Aftertreatment Basics

Module 1

Agenda
1. Emission Overview
2. PM Reduction Technology
a) Diesel Oxidation Catalysts
b) Diesel Particulate Filters

3. NOx Reduction Technology

a) Selective Catalytic Reduction
b) Ammonia Slip Catalyst / AMOX

What drives the need for aftertreatment?

Regulated Diesel Emissions
Particulate Matter (PM)
Made up of Carbon Soot (C), Ash, Organic material
& sulphates
Worsens preexisting respiratory conditions such as
asthma and allergies

Hydrocarbons (HC)
Some have irritating odor, toxic and/or carcinogenic
Contribute to photochemical smog

Carbon Monoxide (CO)

Colorless, odorless and tasteless gas
Toxic in high concentrations

What drives the need for aftertreatment?

Greenhouse Gas (GHG)

Oxides of Nitrogen (NOx)

Made up of colorless nitric
oxide (NO) and reddish-brown,
very toxic and reactive nitrogen
dioxide (NO2)

Comprised of Carbon Dioxide

(CO2), Methane (CH4), Nitrous
Oxide (N2O), Fluorinated
Gases

Contribute to photochemical
smog and acid rain

Gases that trap heat in the

atmosphere raising
temperatures
Smog

Original source: epa.gov

Global Emission Regulations Expanding

Emissions Alignment
Off-Highway
On-Highway

EPA Tier 3 2005

EPA 2002

EPA Tier 4 Interim 2011

EPA 2007

EPA Tier 4 Final

2014

EPA 2010

Cummins Confidential

PM REDUCTION TECHNOLOGY

Diesel Oxidation Catalyst (DOC)

What is a DOC?

PM reduction product

Flow-through substrate

Made of cordierite or metal

No maintenance necessary

Substrate is coated with precious

metals

Platinum (Pt) and Palladium (Pd) as

catalyst
Enables conversion at a lower
temperature
In general, increasing Pt increases
conversion efficiency

Compatible with ULSD and 15 PPM

& 500 PPM sulfur diesel fuels

Light seen through

substrate paths

What does a DOC do?

Provides >90% reduction of CO, HC
Provides 25 50% reduction of PM

Removes Soluble Organic Fraction of PM particle

Promotes passive regen of DPF by creating NO2
Enhances combustion of diesel fuel in the exhaust stream to
generate heat for active regen of DPF
Enhances performance of SCR catalyst with creation of NO2

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DOC Substrate Material Comparison

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Characteristic

Cordierite

Metallic

Thermal Conductivity

Lower

Higher

Strength

Lower

Higher

Wall Thickness

4 to 5 mil (100-125 m)

30-50 m

Cost

Lower

Higher

Weight

Lower

Higher

Diesel Particulate Filter (DPF)

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What is a DPF?
PM reduction product
Wall flow filter
Every other channel is closed, forcing exhaust gas
through walls of filter
Made of cordierite or silicon carbide

Substrate is typically coated with

precious metals
Platinum (Pt) as a catalyst
Palladium (Pd) as catalyst

Requires ULSD at 15 PPM

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What does a DPF do?

Porous ceramic walls capture
soot and ash from exhaust
Soot is removed by periodic
regeneration (active / passive)
Ash accumulates, requiring DPF
removal and maintenance

Provides >90% PM reduction

Traps Carbon Soot, Ash and
Soluble Organic Fraction of
particle
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Clean
Exhaust
PM /
Ash

What is Ash?
Incombustible material that can only be removed by cleaning
Low density ash plug near outlet of filter
High density ash layer on wall thickness increasing from inlet to

Flow

Source: Corning
15

Outlet

Inlet

outlet

What is Regeneration?
Process of removing accumulated soot by conversion into
harmless CO2
Two types of regeneration:
Active regeneration
Requires temperature >500C
Temp achieved by engine management, dosing diesel fuel into exhaust
stream or alternative heat source, eg. burner

Passive regeneration, enabled by DOC

Requires 18:1 NO2:Soot minimum and Temperature >250C
Conditions occur naturally during normal engine operation

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Active Regen

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Passive Regen

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DPF Substrate Material Comparison

Characteristic

Cordierite

Silicon Carbide

Heat Capacity

Lower

Higher

Thermal Conductivity

Lower

Higher

Heat up / Cool Down Rate

Slower

Faster

Moderate

Higher

Flow Restriction

Lower

Higher

Soot Mass Limit

Lower

Higher

Moderate

Higher if asymmetric cell

structure used

Thermal Durability

Ash Capacity

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Cost/liter

Lower

Size (for same application

and duty cycle)

Larger

05/09/16

More
Robust

Size &
Cost
15 30% smaller Benefits
Higher

NOX REDUCTION TECHNOLOGY

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Selective Catalytic Reduction (SCR)

Fundamentals

21

What is SCR?
Chemical process in which toxic NOx is converted to
harmless N2 and H2O
Reductant: Ammonia (NH3)
Catalyst: Copper Zeolite (CuZ) or Iron Zeolite (FeZ) or Vanadia

Flow through substrate, no cleaning necessary

Requires ULSD (<50PPM)
Ammonia is generated by the use of liquid urea (known as
Diesel Exhaust Fluid (DEF) or AdBlue)
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How does SCR work?

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What is Urea or Diesel Exhaust Fluid?

Non-toxic solution of 32.5% Urea and 67.5% Water

Used to deliver Ammonia (toxic) to SCR catalyst

Known as AdBlue in Europe

Concentration ratio with lowest freezing point (-11C)

Eutectic solution concentration does not change with

freezing (partial freezing / thawing of vehicle tank)

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SCR - Catalyst Material Comparison

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Characteristic

Vanadia

Fe-Zeolite

Cu-Zeolite

Low Temperature
NOx Conversion

Lower

Lower

Higher

Click here for more information

High Temperature
NOx Conversion

Lower

Higher

Moderate

NH3 Storage

Lower

Higher

Higher

Cost

Lower

Moderate

Higher

Where Used?

SCR-only
systems Euro IV / V,
Tier 4F,
Emerging
Markets

High exhaust
temperatures
expected typically with
a DPF

Both cool and hot

exhaust
temperatures
expected EPA2010/3, Tier 4F,
Euro VI

What is a Washcoated SCR Substrate?

Cordierite substrate is coated with a thin layer called
washcoat
Washcoat is made up of catalyst
High mechanical strength
High melting point (>1300C)
Catalyst

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What is Extruded SCR?

Substrate and catalyst are same material, i.e. no
cordierite base
Manufactured via the process of extrusion
Contains more catalyst per liter of substrate
Increased SCR reaction = Increased NOx conversion
Enables better fuel economy

Increased deNOx efficiency enables up to 50% length

reduction of SCR substrate
Catalyst

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SCR - Substrate Comparison

Washcoated

Extruded

NOx Conv. per liter

Lower

Higher

Substrate length
for given DeNOx %

X inches

X/2 inches

Heat up / Cool
Down Rate

Slower

Faster

Distribution of
Catalyst

Non-uniform

Uniform

Lower

Higher

NH3 Storage

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What is an Ammonia Slip Catalyst (ASC)?

Captures NH3 that slips past the SCR catalyst during sudden
SCR catalyst temperature increases
Active regen of DPF
Increased engine load

Also known as Ammonia Oxidation (AMOX) catalyst

Flow through substrate coated with oxidation catalyst, Pt

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What does an ASC do?

Converts NH3 gas into harmless N2
Reduces tailpipe emission of NH3 gas to <25 PPM
to protect against:
25-50 ppm - Detectable odor; unlikely to experience adverse
effects
50-100 ppm - Mild eye, nose, and throat irritation; may develop
tolerance in 1-2 weeks with no adverse effects thereafter
140 ppm - Moderate eye irritation; no long-term secondary
effects.

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Upcoming Modules
You have completed the first training module,
Aftertreatment Basics.
Future Modules:
Module 2: Aftertreatment Components & System Features
Module 3: System Integration - Tradeoffs & Benefits of
Different Technologies
Module 4: On-highway versus Off-highway

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CES Account Management Contacts

Off-highway OEM Business:
Chris Calas
Dave Grimm

On-highway N.A. OEM

Business:
John B Carroll

Paul Whittle

Carlos Sustaita

Sean Li

Jane Beaman

Virendra Mohite

Mario Sanchez
Miranda Cross

Cummins Distributor
Business:
Terry Raupp
Kevin Benson
Pat Campbell
Wendy Mayhew
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THANK YOU

33

APPENDIX

34

Cummins Confidential

SCR Catalyst Temperature Response

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35

05/09/16

Cummins Confidential

Why is NH3 Storage Important?

Enables some NOx reduction without urea dosing
Stored NH3 reacts with NOx better than injected NH3
High NH3 storage at low temperature
Stored NH3 will slip with sudden increase in SCR
substrate temperature
Active Regeneration
Increased Load

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Cummins Confidential

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