2O & PM variations on engine at Cummins

– Enable improved efficiency, control and emissions• Develop methods to quantify cylinder and cycle uniformity

– Enable improved efficiency, control and emissions• Improve oil-dilution diagnostic: Fuel-in-Oil (licensed to Da Vinci Emissions Services)

– Enable improved durability, efficiency and emissions– Lower development cost & shorten development time

Self-Diagnosing SmartCatalyst:• Measure intra-SCR catalyst performance distributions

– Distributed NH3 storage distribution & SCR reactions– Improve catalyst design & control for enhanced efficiency & emissions control

• Characterize LNT catalyst reactions and performance distributions– Intermediate NH3 formation and utilization, sulfation & oxygen-storage impacts, water-

gas shift reaction– Combine models w/ measurements to understand reactions and performance– Improved catalyst design & control for enhanced efficiency & emissions control

4 Managed by UT-Battellefor the Department of Energy

Milestones

2009 Milestone:• Demonstrate high-speed exhaust water measurement for

assessing combustion uniformity on development engine at Cummins Engine Plant

2010 Milestones (on target for Sept. 2010 completion):• Characterize variation associated with steady state and transient

engine operation. • Characterize SCR-catalyst performance distribution under select

operating conditions.

5 Managed by UT-Battellefor the Department of Energy

Approach

Develop Diagnostics

Catalyst Applications

Proof-Of-Principle on Engine Iterate on Diagnostics

Diagnostics

Data & Catalyst Understanding

SpecifyDesign Down Select Control

Uniformity

Catalyst EGR

Systems Models

Integrated Partnershipw/ Joint ContributionsORNL Cummins

Picture of engine courtesy of Cummins Inc., and used with permission

Development Needs

Catalyst Applications

Engine Applications

Model Development

Efficient & Clean Engines

Other Non-CRADA Programs Benefit TooDOE, Academia, National Labs, Industry

6 Managed by UT-Battellefor the Department of Energy

Technical Progress: Combustion Uniformity

• Fuel-In-Oil Diagnostic– More sensitive, real-time, on-engine measurement of fuel dilution– Enables improved engine calibration, durability, efficiency & emission;

and lowers development costs– Licensed to Da Vinci Emissions Services & marketed as DAFIO

– Responsive to 2009 Merit Review feedback

• Fast (3kHz) Exhaust Concentration & PM Measurements– Resolves cylinder-to-cylinder & cycle-to-cycle variability– Map cylinder combustion uniformity & variations– Very relevant to high-EGR systems– Enables improved engine design & control, and reduced emissions

7 Managed by UT-Battellefor the Department of Energy

Technical Progress: 1 – Fuel-in-Oil Diagnostic

Fuel-in-Oil Licensed to Da Vinci Emissions Solutions

(addresses 2009 Reviewer comments)

Fast oil-dilution measurement for improved calibrations

• FiO provides–Fast feedback: ~10min–More detailed mapping–Local optima revealed–Better calibrations!

– Durability, efficiency, emissions

• Cummins using FiO

• Continued FiO improvement

• DAFIO Commercialized!

• 2009 SE Region FLC Award Excellence in Tech Transfer

FIO

Fuel In OilMeasurement System

Managed by UT-Battelle for the Department of Energy

8 Managed by UT-Battellefor the Department of Energy

•Objective– Resolve cylinder-specific exhaust– Assess combustion uniformity– Single-cylinder engine data from a

multi-cylinder engine

• Approach– Fast-Scan NIR measurements– Fast-Scan NIR laser

– Version of 45kHz FDML laser– 3kHz scan 1330 to 1380 nm

– [H2O] via absorbing λ– PM via non-absorbing λ

• Purpose– rapid feedback to guide engine

development & modeling Fiber pitch Exhaust

Time

Inte

nsity

[V] Scan H2O Spectra

(Blue)(Red) (Red)

Photo detector

SOA

FSNIR3 kHz

Tech. Progress: 2a – Fast Exhaust H2O Measurements

Fast Scan NIR (FSNIR) LaserMeasures engine variations for improved efficiency & emissions

Purge Purge

9 Managed by UT-Battellefor the Department of Energy

0 20 40 60 800.10

0.15

0.20

0.25

0.30

0.35

0 120 240 360 480 600 720

#42.07

#31.37 #1

1.15

H2O

Time [ms]

#2: 1

Crank Angle [deg]

Cylinder-Resolved H2O & PM Measurements Demonstrated

• Single cylinder resolution

• Combustion uniformity resolved

• Applications:– Map combustion variations– Impact of design changes– Mitigation strategies– Transient EGR feedback– Load transients– Improved control and

reduced emissions

Cylinder Combustion Variationw/ base fueling

Tech. Progress: 2b – Fast Exhaust H2O Measurements

1.7L Mercedes at ORNL

0 20 40 60 800.0

0.1

0.2

0.3

0.4

0.5

0.60 120 240 360 480 600 720

#4#3#1

H2O

[a.u

.]

Time [ms]

1500 RPM

#2

Crank Angle Degrees

Cylinders Individually Enriched for 10s

10 Managed by UT-Battellefor the Department of Energy

Measurements at CumminsCylinder-Resolved H2O & PM

Demonstrated

• Single-cylinder resolution

• NIR PM tracks Celesco

• More work to do:– Alternate optical access design– Complex pressure influence– Modify for CO2 measurement

• Shows project approach: – Develop instrument in lab– Proof on engine at ORNL– Apply at Cummins– Iterate

Tech. Progress: 2c – Fast Exhaust H2O Measurements

Larger Development Engine at Cummins

Fast NIR vs Celesco PM Measurements

Celesco PM Value

Fast

NIR

PM

Val

ue

Exhaust Measurement

Point

Crank Angle (degrees)

Exha

ust H

2O C

once

ntra

tion

D E FCB G HA

All Cyls @ 80%

Cyl ‘E’ @ 100%Other Cyls @ 80%

Cylinder-Resolved H2O Measurements

Sample in pipe between exhaust manifold and turbo

11 Managed by UT-Battellefor the Department of Energy

Cycle

-inte

grat

ed va

lue

(ppm

x s)

Model

NOx

NH3

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

0 0.2 0.4 0.6 0.8 1

NOx

NH3

ExperimentCLEERS LNT, 60/5-s lean/rich cycling, 300 °C

Fractional LNT length

Technical Progress: Self-Diagnosing SmartCatalysts

• Intra-catalyst distributed measurements– Provide unique insights & practical solutions

SpaciMS received 2009 National FLC Award Optical fiber sensors in development

• Intermediate Ammonia Formation and Utilization– Basic understanding of LNT regeneration– NH3 management (lean-gas, light diesel, 2-fuel)– Dual LNT-SCR system design

Experiments and modeling continuing Joint modeling efforts w/:

– CLEERS– Louise Olsson, Chalmers– Petr Koci, Prague Institute of Chemical Technology

• Distributed SCR Reactions & Ammonia Storage– Basic understanding of SCR reactions– Improve design and performance– Identify advanced control strategies for improve performance

12 Managed by UT-Battellefor the Department of Energy

Technical Progress: Intra-SCR Distributed NH3 StorageCummins 4-Step Protocol

• 4Step Protocol resolves:– Dynamic, Unused & Total NH3

Capacity

• Reactor modified for intra-SCR measurements– T>195C throughout reactor and

up to SpaciMS inlet

• Initial work:– CLEERS-Reference Fe SCR– 225 & 325C (225C shown)

– SCR effluent

• Qualitative observations: – NH3 inhibition at 225C vs. 325C– Greater total capacity at 225C– Less unused capacity at 225C

0

100

200

0 20 40 60 80 100 120 140 160 180Time (min)

NO

& N

H3 (

ppm

)

200ppm NO 200ppm NO200ppm NH3200ppm NO + 200ppm NH3

NH3 inhibition?

Total: 0.68g/L

Dynamic: 0.67g/L

Unused: 0.05g/L

NO puff due to inhibition?

SCR NH3 Storage Resolved,Intra-SCR Storage Distribution Next

SCR Effluent, 225C, w/o H2O & CO2

13 Managed by UT-Battellefor the Department of Energy

Collaborations & Coordination

• Cummins• CLEERS (DOE VT funded)

– NH3 measurements & modeling, SCR measurements• Johnson Matthey - Optical fiber sensor development• Umicore - CLEERS LNT & SCR catalysts• U. Houston w/ U. Kentucky, Ford, BASF & ORNL (DOE VT funded)

– Advanced Combustion and Emissions Controls R&D– Intra-catalyst reaction distribution measurements

• Michigan Tech. U. (DOE VT funded)– Similar to U.H. ACEC project above

• LECA (DOE VT funded)– Exhaust H2 & O2 and catalyst measurements

• Prof. Louise Olsson, Chalmers– Modeling NH3 formation and utilization (MS student)– SCR measurements (PhD student, @ ORNL June-October)

• Dr. Petr Koci, Prague Institue of Chemical Technology– Modeling NH3 formation and utilization (@ ORNL in June)

• Dr. Alex Goguet, Queen’s University Belfast– Development of Time-of-Flight SpaciMS

• Dr. Kent Froelund, Da Vinci Emissions Services– DAFIO licensed for commercial sales

14 Managed by UT-Battellefor the Department of Energy

Future Work

2010 Work:• Map NH3 storage distribution throughout SCR catalyst

– Temperature & NO2/NOx sweeps• Eliminating purge tubes in FSNIR measurement• Fiber-based O2/reductant diagnostic for engine uniformity measurements• Modeling intermediate NH3 (joint w/ CLEERS, Chalmers & ICT Prague)

– Parallel vs. sequential regeneration pathways

2011 Work:• Assess O2/reductant diagnostic on engine• Measure engine intake uniformity and variations• Correlate NH3 storage distributions w/ performance parameters

– Identify strategies for SCR-catalyst control• Modeling SCR reactions & NH3 storage w/ Chalmers• Fiber-based and other simple NH3 diagnostics• Inhibitor impact on SCR catalyst reaction and storage distributions

15 Managed by UT-Battellefor the Department of Energy

Summary

• Fuel-In-Oil Diagnostic licensed to Da Vinci Emissions Services– Being applied at Cummins for improved durability, efficiency and emissions– Commercially available for all (cf. 2009 Review feedback)

• Cylinder-resolved H2O & PM measurements demonstrated (2009 milestone)– Evaluates engine variations and mitigation strategies for improved efficiency, control and emissions– Applicable to Cummins SuperTruck program– Expanding to CO2 & intake measurements

• Distributed intra-catalyst measurements drive practical advances– SpaciMS measurements of SCR NH3 storage demonstrated – Next step is to measure intra-SCR distributed storage & variations w/ conditions– Continuing work on LNT NH3 pathways, and sulfation of LNT WGSR & NOx storage functions– Drives design, modeling, specification and control (OBD) for improved emissions & efficiency

• CRADA approach consistently yields practical techniques and solutions– E.g., EGR mixing, Fuel dilution, Catalyst & Engine control, Models, SpaciMS, OBD

• Future work focuses on: – Studying engine variations and mitigation strategies (2010 milestone)– Advanced variation diagnostics– Distributed intra-SCR chemistry and performance (2010 milestone) 2010

Award