Model-based optimization of parameters for a diesel engine SCR system

A Selective Catalytic Reduction (SCR) system simulation model for diesel engines was established based on MATLAB/Simulink. The model includes four subsystems: signal acquisition, DEF (Diesel Exhaust Fluid) dosing control, catalytic chemistry reaction and NO_X emissions reduction. The SCR control strategy was optimized based on ETC simulation results. Simulation and test results indicate that the model developed in this paper can predict ETC NO_X emissions accurately.     

Model-based control system design in a urea-SCR aftertreatment system based on NH3 sensor feedback

This paper presents preliminary control system simulation results in a urea-selective catalytic reduction (SCR) aftertreatment system based on NH₃ sensor feedback. A four-state control-oriented lumped parameter model is used to analyze the controllability and observability properties of the urea-SCR plant. A model-based estimator is designed via simulation and a control system is developed with design based on a sliding mode control framework. The control system based on NH₃ sensor feedback is analyzed via simulation by comparing it to a control system developed based on NO_x sensor feedback. Simulation results show that the NH₃ sensor-based strategy performs very similarly in comparison to a NO_x sensor-based strategy. The control system performance metrics for NO_x index, urea index, urea usage, and NH₃ slip suggest that the NO_x sensor can be a potential alternative to a NO_x sensor for urea-SCR control applications.     

Urea-SCR system optimization with various combinations of mixer types and decomposition pipe lengths

The demand for NO_x after-treatment system has increased dramatically due to the stricter NO_x emission regulations for diesel vehicles. The urea-SCR system is one of the NO_x after-treatment methods found to be quite effective to meet the regulation requirement enforced by various authorities including the Euro-6. In order to develop an effective urea-SCR system, it is critical to establish an even distribution of reductant over the catalyst surface since this favorable distribution can increase reduction reaction and in turn, improve NO_x conversion efficiencies. In the current study, a number of design variations of the urea-SCR system which included two mixer types and three decomposition pipe lengths, were evaluated systematically using CFD analysis and experimental measurements. The purpose of the CFD analysis was to estimate the distribution of reductant within the urea-SCR system with a specific configuration and the purpose of the engine emission test was to measure the amount of NO_x reduction, respectively. The results from the systematic analysis revealed the relation between the reductant distribution over the SCR and the performance of the NO_x reduction.     

Effect of UWS injection at low exhaust gas temperature on NO<Subscript>x</Subscript> removal efficiency of diesel engine

Urea-SCR systems have been widely used in diesel vehicles according to the strengthened NO_x (Nitrogen Oxides) emission standard. The NO_x removal efficiencies of the latest well optimized urea-SCR system are above 90 % at moderate exhaust gas temperature of 250 ~ 450 °C. However, a large amount of NO_x is emitted from diesel vehicles at cold start or urban driving conditions, when the exhaust gas temperature is not high enough for SCR catalyst activation. Although many researchs have been stuied to improve NO_x conversion efficiency at these low temperature conditions, it is still one of important technical issues. In this study, the effect of UWS injection at low exhaust gas temperature conditions is studied. This study uses a 3.4 L diesel engine equipped with a commertial urea SCR system. As a result, it is found that about 5 % of NO_x removal efficiency is improved in the NRTC test when UWS injection starts at the SCR inlet temperature of 150 °C compared to 200 °C. It is also found that urea deposits can be formed on the wall of exhaust pipe, when the local wall temperature is lower than temperature of urea decomposition.     

Exhaust emissions and its control methods in compression ignition engines: A review

Extensive usage of automobiles has certain disadvantages and one of them is its negative effect on environment. Carbon dioxide (CO₂), carbon monoxide (CO), hydrocarbons (HC), oxides of nitrogen (NO_x), sulphur dioxide (SO₂) and particulate matter (PM) come out as harmful products during incomplete combustion from internal combustion (IC) engines. As these substances affect human health, regulatory bodies impose increasingly stringent restrictions on the level of emissions coming out from IC engines. This trend suggests the urgent need for the investigation of all aspects relevant to emissions. It is required to modify existing engine technologies and to develop a better after-treatment system to achieve the upcoming emission norms. Diesel engines are generally preferred over gasoline engines due to their undisputed benefit of fuel economy and higher torque output. However, diesel engines produce higher emissions, particularly NO_x and PM. Aftertreatment systems are costly and occupy more space, hence, in-cylinder solutions are preferred in reducing emissions. Exhaust gas recirculation (EGR) technology has been utilized previously to reduce NO_x. Though it is quite successful for small engines, problem persists with large bore engines and with high rate of EGR. EGR helps in reducing NO_x, but increases particulate emissions and fuel consumption. Many in-cylinder solutions such as lower compression ratios, modified injection characteristics, improved air intake system etc. are required along with EGR to accomplish the future emission norms. Modern combustion techniques such as low temperature combustion (LTC), homogeneous charge compression ignition (HCCI), premixed charge compression ignition (PCCI) etc. would be helpful for reducing the exhaust emissions and improving the engine performance. However, controlling of autoignition timing and achieving wider operating range are the major challenges with these techniques. A comprehensive review of diesel engine performance and emission characteristics is given in this paper.     

Real-time empirical NO<Subscript>x</Subscript> model based on In-cylinder pressure measurements for light-duty diesel engines

This paper proposes a real-time empirical model of NO_x emissions for diesel engines. The proposed model predicts the level of NO_x emissions using an empirical model developed based on the thermal NO formation mechanism, the extended Zeldovich mechanism. Since it is difficult to consider the exact physical NO formation phenomena in real-time applications, the proposed algorithm adapts the key factors of the NO formation mechanism from the extended Zeldovich mechanism: temperature of the burned gas, concentration of the gas species, and combustion duration where NO is generated. These factors are considered in a prediction model as four parameters: exhaust gas recirculation rate (EGR rate), crank angle location of 50 % of mass fraction burned (MFB50), exhaust lambda value, and combustion acceleration. The proposed prediction model is validated with various steady engine experiments that showed a high linear correlation with the NO_x emission measured by a NO_x sensor. Furthermore, it is also validated for transient experiments.     

Performance of the NOx sensor based on mixed potential for automobiles in exhaust gases

The NO_x sensor based on mixed potential was made by laminating YSZ green sheets, on which electrodes including an NO_x sensing electrode, an NO_x conversion electrode, a Pt heater and thermocouple were printed and sintered. The output signal of this sensor was fairly independent of gas temperatures and the velocity of gas flows in the test gases. The engine test for the exhaust gases at around λ=1 showed that the sensor outputs changed corresponding to NO_x concentrations from the gas analyzer. It is expected that this sensor based on mixed potential can be utilized for automobiles.     

Effect of Hydrothermal Aging over a Commercial DOC on NO<Subscript>2</Subscript> Production and Subsequent SCR Efficiency

In this study, the effect of hydrothermal aging over a commercial diesel oxidation catalyst (DOC) on deterioration in nitrogen dioxide (NO₂) production activity has been experimentally investigated based on a micro-reactor DOC experiment. Through this experimental result, the NO₂ to nitrogen oxides (NOx) ratio at DOC outlet has been mathematically expressed as a function of DOC temperature according to various aging conditions. The current study reveals that the catalyst aging temperature is a more dominant factor than the aging duration in terms of the decrease in NO₂ production performance through DOC. The DOC sample hydrothermally aged for 25 h at 750 °C has displayed the lowest NO₂ to NOx ratio compared to the samples aged for 25 ~ 100 h at 650 °C. Also, in this study, the impact of hydrothermal aging of a DOC on the selective catalytic reduction (SCR) efficiency in a ‘DOC + SCR’ aftertreatment system was predicted by using transient SCR simulations. To validate the SCR simulation, this study has conducted a dynamometer test of a non-road heavy-duty diesel engine with employing a commercial ‘DOC + SCR’ system on the exhaust line. The current study has quantitatively estimated the effect of the variation in NO₂ to NOx ratio due to the hydrothermal aging of DOC on the NOx removal efficiency of SCR.     

NOx reduction characteristics of Pt-ZSM-5 catalyst with diesel engine exhaust

The platinum ion-exchanged ZSM-5 zeolite catalyst (Pt-5), which reduces nitrogen oxides (NO_x) in the presence of oxygen and hydrocarbons, was applied to actual diesel engine exhaust. Compared to the Cooper ion-exchanged ZSM-5 zeolite catalyst, the Pt-Z had higher NO_x reduction efficiency, η_NOx = 33%, and lower activation temperature, 250°C, in normal engine operation. It was found that water in the exhaust gas did not apparently affect the NO_x reduction, while the reduction efficiency was significantly affected by the aspect ratio of the catalyst reactor and by the shape of the catalyst, i.e. pellet or honeycomb.     

Effect of operating parameters on diesel/propane dual fuel premixed compression ignition in a diesel engine

In this research, the effects of three operating parameters (Diesel injection timing, propane ratio, and exhaust gas recirculation (EGR) rates) in a diesel-propane dual fuel combustion were investigated. The characteristics of dual-fuel combustion were analyzed by engine parameters, such as emission levels (Nitrogen oxides (NO_x) and particulate matter (PM)), gross indicated thermal efficiency (GIE) and gross IMEP Coefficient of Variance (CoV). Based on the results, improving operating strategies of the four main operating points were conducted for dual-fuel PCCI combustion with restrictions on the emissions and the maximum pressure rise rate. The NOx emission was restricted to below 0.21 g/kWh in terms of the indicated specific NO_x (ISNO_x), PM was restricted to under 0.2 FSN, and the maximum pressure rise rate (MPRR) was restricted to 10 bar/deg. Dual-fuel PCI combustion can be available with low NO_x, PM emission and the maximum pressure rise rate in relatively low load condition. However, exceeding of PM and MPRR regulation was occurred in high load condition, therefore, design of optimal piston shape for early diesel injection and modification of hardware optimizing for dual-fuel combustion should be taken into consideration.     

Numerical analysis of the effect of inhomogeneous pre-mixture on the pressure rise rate in an HCCI engine using multi-zone chemical kinetics

The HCCI (Homogeneous Charge Compression Ignition) engine is an internal combustion engine under development, which is capable of providing both high diesel-like efficiency and very low NO_x and particulate emissions. However, several technical issues must be resolved before the HCCI engine is ready for widespread application. One issue is that its operating range is limited by an excessive pressure rise rate which is caused by the excessive heat release from its selfaccelerated combustion reaction and the resulting engine knock in high-load conditions. The purpose of this study was to evaluate the potential of thermal and fuel stratification for reducing the pressure rise rate in HCCI engines. The NO_x and CO concentrations in the exhaust gas were also evaluated to confirm combustion completeness and NO_x emissions. The computational work was conducted using a multi-zone code with detailed chemical kinetics, including the effects of thermal and fuel stratification on the onset of ignition and the rate of combustion. The engine was fueled with dimethyl ether (DME) which has a unique two-stage heat release, and methane which has a one-stage heat release.     

Heat exchanger/catalytic system for reducing the exhaust emissions from diesel engines

A system has been researched over the past 3 years for reducing the exhaust pollutants from diesel engines for light commercial vehicles. The system researched achieves Euro 6 standards for reduction of polluting gases (CO, HC, PM, NO). It consists of 4 main sections: 1. A heater and heat exchanger (HE); 2. A CO/HC oxidising catalyst (D°C); 3. Pt catalyst on a diesel particulate filter (DPF); 4. A NO reducing reaction (SCR) within the DPF. The system operates as follows. The exhaust gas contains oxidising gases, namely both O₂ and NO₂. The levels of CO and HC are oxidised by O₂ to CO₂ for temperatures above 200°C. Carbon (PM) is oxidised to CO₂ by NO₂ but requires a temperature above 250°C. The operating exhaust temperature of 300°C is ideal for the removal of NO by using the Pt catalyst and the CO generated within the DPF. The heater is required to be able to raise the exhaust temperature at any time to 300°C in order to optimise the performance of the system, since diesel engine exhaust temperatures vary between 160°C (slow speeds) to 350°C (high speeds). Considerable heat is required (??3 kW) to maintain the exhaust gas for a 2l engine at 300°C for engine idle conditions. Therefore a heat exchanger is required to re-circulate the input heat and thereby reduce the maximum power consumption to a maximum of 500W over the engine full operating test cycle. This energy is supplied by the engine battery and alternator. Experimental results have been obtained for the exhaust from a Kubota diesel engine and the reductions in exhaust emissions of 83% (CO/ HC), 58% (NOx) and 99% (PM) were obtained. The PM was continuously cleaned so that there was no build up of back pressure.     

Gain scheduled linear quadratic tracking system tuned optimally by covariance matrix adaption evolutionary strategy for automotive engine coldstart control

In this paper, a gain scheduled linear quadratic tracking system (LQTS) tuned optimally by an evolutionary strategy (ES) is devised to reduce the total tailpipe hydrocarbon (HC) emissions of an automotive engine over the coldstart period. As the engine’s behavior during coldstart operations is nonlinear, the system dynamics is clearly analyzed and represented by a number of separate linear models generated based on a coldstart model verified by experimental data. An independent LQTS is then implemented for each of these linear models. In this way, several control laws are created, and the corresponding gains are calculated for each of the independent control laws. ES is then used to tune the adjustable parameters of LQTSs to calculate the control inputs, namely air/fuel ratio (AFR) and spark timing (Δ), such that the resulting exhaust gas temperature (T _exh) and engine-out HC emissions (HC _raw) be close to a set of optimum profiles. This enables the controller reduce the cumulative tailpipe hydrocarbon emissions (HC _cum) to the highest possible extent. To demonstrate the acceptable performance of the proposed controller, an optimal controller derived from the Pontryagin’s minimum principle (PMP) is also taken into account. Based on the results of the conducted comparative study, it is shown that the proposed control technique has a very good performance, and also, can be easily used for real-time applications, as it consumes a remarkably trivial computational time for calculating the controlling commands.     

Experimental study on the characteristics of nano-particle emissions from a heavy-duty diesel engine using a urea-SCR system

Particulate matter in diesel engine exhaust, particularly nano-particles, can cause serious human health problems including diseases such as lung cancer. Because diesel nano-particle issues are of global concern, regulations on particulate matter emissions specify that not only the weight of particulate matter emitted but also the concentration of nanoparticles must be controlled. This study aimed to determine the effects on nano-particle and PM emissions from a diesel engine when applying a urea-SCR system for NO_x reduction. We found that PM weight increases by approximately 90% when urea is injected in ND-13 mode over the emission without urea injection. Additionally, PM weight increases as the NH₃/NO_x mole ratio is increased at 250 °C. In SEM scans of the collected PM, spherical particles were observed during urea injection, with sizes of approximately 200 nm to 1 μm. This study was designed to determine the conditions under which nano-particles and PM are formed in a urea-SCR system and to relate these conditions to particle size and shape via a quantitative analysis in ND-13 mode.     

Majorization of working parameters for non-thermal plasma reactor and impact on no oxidation of diesel engine

The main target of this work is to realize the function of pre-oxidizing NO from diesel engine’s exhaust by using self-designed double-dielectric Non-thermal Plasma (NTP) reactor. The majorized discharge frequency and discharge peak to peak voltage (V_p-p) range for NTP reactor were obtained through air discharge test. The diesel engine test bench was established to observe the effect of NTP on the volume fraction of NO. The results showed that there were more active substances and fewer by-products in NTP reactor when discharge frequency was 9 kHz and V_p-p was between 9 kV and 23 kV; Exhaust flows had insignificant effect on the performance of NTP pre-oxidizing NO; The ability of NTP to pre-oxidize NO gradually weakened with the increase of engine load, and when the engine load were 0 % and 25 %, the ratio of NO/NO₂ could reach 1. In such working conditions, SCR system could improve the conversion rate of the NO_x at low-temperature zone through quick reaction combined with NTP.     

Reduction of emissions with propane addition to a diesel engine

Recent studies on dual-fuel combustion in compression-ignition (CI) engines, also known as diesel engines, fall into two categories. In the first category are studies focused on the addition of small amounts of gaseous fuel to CI engines. In these studies, gaseous fuel is regarded as a secondary fuel and diesel fuel is regarded as the main fuel for combustion. The objectives of these studies typically involve reducing particulate matter (PM) emissions by using gaseous fuel as a partial substitution for diesel fuel. However, the addition of gaseous fuel raises the combustion temperature, which increases emissions of nitrogen oxides (NO_x). In the second category are studies focused on reactivity-controlled compression-ignition (RCCI) combustion. RCCI combustion can be implemented by early diesel injection with a large amount of low-reactivity fuel such as gasoline or gaseous fuel. Although RCCI combustion promises lower NO_x and PM emissions and higher thermal efficiency than conventional diesel combustion, it requires a higher intake pressure (usually more than 1.7 bars) to maintain a lean fuel mixture. Therefore, in this study, practical applications of dual-fuel combustion with a low air-fuel ratio (AFR), which implies a low intake pressure, were systemically evaluated using propane in a diesel engine. The characteristics of dualfuel combustion for high and low AFRs were first evaluated. The proportion of propane used for four different operating conditions was then increased to decrease emissions and to identify the optimal condition for dual-fuel combustion. Although the four operating conditions differ, the AFR was maintained at 20 (? approximately equal to 0.72) and the 50% mass fraction burned (MFB 50) was also fixed. The results show that dual-fuel combustion can reduce NO_x and PM emissions in comparison to conventional diesel combustion.     

Comparison of HC species from diesel combustion modes and characterization of a heat-up doc formulation

This study summarizes engine speed and load effects on HC species emissions from premixed charge compression ignition (PCI) and conventional diesel combustion, and it evaluates diesel oxidation catalyst (DOC) formulations on a gas flow reactor for the purpose of diesel particulate filter regeneration or lean NO_x trap desulfation. HC emissions are sampled simultaneously by a Tedlar bag for light HC species and by a Tenax TA™ adsorption trap for semi-volatile HC species, and they are analyzed by gas chromatography with a flame ionization detector. The bulk temperature and residence time during combustion are key parameters that are important for understanding the effects of speed and load on engine-out HC emissions. The degree of post-flame oxidation is higher in PCI than in conventional combustion, and it is increased for PCI with a higher speed and load, as indicated by a lower fuel alkanes/THC ratio, a higher alkenes/fuel alkanes ratio, and a higher methane/THC ratio. Ethene and n-undecane are two representative HC species, and they are used as a surrogate mixture in the gas flow reactor to simulate PCI and conventional combustion with in-cylinder post fuel injection. Among the three DOC formulations tested, the catalyst with constituent precious metals of platinum and palladium (PtPd) showed the best light-off performance, followed by PtPd with an addition of cerium dioxide (PtPd+CeO₂), and platinum (Pt), regardless of exhaust compositions. Conventional combustion exhaust composition shows a lower light-off temperature than that of PCI, regardless of catalyst formulation.     

分子筛型SCR对车用柴油机排放改善的试验研究

商用车柴油机多采用DOC+SCR的后处理系统来满足国Ⅳ、国Ⅴ排放标准的要求,而不同类型SCR的催化特性对最终污染物排放影响也不同。试验获取了一支铜基分子筛型SCR,基于1台2.8L柴油机和一支钒基SCR,运行了车用柴油机稳态循环(ESC)和瞬态排放循环(ETC),研究并分析了其对柴油机污染物的减排特性。结果表明,相较于钒基SCR,运行ETC循环时分子筛型SCR对发动机NOx和PM排放的减排效率分别提升19%和33%;分子筛型SCR对NOx的低温转化效率更高,且由于对排气流量不敏感,在高空速工况下其转化效率显著高于钒基SCR;分子筛型SCR对颗粒物个数的减排效率弱于钒基SCR,达7%以上,容易将大质量颗粒物分解为小质量颗粒物;两种SCR均对CO和HC具有一定的减排效果,减排率可达20%左右。     

Development of new 4-valve/cylinder small DI diesel engine

Nitrous oxide (NO_x) and the particulate matter contained in the exhaust given off by diesel powered vehicles have been identified as elements responsible for polluting the atmosphere. As such, these emissions have been the targets of increasingly strict emission control regulations. Plans are underway to introduce regulations that are even stricter some time early in the next century. The advanced thermal efficiency offered by diesel engines is a feature clearly desired for its potential contribution toward energy conservation and the reduction of global warming. Research and development on the highly thermal-efficient direct-injection diesel engine are progressing at a rapid pace in Europe where introduction of a carbon dioxide tax is under consideration.     

Evaluation and visualization of stratified ultra-lean combustion characteristics in a spray-guided type gasoline direct-injection engine

To comply with reinforced emission regulations for harmful exhaust gases, including carbon dioxide (CO₂) emitted as a greenhouse gas, improved technologies for reducing CO₂ and fuel consumption are being developed. Stable lean combustion, which has the advantage of improved fuel economy and reduced emission levels, can be achieved using a sprayguided-type direct-injection (DI) combustion system. The system comprises a centrally mounted injector and closely positioned spark plugs, which ensure the combustion reliability of a stratified mixture under ultra-lean conditions. The aim of this study is to investigate the combustion and emission characteristics of a lean-burn gasoline DI engine. At an excess air ratio of 4.0, approximately 23% improvement in fuel economy was achieved through optimal event timing, which was delayed for injection and advanced for ignition, compared to that under stoichiometric conditions, while NO_x and HC emissions increased. The combustion characteristics of a stratified mixture in a spray-guided-type DI system were similar to those in DI diesel engines, resulting in smoke generation and difficulty in three-way catalystutilization. Although a different operating strategy might decrease fuel consumption, it will not be helpful in reducing NO_x and smoke emissions; therefore, alternatives should be pursued to achieve compliance with emission regulations.