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A promising SCR-only solution is presented to meet post-2010 NOx emission targets for heavy duty applications. The proposed concept is based on an engine from a EURO IV SCR application, which is considered optimal with respect to fuel economy and costs. The addition of advanced SCR after treatment comprising a standard and a close-coupled SCR catalyst offers a feasible emission solution, especially suited for EURO VI. In this paper, results of a simulation study are presented. This study concentrates on optimizing SCR deNOx performance. Simulation results of cold start FTP and WHTC test cycles are presented to demonstrate the potential of the close-coupled SCR concept. Comparison with measured engine out emissions of an EGR engine shows that a close-coupled SCR catalyst potentially has NOx reduction performance as good as EGR. Practical issues regarding the use of an SCR catalyst in close-coupled position will be addressed, as well as engine and exhaust layout.

An experimental study was performed to develop a more fundamental understanding of the effects of secondary air injection (SAI) on exhaust gas emissions and catalyst light-off characteristics during cold start of a modern SI engine. The effects of engine operating parameters and various secondary air injection strategies such as spark retardation, fuel enrichment, secondary air injection location and air flow rate were investigated to understand the mixing, heat loss, and thermal and catalytic oxidation processes associated with SAI. Time-resolved HC, CO and CO₂ concentrations were tracked from the cylinder exit to the catalytic converter outlet and converted to time-resolved mass emissions by applying an instantaneous exhaust mass flow rate model. A phenomenological model of exhaust heat transfer combined with the gas composition analysis was also developed to define the thermal and chemical energy state of the exhaust gas with SAI.

Engine-out HC emissions from a PFI spark ignition engine were measured using a gas chromatograph and a flame ionization detector (FID). Two port fuel injectors were used respectively for ethanol and gasoline so that the delivered fuel was comprised of 0, 25, 50, 75 and 100% (by volume) of ethanol. Tests were run at 1.5, 3.8 and 7.5 bar NIMEP and two speeds (1500 and 2500 rpm). The main species identified with pure gasoline were partial reaction products (e.g. methane and ethyne) and aromatics, whereas with ethanol/gasoline mixtures, substantial amounts of ethanol and acetaldehyde were detected. Indeed, using pure ethanol, 74% of total HC moles were oxygenates. In addition, the molar ratio of ethanol to acetaldehyde was determined to be 5.5 to 1. The amount (as mole fraction of total HC moles) of exhaust aromatics decreased linearly with increasing ethanol in the fuel, while oxygenate species correspondingly increased.

The high load limit of a boosted homogeneous-charge-compression-ignition (HCCI) engine operating on negative-valve-overlap (NVO) was assessed. When operating under stoichiometric condition with no external dilution, the load, as measured by the net indicated mean effective pressure (NIMEP), increased with increase in manifold absolute pressure (MAP), and with decrease in trapped amount of residual gas. The maximum pressure rise rate (MPRR), however, also increased correspondingly. When the MAP and the amount of residual gas were adjusted so that the engine operating point could be held at a constant MPRR value, the NIMEP increased with the simultaneous decrease in MAP and residual until the misfire limit was reached. Therefore if a MPRR ceiling is imposed, the high load limit of an HCCI engine is at the intersection of the constraining MPRR line and the misfire line.

Ash, primarily derived from diesel engine lubricants, accumulates in diesel particulate filters directly affecting the filter's pressure drop sensitivity to soot accumulation, thus impacting regeneration frequency and fuel economy. After approximately 33,000 miles of equivalent on-road aging, ash comprises more than half of the material accumulated in a typical cordierite filter. Ash accumulation reduces the effective filtration area, resulting in higher local soot loads toward the front of the filter. At a typical ash cleaning interval of 150,000 miles, ash more than doubles the filter's pressure drop sensitivity to soot, in addition to raising the pressure drop level itself. In order to evaluate the effects of lubricant-derived ash on DPF pressure drop performance, a novel accelerated ash loading system was employed to generate the ash and load the DPFs under carefully-controlled exhaust conditions.

Mechanisms of NH₃ generation using LNT-like catalysts have been studied in a bench reactor over a wide range of temperatures, flow rates, reformer catalyst types and synthetic exhaust-gas compositions. The experiments showed that the on board production of sufficient quantities of ammonia on board for SCR operation appeared feasible, and the results identified the range of conditions for the efficient generation of ammonia. In addition, the effects of reformer catalysts using the water-gas-shift reaction as an in-situ source of the required hydrogen for the reactions are also illustrated. Computations of the NH₃ and NOx kinetics have also been carried out and are presented. Design and impregnation of the SCR catalyst in proximity to the ammonia source is the next logical step. A heated synthetic-exhaust gas flow bench was used for the experiments under carefully controlled simulated exhaust compositions.

The effects of charge motion and laminar flame speeds on combustion and exhaust temperature have been studied by using an air jet in the intake flow to produce an adjustable swirl or tumble motion, and by replacing the nitrogen in the intake air by argon or CO₂, thereby increasing or decreasing the laminar flame speed. The objective is to examine the "Late Robust Combustion" concept: whether there are opportunities for producing a high exhaust temperature using retarded combustion to facilitate catalyst warm-up, while at the same time, keeping an acceptable cycle-to-cycle torque variation as measured by the coefficient of variation (COV) of the net indicated mean effective pressure (NIMEP). The operating condition of interest is at the fast idle period of a cold start with engine speed at 1400 RPM and NIMEP at 2.6 bar. A fast burn could be produced by appropriate charge motion. The combustion phasing is primarily a function of the spark timing.

Ammonia oxidation (AMOX) catalysts are critical parts of most diesel aftertreatment systems around the world. These catalysts are positioned downstream of selective catalytic reduction (SCR) catalysts and remove unreacted NH3 that passes through the SCR catalyst. In many configurations, the AMOX catalyst is situated after a diesel oxidation catalyst and catalyzed diesel particulate filter that oxidize CO and hydrocarbons. However, in Euro V and proposed Tier 4 final aftertreatment architectures there is no upstream oxidation catalyst. In this study, the impact of hydrocarbons is evaluated on two different types of AMOX catalysts. One has dual washcoat layers-SCR washcoat on top of PGM washcoat-and the other has only a PGM washcoat layer. Results are presented for NH3 and hydrocarbon oxidation, NOx and N2O selectivity, and hydrocarbon storage. The AMOX findings are rationalized in terms of their impact on the individual oxidation and SCR functions.

In this study, the formation and decomposition of ammonium nitrate (AN) on a state-of-the-art extruded vanadium-based SCR catalyst (V-SCR) under simulated exhaust conditions has been evaluated. Results show that AN readily forms and accumulates at temperatures below 200°C when exposed to NH3 and NO2. The rate of AN accumulation increases with decreasing temperature. A new low temperature NH3 release peak (not present following NH3 storage conditions with NH3 only) becomes apparent after AN accumulation at 100 and 125°C. This new NH3 release, with a peak release temperature of approximately 180°C, is evaluated in detail to better determine its origin. BET surface area, and thermal gravimetric analysis/differential scanning calorimetry (TGA/DSC), and reactor-based experiments are all used to characterize AN formed on the V-SCR catalyst in comparison to pure AN.

Lean-burn natural gas (NG) engines are used world-wide for both stationary power generation and mobile applications ranging from passenger cars to Class 8 line-haul trucks. With the recent introduction of hydraulic fracturing gas extraction technology and increasing availability of natural gas, these engines are receiving more attention. However, the reduction of unburned hydrocarbon emissions from lean-burn NG and dual-fuel (diesel and natural gas) engines is particularly challenging due to the stability of the predominant short-chain alkane species released (e.g., methane, ethane, and propane). Supported Pd-based oxidation catalysts are generally considered the most active materials for the complete oxidation of low molecular weight alkanes at temperatures typical of lean-burn NG exhaust. However, these catalysts rapidly degrade under realistic exhaust conditions with high water vapor concentrations and traces of sulfur.

Heavy-duty diesel engines are used in different application areas, like long-haul, city distribution, dump truck and building and construction industry. For these wide variety of areas, the engine performance needs to comply with the real-world legislation limits and should simultaneously have a low fuel consumption and good drivability. Meeting these requirements takes substantial development and calibration effort, where an optimal fuel consumption for each application is not always met in practice. TNO's Integrated Emission Management (IEM) strategy, is able to deal with these variations in operating conditions, while meeting legislation limits and obtaining on-line cost optimization. Based on the actual state of the engine and aftertreatment, optimal air-path setpoints are computed, which balances EGR and SCR usage.

One field-returned DPF loaded with a high amount of ash is examined using experimental and modeling approaches. The ash-related design factors are collected by coupling the inspection results from terahertz spectroscopy with a calibrated DPF model. The obtained ash packing density, ash layer permeability and ash distribution profile are then used in the simulation to assess the ash impact on DPF backpressure and regeneration behaviors. The following features have been observed during the simulation: 1 The ash packing density, ash layer permeability and ash distribution profile should be collected at the same time to ensure the accurate prediction of ash impact on DPF backpressure. Missing one ash property could mislead the measurement of the other two parameters and thus affects the DPF backpressure estimation. 2 The ash buildup would gradually increase the frequency for the backpressure-based active soot regeneration.

Cylinder pressure-based combustion control is widely introduced for passenger cars. Benefits include enhanced emission robustness to fuel quality variation, reduced fuel consumption due to more accurate (multi-pulse) fuel injection, and minimized after treatment size. In addition, it enables the introduction of advanced, high-efficient combustion concepts. The application in truck engines is foreseen, but challenges need to be overcome related to durability, increased system costs, and impact on the cylinder head. In this paper, a new single cylinder pressure sensor concept for heavy-duty Diesel engines is presented. Compared to previous studies, this work focuses on heavy-duty Diesel powertrains, which are characterized by a relatively flexible crank shaft in contrast to the existing passenger car applications.

The first 3 cycles in the cold crank-start process at 20°C are studied in a GDI engine. The focus is on the dependence of the HC and PM/PN emissions of each cycle on the injection strategy and combustion phasing of the current and previous cycles. The PM/PN emissions per cycle decrease by more than an order of magnitude as the crank-start progresses from the 1st to the 3rd cycle, while the HC emissions stay relatively constant. The wall heat transfer, as controlled by the combustion phasing, during the previous cycles has a more significant influence on the mixture formation process for the current cycle than the amount of residual fuel. The results show that the rise in HC emissions caused by the injection spray interacting with the intake valves and piston crown is reduced as the cranking process progresses. Combustion phasing retard significantly reduces the PM emission. The HC emissions, however, are relatively not sensitive to combustion phasing in the range of interest.

This work examines the effect of valve timing during cold crank-start and cold fast-idle (1200 rpm, 2 bar NIMEP) on the emissions of hydrocarbons (HC) and particulate mass and number (PM/PN). Four different cam-phaser configurations are studied in detail: 1. Baseline stock valve timing. 2. Late intake opening/closing. 3. Early exhaust opening/closing. 4. Late intake phasing combined with early exhaust phasing. Delaying the intake valve opening improves the mixture formation process and results in more than 25% reduction of the HC and of the PM/PN emissions during cold crank-start. Early exhaust valve phasing results in a deterioration of the HC and PM/PN emissions performance during cold crank-start. Nevertheless, early exhaust valve phasing slightly improves the HC emissions and substantially reduces the particulate emissions at cold fast-idle.

The oxidation of short-chain alkanes, such as methane, ethane, and propane, from the exhaust of lean-burn natural gas and lean-burn dual-fuel (natural gas and diesel) engines poses a unique challenge to the exhaust aftertreatment community. Emissions of these species are currently regulated by the US Environmental Protection Agency (EPA) as either methane (Greenhouse Gas Emissions Standards) or non-methane hydrocarbon (NMHC). However, the complete catalytic oxidation of short-chain alkanes is challenging due to their thermodynamic stability. The present study focuses on the oxidation of short-chain alkanes by vanadium-based and Cu/zeolite selective catalytic reduction (SCR) catalysts, generally utilized to control NOx emissions from lean-burn engines. Results reveal that these catalysts are active for short-chain alkane oxidation, albeit, at conversions lower than those generally reported in the literature for Pd-based catalysts, typically used for short-chain alkane conversion.

The increasing use of gasoline direct injection (GDI) engines coupled with the implementation of new particulate matter (PM) and particle number (PN) emissions regulations requires new emissions control strategies. Gasoline particulate filters (GPFs) present one approach to reduce particle emissions. Although primarily composed of combustible material which may be removed through oxidation, particle also contains incombustible components or ash. Over the service life of the filter the accumulation of ash causes an increase in exhaust backpressure, and limits the useful life of the GPF. This study utilized an accelerated aging system to generate elevated ash levels by injecting lubricant oil with the gasoline fuel into a burner system. GPFs were aged to a series of levels representing filter life up to 150,000 miles (240,000 km). The impact of ash on the filter pressure drop and on its sensitivity to soot accumulation was investigated at specific ash levels.

Heavy-duty diesel engines are used in a wide range of applications. For varying operating environments, the engine and aftertreatment system must comply with the real-world emission legislation limits. Simultaneously, minimal fuel consumption and good drivability are crucial for economic competitiveness and usability. Meeting these requirements takes substantial development and calibration effort, and complying with regulations results in a trade-off between emissions and fuel consumption. TNO's Integrated Emission Management (IEM) strategy finds online, the cost-optimal point in this trade-off and is able to deal with variations in operating conditions, while complying with legislation limits. Based on the actual state of the engine and aftertreatment system, an optimal engine operating point is computed using a model-based optimal-control algorithm.

The gasoline direct injection (GDI) engine particulate emission sources are assessed under cold start conditions: the fast idle and speed/load combinations representative of the 1st acceleration in the US FTP. The focus is on the accumulation mode particle number (PN) emission. The sources are non-fuel, combustion of the premixed charge, and liquid fuel film. The non-fuel emissions are measured by operating the engine with premixed methane/air or hydrogen/air. Then the PN level is substantially lower than what is obtained with normal GDI operation; thus non-fuel contribution to PN is small. When operating with stoichiometric premixed gasoline/air, the PN level is comparable to the non-fuel level; thus premixed-stoichiometric mixture combustion does not significantly generate particulates. For fuel rich premixed gasoline/air, PN increases dramatically when lambda is less than 0.7 to 0.8.

To meet future particle mass and particle number standards, gasoline vehicles may require particle control, either by way of an exhaust gas filter and/or engine modifications. Soot levels for gasoline engines are much lower than diesel engines; however, non-combustible material (ash) will be collected that can potentially cause increased backpressure, reduced power, and lower fuel economy. The purpose of this work was to examine the ash loading of gasoline particle filters (GPFs) during rapid aging cycles and at real time low mileages, and compare the filter performances to both fresh and very high mileage filters. Current rapid aging cycles for gasoline exhaust systems are designed to degrade the three-way catalyst washcoat both hydrothermally and chemically to represent full useful life catalysts. The ash generated during rapid aging was low in quantity although similar in quality to real time ash. Filters were also examined after a low mileage break-in of approximately 3000 km.