Fast Diesel Aftertreatment Heat-Up Using CDA and an Electrical Heater Between 1.2 and 5.0 kW

Zavala, Bryan; McCarthy, James E.; Matheaus, Andrew; Sharp, Christopher

doi:10.3389/fmech.2022.918003

Cited by 6 publications

(13 citation statements)

References 23 publications

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“…These were production thermocouples that protrude 2 inches from the wall. This is consistent with other EH works in the past (Matheaus et al, 2021;Zavala et al, 2022). The voltage and current measurements were recorded at the EH and used to calculate the electrical power supplied to it.…”

Section: Electric Heater (Eh) Powersupporting

confidence: 82%

“…Additional work was performed on this experiment. Zavala et al (Zavala et al, 2022) found that similar excellent NO x control can be achieved with a maximum of 2.4 kW heating power. Reducing the heater power aids in reducing CO 2 since the engine is required to generate the electricity used to power the EH.…”

Section: Introductionmentioning

confidence: 86%

“…The aftertreatment system used in this work was hydrothermally aged by utilizing an accelerated aging protocol on a burner based aging platform. The aging protocol targeted the aftertreatment system with the equivalent amount of thermal exposure for a Full Useful Life (FUL) system i.e., 435,000 miles or 9,800 h of service accumulation time similar to previous works (Matheaus et al, 2021;McCarthy et al, 2022;Zavala et al, 2022). The catalysts at the end of this aging cycle are commonly referred to as "Development Aged" end of life catalysts.…”

Section: Aftertreatmentmentioning

confidence: 99%

“…The EH was powered up by an external power supply in the same way as previous work (Zavala et al, 2022) and similar to representative burner work (McCarthy et al, 2022). The control algorithm was Proportional Integral Derivative (PID) control as a basis and varied the voltage output of the power supply from 0 to 48 V. In this work, the feedback control for the PID was based on the average LO-SCR temperature.…”

Section: Electric Heater (Eh) Powermentioning

confidence: 99%

“…Most of the ongoing research works to achieve 2027 NO x regulations are with the addition of Light-Off Selective Catalytic Reduction (LO-SCR) to the current production aftertreatment systems (Kasab et al, 2021b;Sharp et al, 2021;Zavala et al, 2022). The LO-SCR gains a benefit of reaching the light off temperature faster than the primary SCR by staying closer to the engine.…”

Section: Introductionmentioning

confidence: 99%

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Meeting future NOX emissions using an electric heater in an advanced aftertreatment system

Meruva

Matheaus²,

Sharp³

et al. 2022

Front. Mech. Eng.

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Engine and aftertreatment solutions are being identified to meet the upcoming ultra-low NOx regulations on heavy duty vehicles as published by the California Air Resources Board (CARB) and proposed by the United States Environmental Protection Agency (US EPA) for the year 2027 and beyond. These standards will require changes to current conventional aftertreatment systems for dealing with low exhaust temperature scenarios. One approach to meeting this challenge is to supply additional heat from the engine; however, this comes with a fuel penalty which is not attractive and encourages other options. Another method is to supply external generated heat directly to the aftertreatment system. The following work focuses on the later approach by maintaining the production engine calibration and coupling this with an Electric Heater (EH) upstream of a Light-Off Selective Catalytic Reduction (LO-SCR) followed by a primary aftertreatment system containing a downstream Selective Catalytic Reduction (SCR). External heat is supplied to the aftertreatment system using an EH to reduce the Tailpipe (TP) NOx emissions with minimal fuel penalty. Two configurations have been implemented, the first is a Close Coupled (CC) LO-SCR configuration and the second is an Underfloor (UF) LO-SCR configuration. The CC LO-SCR configuration shows the best outcome as it is closer to the engine, helping it achieve the required temperature with lower EH power while the UF LO-SCR configurations addresses the real-world packaging options for the LO-SCR. This work shows that a 7 kW EH upstream of a LO-SCR, in the absence of heated Diesel Exhaust Fluid (DEF), followed by a primary aftertreatment system met the 2027 NOx regulatory limit. It also shows that the sub-6-inch diameter EH with negligible pressure drop can be easily packaged into the future aftertreatment system.

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Section: Electric Heater (Eh) Powersupporting

confidence: 82%

Section: Introductionmentioning

confidence: 86%

Section: Aftertreatmentmentioning

confidence: 99%

Section: Electric Heater (Eh) Powermentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Meeting future NOX emissions using an electric heater in an advanced aftertreatment system

Meruva

Matheaus²,

Sharp³

et al. 2022

Front. Mech. Eng.

Self Cite

View full text Add to dashboard Cite

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Burner based thermal management approach utilizing in-exhaust burner technology with a CDA equipped engine

Zavala

McCarthy²,

Harris³

2023

Front. Mech. Eng.

Self Cite

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Commercial vehicles require fast aftertreatment heat-up to move the SCR catalyst into the most efficient temperature range to meet upcoming NOX regulations while minimizing CO2. One solution to this challenge is to add a fuel burner upstream of the con`ventional heavy-duty diesel aftertreatment system. The focus of this paper is to optimize a burner based thermal management approach. The objective included complying with CARB’s 2027 low NOX emissions standards for on-road heavy duty diesel engines. This was accomplished by pairing the burner system with cylinder de-activation on the engine and/or a light-off SCR sub-system. A system solution is demonstrated using a heavy-duty diesel engine with an aged aftertreatment system targeted for 2027 emission levels using various levels of controls. The baseline layer of controls includes cylinder deactivation to raise the exhaust temperature more than 100°C in combination with elevated idle speed to increase the mass flowrate through the aftertreatment system. The combination of operating the fuel burner, cylinder deactivation and elevated idle speed (during cold start) allows the aftertreatment system to heat up in a small fraction of the time demonstrated by today’s systems. Performance was quantified over the cold FTP, hot FTP, low load cycle (LLC) and the U.S. beverage cycle. The improvement in NOX reduction and the CO2 savings over these cycles are highlighted.

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Meeting future NOX emission regulations by adding an electrically heated mixer

et al. 2022

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New regulations by the California Air Resources Board (CARB) demand a stringent 0.02 g/hp-hr tailpipe NOx limit by the year 2027, requiring Selective Catalytic Reduction (SCR) catalysts to provide high NOx conversions even at low (below 200°C) exhaust temperatures. This work describes utilizing an Electrically Heated Mixer System (EHM system) upstream of a Light-Off Selective Catalytic Reduction (LO-SCR) catalyst followed by a conventional aftertreatment (AT) system containing DOC, DPF, and SCR, enabling high NOx conversions meeting CARB’s NOx emission target. The AT catalysts were hydrothermally aged to Full Useful Life. Conventional unheated Diesel Exhaust Fluid (DEF) was injected upstream of both the LO-SCR and primary downstream SCR. The EHM system allowed for DEF to be injected as low as 130°C upstream of the LO-SCR, whereas, in previous studies, unheated DEF was injected at 180°C or dosed at 130°C with heated DEF. The combination of unheated DEF, EHM system, LO-SCR, and downstream SCR enabled the needed increase in NOx efficiency in low exhaust temperatures, which was observed in drive cycles such as in cold-FTP, LLC, and World Harmonized Transient Cycle (WHTC). There were several-fold reductions in tailpipe NOx using this configuration compared to its baseline: 3.3-fold reduction in FTP, 22-fold in Low Load Cycle (LLC), 38-fold in Beverage Cycle, 8-fold in “Stay Hot” Cycle, and 10-fold in WHTC. Finally, it is shown that the EHM system can heat the exhaust gas, such as during a cold start, without needing additional heating hardware integrated into the system. These results were observed without performing changes in the engine base calibration.

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Fast Diesel Aftertreatment Heat-Up Using CDA and an Electrical Heater Between 1.2 and 5.0 kW

Cited by 6 publications

References 23 publications

Meeting future NOX emissions using an electric heater in an advanced aftertreatment system

Meeting future NOX emissions using an electric heater in an advanced aftertreatment system

Burner based thermal management approach utilizing in-exhaust burner technology with a CDA equipped engine

Meeting future NOX emission regulations by adding an electrically heated mixer

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