9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Mansour Masoudi

Robert Bosch Corporation

Farmington Hills, Michigan

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Outline
Introduction
Drivers for Exhaust Aftertreatment Technologies
Bosch Denoxtronic Urea Dosing Systems
Exhaust System Optimization at Bosch
Achievements, Current and Future Challenges, Approaches
Conclusions

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2 disposal such as copying and passing on to third parties.
 The Bosch Group - Company Founder

Robert Bosch (1861 - 1942) Founded by Robert Bosch, 1886, “Workshop for
Precision Mechanics and Electrical Engineering” in
Stuttgart, Germany

Company logo: First automotive product, the magneto,

an ignition device

Robert Bosch Foundation

Established in 1964, 92% holding (capital stock)
Since 1964, EUR 737 M spent on charity
Dedicated to promoting public health care, international
understanding, social work, education, the arts and
culture, the humanities, and social and natural
sciences
Sponsors annual fellowship work-and-study programs
in Germany for young American professionals

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 Bosch Group - facts and figures

Structure of the Bosch Group

Sectors --

Bosch Group
Sales: 41.5 billion euros
Associates on Jan. 1, 2006:
251,000

Automotive Industrial Consumer Goods &

Technology Technology Building Technology
Sales: 26.3 billion euros Sales: 5.2 billion euros Sales: 10 billion euros

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4 disposal such as copying and passing on to third parties.
 Bosch Group - facts and figures

Automotive Technology Business Sector

Divisions

Gasoline Systems Car Multimedia1)

Diesel Systems Automotive Electronics

Chassis Systems Brakes Automotive Aftermarket

Chassis Systems Control Steering Systems2)

Energy and Body Systems Bosch Engineering GmbH3)

1)
Blaupunkt GmbH (100% Bosch-owned)
2)
ZF Lenksysteme GmbH (50% Bosch-owned)
3)
Development services in the field of electronic vehicle systems

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5 disposal such as copying and passing on to third parties.
 9th CLEERS Workshop – Selective Catalytic Reduction May 2006
Robert Bosch North America
Farmington Hills, MI
(RBNA) Headquarters
Automotive Diesel Technology Center
Grand Rapids, MI
Original Equipment-Sales,
Unit Injector Truck HD 1)
Application, Engineering PC, LD, MD 1)

Anderson, SC
Broadview, IL
Electronics & Sensors
Aftermarket Sales and Service Center

Headquarters
Development
Manufacturing Charleston, SC
Juarez, Mexico Common Rail Systems Truck HD 1)
Aftermarket Engine Control Unit Unit Injector Truck HD 1)

1) PC…passenger car; LD…light duty; MD…medium duty; HD…heavy duty

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Outline
Introduction
Drivers for Exhaust Aftertreatment Technologies
Bosch Denoxtronic Urea Dosing Systems
Exhaust System Optimization at Bosch
Achievements, Current and Future Challenges, Approaches
Conclusions

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7 disposal such as copying and passing on to third parties.
 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Solutions meeting upcoming Emission Legislations

EU5 US T2B5

To achieve T2B5 it is necessary to…

• Combine lowest engine out emissions with high performance after.tr. system
• Use of an advanced combustion strategy will be mandatory

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

The Tier 2 BIN5 Challenge

MUST: Reduction of NOx raw emission levels
Tier2 BIN5 requires NOx raw emission levels of << 0.30 g/mi over
FTP75 (based on current technology assessment)
MUST: “Rapid Heat-up"
Engine-based
Post engine measures
PLUS: Optimization of exhaust system ‘hardware’
Low light-off temperature
Hydrolysis catalyst
NO2-optimized DOC
….

Only a ‘combination’ of aforementioned measures will be successful

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Exhaust Gas Aftertreatment System Application & Optimization

Example -- SCR technology: NOx conversion is the product of many
affecting parameters which need be “simultaneously” optimized!
SCR catalyst DOC
fuel, lube
catalyst position

exhaust gas
flow pattern NOx Conversion temperature

dosing space velocity

strategy
BOSCH
spray pattern reductant
Core Expertise
mass flow

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Outline
Introduction
Drivers for Exhaust Aftertreatment Technologies
Bosch Denoxtronic Urea Dosing Systems
Exhaust System Optimization at Bosch
Achievements, Current and Future Challenges, Approaches
Conclusions

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11 disposal such as copying and passing on to third parties.
 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

DENOXTRONIC 1 -- for HD
With Air-Support AdBlue - tank
Supply
Module
Air pressure
Temp.-
Filter sensor
AdBlue
AdBlue Dosing level
Compressor Control sensor
Dosing
module Unit

In series production Actuators Sensors

since 2004
Engine CAN
Diagn. CAN
Temp.- Temp.- Exhaust
sensor Atomizer sensor gas sensor

OXI - cat SCR - cat Slip - cat

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

DENOXTRONIC 2 -- for HD
AdBlue - tank
2nd Generation Supply module
DENOXTRONIC2
Not Air-Assisted
Temp.-
sensor
Filter
AdBlue level
sensor
Dosing
DCU control
Bosch unit

Sensors
Actuators Engine CAN
Diagn. CAN
Temp.- Temp.- Exhaust
sensor AdBlue Dosing Module
sensor gas sensor

OXI - cat SCR - cat Slip - cat

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

DNOX PC - LD Level-
sensor

AdBlue-
Tank

Engine
Control
Unit Supply Module on
including Functional Unit
SCR- incl. Splashing
(optional)
functions Measures, Heating
and Temp. Sensor
Actuators Sensors Actuators Sensors

Pressure
Sensor
AdBlue
Temp.- Dosing NOx-
Sensor Module Sensor

Bosch

DPF Mixer SCR-Catalyst

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

PC-LD B1-Sample Design Supply Module

PC/LD: Hardware Components
Functional unit

Dosing Module with

passive cooling

Standard AdBlue Tank Exhaust Tube

(20 – 25 l)

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

PC/LD Tank/Supply Module: B-Sample

Thawing of limited volume to reach dosing mode within 30 minutes

Integration of Supply Module on top of tank
2-Pin-Sensor for level detection (continuous level sensor as back-up)
Splashing measures inside the tank implemented
Customized tank shape possible

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

SCR Technology for: Passenger Car / Light Duty

engine
control
unit*

tank with
supply
module

AdBlue
dosing pipe
module
ECU
control line
*DCU functions integrated, separate DCU available

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Europe: Infrastructure
3 Companies provide AdBlue through their filling station networks

At present:
~ 260 filling stations with pumps
~ 2600 filling stations offer canisters
Various companies offer the distribution of:
• On-site tanks and pumps
• Bulk loads
AdBlue Prices per liter range from €0.65 – €0.82

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Outline
Introduction
Drivers for Exhaust Aftertreatment Technologies
Bosch Denoxtronic Urea Dosing Systems
Exhaust System Optimization at Bosch
Achievements, Current and Future Challenges, Approaches
Conclusions

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19 disposal such as copying and passing on to third parties.
 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

BOSCH Exhaust Gas Treatment Product Portfolio

Filters

* HCI: HydroCarbon Injection

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006
SCR – System Considerations (Example: Passenger Car)
Thermally optimized SCR system controller & software
“Rapid heat-up“ strategy • Dosing strategy
exhaust manifold
AdBlue canister

Emissions-optimized SCR catalyst

engine • Light-off temperature/ time
• Formulation

DOC, DPF
• Location
• NO2-optimized DOC Sensors
• Temperature
• NOx
• sensor(s) location
Dosing system • ‘Is it NOx or Ammonia?’
Thermally-optimized • Dosing module temperature
exhaust pipes (must be < ~ 120 C) – (DPF regen, Reductant distribution in exhaust gas
mountain drives, summer trips, …) • Dosing module location
• Thawing strategy • Spray quality
• Purging strategy to eliminate risk of • Distribution quality (uniformity) of Ammonia
damage in freezing conditions • Use of mixer?
• .… • Exhaust system design (geometry)
• Simulation-based investigations
•….
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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

‘Classic’ Arrangement: (C)DPF followed by SCR

TF IC TC

AMS
EGR

C
DO

PF
CD
SCR

AdBlue Dosing Module

☺ close-coupled DOC + CDPF ease of CDPF active regeneration

☺ passive (C)DPF regeneration (NO2 effect) can be more effectively utilized
☺ allows most compact system
SCR in underfloor position temperature management means most likely required

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Alternative Arrangement: SCR followed by (C)DPF

TF IC TC

AMS
EGR

C
DO Hydrocarbon Injection (HCI) Module

AdBlue Dosing Module SCR DOC DPF

☺ rapid light-off of SCR converter

passive (C)DPF regeneration less effective
SCR-friendly DPF regeneration difficult supporting measures like HCI might be required!
bulky system (2nd DOC, mixing length for both AdBlue and HC, …)
system complexity

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006
SCR – System Considerations (Example PC)
Thermally optimized SCR system controller & software
“Rapid heat-up“ strategy • Dosing strategy
exhaust manifold
AdBlue canister

Emissions-optimized SCR catalyst

engine • Light-off temperature/ time
• Formulation

DOC+DPF
• Location
• NO2-optimized DOC
Sensors
• Temperature
• NOx
• sensor(s) location
Dosing system • ‘Is it NOx or Ammonia?’
Thermally-optimized • Dosing module temperature
(must be < ~ 120 C) – (DPF regen, Reductant distribution in exhaust gas
exhaust pipes • Dosing module location
mountain drives, summer trips, …)
• Thawing strategy • Spray quality
• Distribution quality (uniformity) of Ammonia
• Purging strategy to eliminate risk of
• Use of mixer?
damage in freezing conditions
• Exhaust system design (geometry)
• .…
• Simulation-based investigations
•…

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Mixers – Effect on spray

Axis
r a y
Sp

Ax is
ra y

Mixer
Air flow Sp

Wall wetting

Air flow

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Mixers – More!
low load medium load high load
60 11 60 46 60 28
without mixer

40 low conversion
13 40 65 40 48
NOx_Koordinate_y [-]

20 20 20

18 71 22 70 73 43 58 72 38
0 0 0

-20 -20 -20

high 72 74 74

-40 conversion -40 -40

19 61 13

-60
Ui = 0.66 -60
Ui = 0.92 -60
Ui = 0.81
-60 -40 -20 0 20 40 60 -60 -40 -20 0 20 40 60 -60 -40 -20 0 20 40 60
NOx_Koordinate_x [-] NOx_Koordinate_x [-] NOx_Koordinate_x [-]
60 61 60 69 60 68

40 65 40 69 40 69
with mixer
NOx_Koordinate_y [-]

NOx_Koordinate_y [-]
20 20 20

58 70 68 69 73 67 66 74 68
0 0 0

-20 -20 -20

63 68 63

-40 -40 -40

53 68 60

-60 -60 -60

Ui = 0.96 Ui = 0.99 Ui = 0.98
-60 -40 -20 0 20 40 60 -60 -40 -20 0 20 40 60 -60 -40 -20 0 20 40 60
NOx_Koordinate_x [-] NOx_Koordinate_x [-] NOx_Koordinate_x [-]

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Computational Fluid Dynamic (CFD) at Bosch –

CFD as a Rapid Prototyping Tool

Why CFD? Use in Bosch dosing system

• visualization of processes inside development
exhaust gas systems • CFD coupled with experimental
• optimization of injection, mixing validation
and chemical conversion • prediction of major processes in SCR-
• supporting geometrical SCR based deNOx-systems
catalyst design with focus on • spray - gas interactions
homogeneous reductant agent • spray-wall interaction/ film formation
distribution • homogeneous gas phase reaction (urea to
• establishing a tool for internal NH3 ) / predicting SCR catalyst reactions
and external customer support • pressure loss of SCR catalyst
• ….

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Contributors

SCR Catalyst

tafter SOI = 10ms Urea-Water-Solution

Spray

Thermolysis/Hydrolysis Mixer

Deposition of
AdBlue

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Experience shows customers expect more than "just" components

and software / calibration customers expect total system solutions
and "emissions concept engineering" support

Example: exhaust system optimization by means of CFD as a "total

system" optimization tool.

Layout 1 Layout 2 Layout 3

∆Psim,full load =190 mbar ∆Psim,full load =210 mbar ∆Psim,full load =160 mbar
before optimization: After optimization:
poor homogeneity better homogeneity good homogeneity
∆T = 35 K ∆T = 25 K ∆T = 10 K

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Simulation as a Means of SCR System Optimization

600
FTP75 NOx Raw Emission LDT3 Class Vehicle (4.750 lbs)
FTP75 Tailpipe NOx [mg/mi]

Theoretical rapid heat-up

Theoretical rapid heat-up
CC-DOC + CSF, UF-SCR result assumes a 70 %
500 result assumes a 70 %
NOx reduction in FTP75
Bosch DNOX-PC/LD A0-System NOx reduction in FTP75
phase 1 which would
Reductant: AdBlue phase 1 which would
require a SCR catalyst
require a SCR catalyst
400 ≈ 79 % reduction light off after 120 sec.

≈ 88 % reduction
light off after 120 sec.
Today, catalyst light-off is
Today, catalyst light-off is

≈ 94 % reduction
reached after approx. 250

≈ 91 % reduction
reached after approx. 250
300 sec. leading to a ≈ 40 %
sec. leading to a ≈ 40 %
NOx reduction on FTP75
NOx reduction on FTP75
phase 1.
phase 1.
200
Please keep in mind, that
Please keep in mind, that
NOx raw emission level
NOx raw emission level
100 given here is too high for
115 given here is too high for
a series production
a series production
65 50 Tier2/BIN5 application!
Tier2/BIN5 application!
35
0
before flow exhaust
before optimization
after flow
after optimization
exhaustwith rapid heat-up
plus rapid withtheo.
rapid
heat-up plusheat-up STATUS
rapid heat-up
system optimization system optimization (THEORY) (STATUS)

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Simulation of Reactions
NOx-Conversion NOx-Conversion

NOx-Conversion NOx-Conversion

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Simulation of Various Species

spray evaporation wall film
Catalyst
danger of fouling

thermolysis/hydrolysis
Spray vapor Mass Fraction [-]
Injection of AdBlue
0 5e-3 1e-2 1.5e-2 2e-2
valve location at the bottom
Mole fraction H2O [-]
SCR reactions

Mole fraction NH3 [-] Hydrolysis in the catalyst

Mole fraction HNCO [-] NH3-Oxidation in the catalyst

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Simulation Close-Coupled with Experiments

reductant distribution gas flow distribution
(test) (simulation)

overlapping
(schematic)
Re
duc F low
tan s
tF
low Ga

Improvement in SCR catalyst performance due to

enhanced flow-spray-NH3 mixing

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006
SCR – System Considerations (Example PC)
Thermally optimized SCR system controller & software
“Rapid heat-up“ strategy • Dosing strategy
exhaust manifold
AdBlue canister

Emissions-optimized SCR catalyst

engine • Light-off temperature/ time
• Formulation

DOC+DPF
• Location
• NO2-optimized DOC
Sensors
• Temperature
• NOx
• sensor(s) location
Dosing system • ‘Is it NOx or Ammonia?’
Thermally-optimized • Dosing module temperature Reductant distribution in exhaust gas
exhaust pipes (must be < ~ 120 C) – (DPF regen,
• Dosing module location
mountain drives, summer trips, …)
• Spray quality
• Thawing strategy
• Distribution quality (uniformity) of Ammonia
• Purging strategy to eliminate risk of • Use of mixer?
damage in freezing conditions • Exhaust system design (geometry)
• .… • Simulation-based investigations
• ….

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006
FUL: Full Useful Life = 120k mi

SCR Light-off during FTP75 HUL: Half Useful Life = 50k mi

NOx Conversion [%] 100

80
60
40
20
NOx raw emission
0

NOx (not phase-weighted!): 400

Cumulated NOx [g]

before SCR Converter NOx after SCR ≈

Temperature [°C]
4
after SCR Converter Tier2/BIN5 FUL
300

200
2
100
Virtually no NOx target: Tier2/BIN5
conversion for 200s0 HUL – 30 %
0
Cold start management (corresponding to
0 200 400 600 800 1000 1200 1400 1600 1800 2000
a > 90 % NOx
is required.
Elapsed Time of Cycle [sec] con-version target)

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006
SCR – System Considerations (Example PC)
Thermally optimized SCR system controller & software
“Rapid heat-up“ strategy • Dosing strategy
exhaust manifold
AdBlue canister

Emissions-optimized SCR catalyst

engine • Light-off temperature/ time
• Formulation

DOC+DPF
• Location Sensors
• NO2-optimized DOC • Temperature
• NOx
• sensor(s) location
Dosing system • ‘Is it NOx or Ammonia?’
Thermally-optimized • Dosing module temperature
Reductant distribution in exhaust gas
exhaust pipes (must be < ~ 120 C) – (DPF regen,
mountain drives, summer trips, …)
• Dosing module location
• Spray quality
• Thawing strategy
• Distribution quality (uniformity) of Ammonia
• Purging strategy to eliminate risk of
• Use of mixer?
damage in freezing conditions
• Exhaust system design (geometry)
• .…
• Simulation-based investigations
• ….

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Structure of SCR-software
Dosing strategy SCR system OBD
Calculation of required AdBlue quantity Monitoring of
•NOx-raw emission model •SCR-catalyst
•SCR-catalyst model •NOx-sensor
•adaptation •temperature sensor (exhaust gas)

Dosing system control Dosing system OBD

Monitoring of Monitoring of
•injection of requested AdBlue quantity •dosing valve
•anti-freeze •pump
•protection of components •temperature- and pressure-sensors

Additional SCR relevant SW (under development)

•Catalyst heating, requires interventions in engine management
•Interaction SCR ↔ DPF (No dosing during DPF-regeneration

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006
SCR – System Considerations (Example PC)
Thermally optimized SCR system controller & software
“Rapid heat-up“ strategy • Dosing strategy
exhaust manifold
AdBlue canister
a n t!
Emissions-optimized g n ific y! SCR catalyst
engine i s si olog • Light-off temperature/ time
l e xity techn • Formulation
m p ay’
m co
n d -p l
e
DOC+DPF s yst lug-a
C R a ‘p Sensors
• Location l S ot
• NO2-optimized DOC Tota s n • Temperature
C Ri • NOx
S • sensor(s) location
• ‘Is it NOx or Ammonia?’
Dosing system
Thermally-optimized • Dosing module temperature Reductant distribution in exhaust gas
exhaust pipes (must be < ~ 120 C) – (DPF regen, • Dosing module location
mountain drives, summer trips, …) • Spray quality
• Thawing strategy • Distribution quality (uniformity) of Ammonia
• Purging strategy to eliminate risk of • Use of mixer?
damage in freezing conditions • Exhaust system design (geometry)
• .… • Simulation-based investigations
• ….

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

SCR Technology Challenges

Challenges: Approaches:
minimization of ammonia slip closed-looped control,
whilst maximizing NOx conversion exhaust system optimization
minimization of reductant minimization of NOx raw
consumption emissions
minimization of reductant tank see above
volume (mass)
cold climate operability system heating, non-solidifying
(below - 11°C) reductant
low exhaust gas temperature "rapid-heat up", advanced catalyst
performance improvement technologies
maximization of NOx reduction
ultra-low quantity dosing systems modified injectors, high precision
dosing quantity control

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

conclusions Pressure
Sensor

DPF

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 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Conclusions
For European cycles similar to NEDC --
Key Challenge: Limited NOx conversion at low temperatures which
require ‘counter measures’ (e.g. rapid heat up via engine)
Counter measures possibly not necessary for moderate NOx
conversion rates

For US test cycle conditions --

US06 compliance is currently considered not a major challenge
US FTP75 lifetime compliance a challenge.
Lower raw NOx raw emissions (< 0.3 g/mi)
"Rapid heat-up" expected to be required

Progress is being made in reducing overall complexity of SCR technology

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41 disposal such as copying and passing on to third parties.
 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Conclusions -- SCR Technology Outlook

SCR currently is the preferred technology to meet highest NOx conversion

requirements over lifetime for HD / OHW applications and passenger car/
light duty applications (e.g. US Tier2/BIN5).

Advanced FIE / combustion systems are vital for meeting TIER2, EURO5
and beyond

Bosch's philosophy: Customers expect ‘total system knowledge’ --

emission concepts engineering, i.e. significantly more than components,
systems and calibration!

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of
42 disposal such as copying and passing on to third parties.
 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

Bosch’s Achievements / Contributions:

Proven technology for on-road HD vehicle application (series introduction
since late 2004)
Successful demonstration of Denox PC/LD applications in various programs
for all types of emission test cycles

Bosch’s expertise in fuel injection systems and after-treatment

technologies (specifically urea dosing systems) combined with its ‘total
systems solutions’ approach provide the needed know-how and
products to meet future, stringent emissions requirements

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of
43 disposal such as copying and passing on to third parties.
 9th CLEERS Workshop – Selective Catalytic Reduction May 2006

AP/ENS3 | 5/3/06 | 685 445a | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of
44 disposal such as copying and passing on to third parties.