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Technical Paper

Urea Deposit Predictions on a Practical Mid/Heavy Duty Vehicle After-Treatment System

Urea/SCR systems have been proven effective at reducing NOx over a wide range of operating conditions on mid/heavy duty diesel vehicles. However, design changes due to reduction in the size of modern compact Urea/SCR systems and lower exhaust temperature have increased the possibility of urea deposit formation. Urea deposits are formed when urea in films and droplets undergoes undesirable secondary reactions and generate by-products such as ammelide, biuret and cyanuric Acid (CYA). Ammelide and CYA are difficult to decompose which lead to the formation of solid deposits on the surface. This phenomenon degrades the performance of the after treatment system by decreasing overall mixing efficiency, lowering de-NOx efficiency and increasing pressure drop. Therefore, mitigating urea deposits is a primary design goal of modern diesel after-treatment systems.
Technical Paper

Adequacy of Reduced Order Models for Model-Based Control in a Urea-SCR Aftertreatment System

Model-based control strategies are important for meeting the dual objective of maximizing NOx reduction and minimizing NH3 slip in urea-SCR catalysts. To be implementable on the vehicle, the models should capture the essential behavior of the system, while not being computationally intensive. This paper discusses the adequacy of two different reduced order SCR catalyst models and compares their performance with a higher order model. The higher order model assumes that the catalyst has both diffusion and reaction kinetics, whereas the reduced order models contain only reaction kinetics. After describing each model, its parameter identification and model validation based on experiments on a Navistar I6 7.6L engine are presented. The adequacy of reduced order models is demonstrated by comparing the NO, NO2 and NH3 concentrations predicted by the models to their concentrations from the test data.
Technical Paper

A Modeling Study of SCR Reaction Kinetics from Reactor Experiments

In order to further characterize and optimize the performance of Selective Catalytic Reduction (SCR) aftertreatment systems used on heavy-duty diesel engines, an accurately calibrated high-fidelity multi-step global kinetic SCR model and a reduced order estimator for on-board diagnostic (OBD) and control are desirable. In this study, a Cu-zeolite SCR catalyst from a 2010 Cummins ISB engine was experimentally studied in a flow reactor using carefully designed protocols. A 2-site SCR model describing mass transfer and the SCR chemical reaction mechanisms is described in the paper. The model was calibrated to the reactor test data sets collected under temperatures from 200 to 425 °C and SCR space velocities of 60000, 90000, and 120000 hr-1. The model parameters were calibrated using an optimization code to minimize the error between measured and simulated NO, NO₂, N₂O, and NH₃ gas concentration time histories.
Technical Paper

Towards Quantitative Prediction of Urea Thermo-Hydrolysis and Deposits Formation in Exhaust Selective Catalytic Reduction (SCR) Systems

In order to assist in fast design cycle of Diesel engines selective catalytic reduction (SCR) exhaust systems, significant endeavour is currently afford to improve numerical simulation accuracy of urea thermo-hydrolysis. In this article, the achievements of a recently developed urea semi-detailed decomposition chemical scheme are assessed using several available databases from the literature. First, evaporation and thermo-hydrolysis of an urea-water solution (UWS) single-droplet, hanged on a thermocouple with 127 µm diameter, have been simulated at ambient temperature conditions ranging from 473K to 773K. It has been shown that the numerical results, in terms of rates of evaporation and gasification of urea, as well as droplet temperature history are very close to the experiments if the heat flux coming from the thermocouple wire is properly considered.
Journal Article

Model-Based Estimation and Control System Development in a Urea-SCR Aftertreatment System

In this paper, a model-based linear estimator and a non-linear control law for an Fe-zeolite urea-selective catalytic reduction (SCR) catalyst for heavy duty diesel engine applications is presented. The novel aspect of this work is that the relevant species, NO, NO2 and NH3 are estimated and controlled independently. The ability to target NH3 slip is important not only to minimize urea consumption, but also to reduce this unregulated emission. Being able to discriminate between NO and NO2 is important for two reasons. First, recent Fe-zeolite catalyst studies suggest that NOx reduction is highly favored by the NO 2 based reactions. Second, NO2 is more toxic than NO to both the environment and human health. The estimator and control law are based on a 4-state model of the urea-SCR plant. A linearized version of the model is used for state estimation while the full nonlinear model is used for control design.
Technical Paper

Accelerating Accurate Urea/SCR Film Temperature Simulations to Timescales Needed for Urea Deposit Predictions

In a NOx-reducing aftertreatment system utilizing urea water solution as the ammonia precursor, solid deposits are a side effect that reduce system performance by blocking flow passages, the injector, and causing maldistribution of ammonia at the catalyst. These solid urea decomposition by-products can take many minutes or hours to form. Since the urea-containing liquid film must lie in a specific temperature range for solid deposit formation, knowledge of the quasi-steady location, temperature, and composition of the film are an essential first step to deposit chemistry modeling. Of equal importance is developing a technique to accelerate CFD simulations such that minutes to hours of simulation time can be achieved in a reasonable wall-clock time. Determining the quasi-steady film locations and temperatures accurately with CFD is an area of active development.