Selective Catalytic Reduction for Diesel Engines
I.D. # C0913 Duration 2 Days

Stringent requirements of reduced NOx emission limits in the US have presented engineers and technical staff with numerous challenges. Several in-cylinder technical solutions have been developed for diesel engines to meet 2010 emission standards. These technologies have been optimized and have yielded impressive engine-out results in their ability to reduce emissions to extremely low levels. However, current and state-of-the-art in-cylinder solutions have fallen short of achieving the limits imposed on diesel emissions for 2010. To help meet emissions requirements, the catalyst industry has developed exhaust emission reduction technologies with impressive levels of performance. These technologies include hydrocarbon selective catalytic reduction (SCR), NOx absorber catalysts, and urea SCR.

This seminar will begin with an explanation of NOx formation in diesel engines and in-cylinder methods for reducing these emissions. The aftertreatment systems for NOx reduction will be explained and the advantages and disadvantages of these emission reduction technologies will be discussed.

In this two-day seminar, the primary focus is on urea SCR and its technology will be fully examined. The important chemical reactions and methods for improving SCR performance by encouraging desirable reactions and avoiding undesirable reactions are explained. Additionally, the components and control of a urea SCR system are detailed and the necessary sensors for its control are described. The SAE paper Laboratory Testing of Urea-SCR Formulations to Meet Tier 2 Bin 5 Emissions is included in the course materials.

Learning Objectives
By attending this seminar you will be able to:
  • Identify how NOx is formed in diesel engines
  • Identify the in-cylinder means for reducing NOx
  • Evaluate NOx aftertreatment technologies for diesel exhaust.
  • Describe the characteristic of selectivity in catalytic aftertreatment
  • Apply selectivity to urea SCR
  • Describe the features and components of a complete urea SCR system
  • Learn how to optimize the control of a urea SCR
  • Distinguish the differences between various catalytic SCR formulations
Who Should Attend
This seminar will benefit engineers and technical staff who are developing urea aftertreatment systems for diesel engines, including catalyst engineers who supply NOx aftertreatment systems to the diesel industry. Also benefitting will be suppliers of other NOx reducing technologies, such as EGR components and fuel injection systems, as well as on-highway and off-highway diesel engine technical staff.
Prerequisites
Attendees should have knowledge of how a diesel engine operates, including its 4-stroke operation. Additionally, attendees should have basic knowledge of the emission formation mechanism in internal combustion engines.
Seminar Content
DAY ONE
  • Introduction
    • On-Highway diesel emission regulations
    • Non-Road diesel emission regulations
    • Passenger car diesel emission regulations
    • Light-Truck diesel emission regulations
    • EURO IV Regulations
    • EURO V Regulations
    • NOx regulations in Japan
    • Drivers for controlling NOx
  • NOx Formation in Diesel Engines
    • Diffusion combustion model
    • The Zeldovich Mechanism
    • Pressure/Crank angle diagram
    • Heat release rate
  • In-Cylinder Means for NOx Reduction
    • Injection timing retard
    • Multiple injections/combustion cycle
    • Charge air cooling
    • Exhaust gas recirculation
  • NOx Aftertreatment Systems for Diesel Engines
    • Lean NOx Catalysts (LNC), DeNOx Catalysts, HC SCR
    • Lean NOx Trap (LNT), NOx Adsorber Catalyst (NAC also NAK), and NOx Storage Reduction (NSR)
    • Selective Catalytic Reduction (SCR) using urea reductant
    • Derivatives: Ammonium Carbamate, Combination LNT/SCR
  • Urea SCR Technology
    • Chemical reactions
    • Advantages/Disadvantages of the urea SCR system
    • Notable demonstration
DAY TWO
  • Components of the Urea SCR System
    • Catalyst -- Extruded substrate; Coated substrate
    • Catalyst Type -- Vanadia/Titania/Tungsten; Iron Zeolite; Copper Zeolite
    • Catalyst volume and space velocity considerations
    • Urea injection system -- Air-Assist systems; Airless systems
    • NOx sensors
    • Urea specifications and suppliers
  • System Calibration and Control Considerations
    • Effect of NH3/NO
    • Effect of NO2/NO
    • Ammonia slip
    • Exhaust architecture
  • Regulatory and Market Considerations
    • Urea Infrastructure -- Bottles; Dispensers; Co-Fueling
    • End-user and urea refills
    • The Japanese experience
    • The European experience
    • Plans for USA manufacturers
    • Commercial vehicle market projections
  • Urea Production and Distribution
    • The A.D. Little Report
    • The European experience
    • Passenger car diesel emission regulations
    • Light-Truck diesel emission regulations
  • SCR Options and Configurations for Future NOx Limits
    • On-Highway heavy-duty diesels
    • Non-Road diesel engines
    • Passenger car diesels
    • Light-Truck diesels
    • Cold weather operation
  • Closing and Evaluations
Instructor(s): Magdi Khair
Dr. Magdi Khair currently holds the position of Chief Technologist at Watlow, where he is assisting with the introduction of new technologies for the diesel engine industry. Dr. Khair recently retired from the position of Institute Engineer in the Engine, Emissions, and Vehicle Research Division at Southwest Research Institute. He is experienced in the areas of engine testing and exhaust emissions control. His prior experience was with AlliedSignal Automotive Catalyst Company with the development of catalytic aftertreatment for light-duty and heavy-duty diesel engines; Ford New Holland with primary responsibility for the development of the 6.6 and 7.8 liter midrange diesel engines to meet 1991 emissions standards; Bendix Diesel Engine Controls where he led the development of advanced electronically controlled diesel fuel injection systems and also established several cooperative engineering programs with European and North American engine manufacturers; and with Chrysler Corporation where he converted the slant six gasoline engine into an open chamber, pilot injected, and electronically controlled diesel engine, supervised a combustion kinetics project, and participated in the design and development of electronic controls for a passenger car turbine engine. Dr. Khair holds 20 U.S. patents in electronic fuel injection, turbocharging, exhaust gas recirculation, and aftertreatment systems. He has also authored and co-authored numerous SAE and ASME papers. Dr. Khair is the co-author of the Diesel Emissions and their Control a text book marketed by SAE. Dr. Khair received a B.S. in Automotive Engineering from Ain Shams University, an M.S. in Thermodynamics from the University of Birmingham, England, an M.B.A. from Michigan State University, and a PhD in Engineering Management from Warren National University.
Testimonial
"This is a great course for any professionals working in the field of diesel emissions controls. The instructor, Mr. Magdi Khair, was very knowledgeable, and it was clear he spent much time updating the materials to make sure we got the latest information."
Ben Sharpe
Researcher
International Council on Clean Transportation
Fees: $1305 SAE Members*: $1045 - $1175
* The appropriate SAE Member discount will be applied through the Registration process.  Discounts vary according to level of membership: Elite Member 20%; Premium Member 15%; Classic Member 10%
CEU 1.3