Development of Diesel Exhaust Aftertreatment System for Tier II Emissions

Abstract

Due to their excellent fuel efficiency, reliability, and durability, compression ignition direct injection (CIDI) engines have been used extensively to power almost all highway trucks, urban buses, off-road vehicles, marine carriers, and industrial equipment. CIDI engines burn 35 to 50% less fuel than gasoline engines of comparable size, and they emit far less greenhouse gases (Carbon Dioxides), which have been implicated in global warming. Although the emissions of CIDI engines have been reduced significantly over the last decade, there remains concern with the Nitrogen Oxides (NOX) and Particulate Matter (PM) emission levels. In 2000, the US EPA proposed very stringent emissions standards to be introduced in 2007 along with low sulfur (< 15ppm) diesel fuel. The California Air Resource Board (CARB) has also established the principle that future diesel fueled vehicles should meet the same emissions standards as gasoline fueled vehicles and the EPA followed suit with its Tier II emissions regulations. Meeting the Tier II standards requires NOX and PM emissions to be reduced dramatically. Achieving such low emissions while minimizing fuel economy penalty cannot be done through engine development and fuel reformulation alone, and requires application of NOX and PM aftertreatment control devices. A joint effort was made between Cummins Inc. and the Department of Energy to develop the generic aftertreatment subsystem technologies applicable for Light-Duty Vehicle (LDV) and Light-Duty Truck (LDT) engines. This paper provides an update on the progress of this joint development program. Three NOX reduction technologies including plasmaassisted catalytic NOX reduction (PACR), active lean NOX catalyst (LNC), and adsorber catalyst (AC) technology using intermittent rich conditions for NOX reduction were investigated in parallel in an attempt to select the best NOX control approach for light-duty aftertreatment subsystem integration and development. Investigations included system design and analysis, critical lab/engine experiments, and ranking then selection of NOX control technologies against reliability, up-front cost, fuel economy, service interval/serviceability, and size/weight. The results of the investigations indicate that the best NOX control approach for LDV and LDT applications is a NOX adsorber system. A greater than 83% NOX reduction efficiency is required to achieve 0.07g/mile NOX Tier II vehicle-out emissions. Both active lean NOX and PACR technology are currently not capable of achieving the high conversion efficiency required for Tier II, Bin 5 emissions standards. In this paper, the NOX technology assessment and selection is first reviewed and discussed. Development of the selected NOX technology (NOX adsorber) and PM control are then discussed in more detail. Discussion includes exhaust sulfur management, further adsorber formulation development, reductant screening, diesel particulate filter development & active regeneration, and preliminary test results on the selected integrated SOX trap, NOX adsorber, and diesel particulate filter system over an FTP-75 emissions cycle, and its impact on fuel economy. Finally, the direction of future work for continued advanced aftertreatment technology development is discussed. (SAE Paper SAE-2002-01-1867 © 2002 SAE International. This paper is published on this website with permission from SAE International. As a user of this website, you are permitted to view this paper on-line, download this pdf file and print one copy of this paper at no cost for your use only. The downloaded pdf file and printout of this SAE paper may not be copied, distributed or forwarded to others or for the use of others.)