Ford/DOE SCR Program Update Christine Lambert Diesel Exhaust Aftertreatment Ford Research Laboratories June 17, 2004 C. Lambert

Seventh CLEERS Workshop 6/17/2004

DOE Ultra-Clean Fuels Program Outline of Ford’s program to achieve Tier 2 emission standards for 2007 using low sulfur diesel fuel as an enabler for a high efficiency aftertreatment system. Primary Contractor

Subcontractors

Catalyst Suppliers

Phase I - Initial build/test phase (July01-July02) Establish baseline emission control system Deliver engine dynamometer NOx and PM test results Deliver prototype vehicle NOx and PM test results Deliver urea delivery (infrastructure) prototype Phase II - System/component optimization phase (July02-July04) Define final system hardware components Deliver NOx and PM performance data from fresh system Phase III - Durability phase (July04-July05) Definition of durability test procedure Final NOx and PM emission levels Final report for the completed program

C. Lambert

Seventh CLEERS Workshop 6/17/2004

Introduction • Tier 2 Bin 5 standards represent 90-95% NOx and PM reduction from today’s Tier 1 standards for diesels. Standard Tier 1 (100k mi) Tier 2 Bin 5 (120k mi)

NOx (g/mi) 1.25 0.07

PM (g/mi) 0.10 0.01

• NOx and PM control remain a challenge for diesels. • Choices for PM include fuel additive/filter and catalyzed filter. • Choices for NOx include HC SCR, NOx Adsorber, & NH3 SCR.

C. Lambert

Seventh CLEERS Workshop 6/17/2004

Comparison of NOx Reduction Technologies 100 90 80 70

HC SCR

60

Urea SCR

50

LNT

40 30 20 10

US06

FTP-75

0 100

200

300

400

Catalys t Te mpe rature (°C)

C. Lambert

Seventh CLEERS Workshop 6/17/2004

500

600

FTP Fuel Economy Penalty Comparison FTP NOx Conversion (%)

(estimated using 2.5L York Transit feedgas)

100 90 80 70 60

Urea SCR + filter

3% Fuel Penalty from PM Filter

50 40 30 20 10 0 0

2

LNT + filter

HC SCR + filter

4

6

8

FTP Fuel Economy Penalty (%) C. Lambert

Seventh CLEERS Workshop 6/17/2004

10

Use of Modeling for Improved SCR Function • Predict system performance ¾ Predict NOx conversion levels ¾ Predict fuel economy impact ¾ Provide direction for system design

• Evaluate system performance ¾ Diagnose problems with system hardware/strategy ¾ Provide direction for future system testing

C. Lambert

Seventh CLEERS Workshop 6/17/2004

Cu mulative NOx (% of en gine out)

Prediction of FTP Performance 100

Engine out out Engine

90

System A

80

Urea

70 60

Target 90% Conv.

50 40

E

System AA Tailpipe Tailpipe System

T

PM Filter Filter SiC

System B

System B Tailpipe Tailpipe System B

30 20

Urea E

10

System B Tailpipe Tailpipewith withrapid rapidwarm-up warm-up System B

0 0

200

400

600

800

1000 1200 1400

FT P Cycle T im e (seconds)

Rapid warm-up = extra 50°C ramped in over first 30s of test. C. Lambert

SCR

Seventh CLEERS Workshop 6/17/2004

T

DOC

SCR

SiC Filter PM Filter

LDT Exhaust System (NOx) Turbo

Spray Deflector

DOC

SCR Catalyst

DOC

NOx sensor

aqueous urea

C. Lambert

Flow mixing plate

Seventh CLEERS Workshop 6/17/2004

160000

350

140000

300

120000

250

100000

200

80000

150

60000

100

40000

50

20000

-1

400

Space Velocity (hr )

Temperature (°C)

LDT Temperatures and Space Velocity on FTP LDT Temperatures and Space Velocity (without rapid warm-up strategy) FTP-75 Test

0

0

0

500

1000

1500

Time (seconds) Turbo Out

C. Lambert

DOC in

SCR in

SCR out

Space Velocity

Seventh CLEERS Workshop 6/17/2004

2000

Weighted FTP-75 Emissions

(Without Rapid Warm-up Strategies, September 2003) 0.25

0.42

Bag 3 emissions Bag 2 emissions 0.20

0.208 (82%)

Bag 1 emissions Tier II Bin 5 Stds, 120k mi

0.067 (79%)

grams/mile

( ) Catalyst efficiency 0.15

0.033 (94%)

0.10

0.088 (82%) 0.062 (93%)

0.05

0.007 (96%) 0.015 (97%)

0.107 (52%)

0.042 0.004 0.006

0.041 (82%)

0.032

THC

NMHC

0.082 (52%)

0.00

C. Lambert

CO/10

Seventh CLEERS Workshop 6/17/2004

NOx

}

Current range of TP NOx with rapid warm-up strategies

Importance of Urea Mixing (Transient Vehicle Results)

100

Poor mixing Improved mixing

Cumulative TP NOx (% EO NOx)

90 80 70 60 50 40 30 20 10 0 0

250

500

750

1000

1250

test time (s)

C. Lambert

Seventh CLEERS Workshop 6/17/2004

1500

1750

2000

Importance of NO2/NOx Ratio on Aged Catalyst Performance 100 90

NOx Conversion (%)

80 70 60 50 40

HT aged, NO only

30

HT aged, 1:1 NO:NO2

20

sulfated, NO only

10

sulfated, 1:1 NO:NO2

0 150

200

250

300

350

400

450

Catalyst Temperature (°C)

C. Lambert

Seventh CLEERS Workshop 6/17/2004

500

550

600

Impact of HC on SCR performance 100

20

NOx Conversion (%)

80 70 60 50 40 30 20

Degreened Activity (250°C, 20% NO2 in feed) Start HC Addition

18

Activity Regained

16 14 12 10 8

500°C, 10 min

6 % NOx Conv. Cum. HC's

4

10

2

0

0

C. Lambert

Seventh CLEERS Workshop 6/17/2004

Cumulative HCs (g/l catalyst)

End HC Addition

90

Urea Program Prototype Urea Co-fueling System Status • Co-axial nozzle design chosen and improved for durability and reliability. • Urea pumping unit designed and feasible for modern dispenser. • Prototype system being built to evaluate cofueling, including low temp. • Vehicle modified with compatible fill-neck and urea storage for demo.

C. Lambert

Seventh CLEERS Workshop 6/17/2004

Future Work • • • • •

Finalize rapid warm-up strategy Choose final catalyst formulations Aging cycle development – 120k mi NOx and NH3 sensor development Complete urea infrastructure investigation

C. Lambert

Seventh CLEERS Workshop 6/17/2004

Acknowledgements Ford Brendan Carberry, Dick Chase, Bob Hammerle, Dave Kubinski, Paul Laing, Christine Lambert, Mike Levin, Cliff Montreuil, Rick Soltis, Devesh Upadhyay, Michiel van Nieuwstadt, Scott Williams FEV Erik Koehler, Dean Tomazic Exxon Mobil Joan Axelrod, Jeff Beck, Bill Blazowski, Owen Feeley, Rich Grosser, Mike Kerby, Marcus Moore, Mike Noorman, Charlie Schleyer

C. Lambert

Seventh CLEERS Workshop 6/17/2004