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Non-road Tier 4 Final emissions standards offer opportunities for engines to be certified with DOC + SCR aftertreatment systems (ATS), where particulate matter (PM) emissions will be controlled by engine measures. These non-filter systems will not experience high thermal conditions common for filter regeneration and, therefore, will not have the secondary benefit of thermal events removing sulfur from the DOC and SCR aftertreatment. An experimental program was conducted on DOC + SCR systems in which the DOC was selected for the anticipated NO2 and sulfur management requirements of a fixed volume of 3 SCR types (vanadia, copper and iron). Each system was optimized to NOx conversion levels of 90%+ on NRTC cycles then exposed to accelerated sulfur poisoning and various cycles of increasing temperature after each poisoning to observe the performance recovery of the system. Specific sulfur management strategies are defined, depending on technology.

Significant reduction in Nitrogen Oxide (NOx) emissions will be required to meet LEV III/Tier III Emissions Standards for Light Duty Diesel (LDD) passenger vehicles. As such, Original Equipment Manufacturers (OEMs) are exploring all possible aftertreatment options to find the best balance between performance, durability and cost. The primary technology adopted by OEMs in North America to achieve low NOx levels is Selective Catalytic Reduction (SCR). The critical parameters needed for SCR to work properly are: an appropriate reductant such as ammonia (NH3) provided as Diesel Exhaust Fluid (DEF), which is an aqueous urea solution 32.5% concentration in weight with water (CO(NH2)2 + H2O), optimum operating temperatures, and optimum nitrogen dioxide (NO2) to NOx ratios (NO2/NOx). The NO2/NOx ratio is most influenced by Precious Group Metals (PGM) containing catalysts upstream of the SCR catalyst.

The nonroad Final Tier 4 US EPA emission standards require 88% reduction in NOx emission from the Interim Tier 4 standards. It is necessary to utilize aftertreatment technologies to achieve the required NOx reduction. The development of a fuel reformer, lean NOx trap (LNT) and optional selective catalytic reactor (SCR) on a John Deere 4045 nonroad engine is described in this paper. The paper discusses aftertreatment system performance, catalyst formulations and system controls of a fuel vaporizer, fuel reformer, LNT and SCR system designed to meet the nonroad Final Tier 4 emission standards. The 4045 John Deere engine was calibrated and integrated with the aftertreatment system. The system performance was characterized in an engine dynamometer performance test cell, durability test cell and on a vehicle. The catalyst performance was evaluated using aged catalysts and a detailed description of the LNT, DPF and SCR catalysts is provided.

The implementation and development efforts of lean NOx trap catalysts for heavy-duty applications decreased a number of years ago. Most heavy-duty engine manufacturers realized that the system complexity as well as the durability of such a system does not allow large volume production without significant risk. The current consensus of the heavy-duty community is that for 2010 the SCR system will be the prime path to meet the 0.2 g/bHPhr NOx emission standard, although this is subject to adequate infrastructure investment and progress. As a low volume manufacturer, in order to comply with the 2007 heavy-duty phase-in emission standards, General Engine Products (a subsidiary of AM General LLC) integrated a NOx adsorber system on the Optimizer 6500 engine. This engine features split combustion chamber design, rotary fuel injection pump and operates with EGR.

In order to allow continued production of the AM General Optimizer 6500 during MY 2007 through 2010 this IDI engine (Indirect Injection - swirl chamber) requires sophisticated aftertreatment controls while maintaining its fuel economy and durability. The main purpose of the development program was to retain the relatively inexpensive and simple base engine with distributor pump and waste-gated turbocharger, while adding hardware and software components that allow achievement of the phase-in emission standards for 2007 through 2010. The aftertreatment system consists of Diesel Oxidation Catalyst (DOC), NOx Adsorber Catalyst (or DeNOx Trap - DNT) and Diesel Particle Filter (DPF). In addition to the base hardware, an intake air throttle valve and an in-exhaust fuel injector were installed. The presented work will document the development process for a 2004 certified 6.5 l IDI heavy-duty diesel engine to comply with the 2007 heavy-duty emission standards.