Study on Selection of Diesel Engine Exhaust After-Treatment System Materials and Emission Performance for Genset Applications

Year 2023, Volume: 7 Issue: 3, 175 - 186, 30.09.2023

Karthikeyan Subramanian Annamalai Kandaswamy

https://doi.org/10.30939/ijastech..1207224

Abstract

The use of diesel engines for the transportation sector is ubiquitous and covers a broad continuum, like buses, trucks, agriculture, construction equipment, generators, and industrial applications. However, because of their increased use of off-road engines, they contribute more emissions in various sectors than on-road. As a result, worldwide, regardless of ongoing emission control efforts, these off-road, stationary engines also continue to be a substantial source of air pollutant emissions in the United States, European Union and Asian markets. Accordingly, while improving emissions performance, the selection of after-treatment system materials and the use of compatible after-treatment specification selections are also critical. This is only possible by effectively combining clean diesel technologies such as Fuel Injection Equipment (FIE), Turbocharger with Intercooler (TCIC), Cooled Exhaust Gas Recirculation (C-EGR), and after-treatment systems like Diesel Oxidation Catalyst (DOC), Selective Catalytic Reduction (SCR), and Diesel Particulate Filter (DPF). Overall, in this study, the influence of after-treatment system configurations and their effect on emission reduction performance are studied for three different DOC specifications based on emission testing for catalyst and size optimization. With the selected DOC catalyst specification, suitable combinations of DPF and SCR specifications are optimized further using GT-SUIT software simulation. This study was carried out during the conversion of a 15 kW NA engine to a 27 kW TCIC engine to meet diesel engine emission norms.

Keywords

Diesel engine, Catalyst, Emission, Simulation, Genset

References

• [1] Tyagi, N., gupta, S., Bhardwaj, P., Gayen, H. Vijayakumar Thu-lasi. Optimization of GENSET Engine for CPCB- II Norms us-ing Cost Effective Techniques. SAE Technical Paper 2013-01-2838, 2013, https://doi.org/10.4271/2013-01-2838.
• [2] Issa, M., Ibrahim, H., Lepage, R. and Ilinca, A. A Review and Comparison on Recent Optimization Methodologies for Diesel Engines and Diesel Power Generators, Journal of Power and Energy Engineering, 7, 31-56; doi: 10.4236/jpee.2019.76003.
• [3] Karthikeyan.S, Suresh. A. L, Sathyanadan. M, Krishnan.S, Sh-1avan Kumar Srisailam and Weiyong Tang. Performance of BS-VI catalyst and influence of deactivation conditions on emission durability for commercial vehicle applications. Mate-rials today: Proceedings; 2022; https://doi.org/10.1016/j.matpr.2022.09.564.
• [4] Karthikeyan.S, Suresh. A. L, Sathyanadan. And Mahesh. P. A competent top down approach methodology for design and de-velopment of commercial vehicle box type exhaust after treat-ment system. Materials today: Proceeding; 2022. https://doi.org/10.1016/j.matpr.2022.08.556.
• [5] Hirose, S., Miyairi, Y., Katsube, F., Yuuki, K. Hirofumi Sa-kamoto, Claus Vogt, Shuji Fujii. Newly Developed Cordierite Honeycomb Substrate for SCR Coating Realizing System Com-pactness and Low Backpressure. SAE Technical Paper 2012-01-1079, 2012, https://doi.org/10.4271/2012-01-1079.
• [6] Karthikeyan, S., Annamalai, K. Study on Performance En-hancement Technologies for Two Cylinder Diesel Engine for Off-Road Applications. In: Narasimhan, N.L., Bourouis, M., Raghavan, V. Recent Advances in Energy Technologies. Lec-ture Notes in Mechanical Engineering. Springer, Singapore; 2023 https://doi.org/10.1007/978-981-19-3467-4_37
• [7] Harne, P., Dhamangaonkar, P., and Kalaiselvan, K. Perfor-mance Assessment of Urea-Selective Catalytic Reduction (SCR) Technology in On-Road 6-Cylinder Heavy-Duty Diesel Engine. SAE Technical Paper 2020-28-0324, 2020; https://doi.org/10.4271/2020-28-0324.
• [8] Hirose, S., H. Yamamoto, H. Suenobu, H. Sakamoto, F. Katsube, P. Busch, A. Martin, R. Kai, and C. D. Vogt. Devel-opment of High Porosity Cordierite Honeycomb Substrate for SCR Application to Realize High NOx Conversion Efficiency and System Compactness. SAE International Journal of Materi-als and Manufacturing. 2014:7(3). http://www.jstor.org/stable/26268654.
• [9] De Rudder, K., Tier 4 High Efficiency SCR for Agricultural Applications, SAE Int. J. Commercial. Veh. 2012;5(1):386-394. https://doi.org/10.4271/2012-01-1087.
• [10] Kiminobu Hirata, Nobuhiko Masaki, Hiroki Ueno and Hisashi Akagawa. Development of urea SCR system for Heavy –Duty Commercial vehicles. SAE Technical Paper 2005-0-1860; https://doi.org/10.4271/2005-01-1860.
• [11] Subramanian, K., A, S., Mahadevan, S., and Sadagopan, K. Emission Performance and Durability Validation Methodol-ogy for Heavy Commercial Vehicle After-treatment Systems. SAE Technical Paper 2022-28-0327; 2022. https://doi.org/10.4271/2022-28-0327.
• [12] S. Karthikeyan, K. Annamalai and M. Sathyanandan. Diesel engine performance improvement with suitable low cost technologies for tractor applications. Progress in Industrial Ecology, An International Journal; 2015. https://doi.org/10.1504/PIE.2015.073087.
• [13] Karthikeyan.S and Annamalai. Study on Exhaust Emis-sion Performance with advanced after-treatment systems for two-cylinder diesel engine, 4th International conference on ad-vances in mechanical engineering; India, 2022.
• [14] Niemi, S., Laurén, M., and Murtonen, T. Effect of Waste-Gate Turbocharging on the Exhaust Particulate Matter of an Off-Road Diesel Engine. SAE Technical Paper 2002-01-2159, 2002; https://doi.org/10.4271/2002-01-2159.
• [15] Zagade, B., Sharma, V., and Körfer, T, Tuning and Vali-dation of DPF for India Market. SAE Technical Paper 2017-26-0135, 2017; https://doi.org/10.4271/2017-26-0135.
• [16] Iwasaki, S., Mizutani, T., Miyairi, Y., Yuuki, K. et al. New Design Concept for Diesel Particulate Filter. SAE Int. J. Engines. 2011;4(1):527-536. https://doi.org/10.4271/2011-01-0603.
• [17] Nishioka, A., Sukegawa, Y., Katogi, K., Mamada, H., Takehiko Kowatari, Toshifumi Mukai, Hiroshi Yokota. A Study of a New Aftertreatment System (2): Control of Urea So-lution Spray for Urea-SCR. SAE Technical Paper 2006-01-0644, 2006; https://doi.org/10.4271/2006-01-0644.