Advanced CIDI Emission Control System Development
Ford Motor Company, with ExxonMobil and FEV, participated in the Department of Energy's (DOE) Ultra-Clean Transportation Fuels Program with the goal to develop an innovative emission control system for light-duty diesel vehicles. The focus on diesel engine emissions was a direct result of the improved volumetric fuel economy (up to 50%) and lower CO2 emissions (up to 25%) over comparable gasoline engines shown in Europe. Selective Catalytic Reduction (SCR) with aqueous urea as the NOx reductant and a Catalyzed Diesel Particulate Filter (CDPF) were chosen as the primary emission control system components. The program expected to demonstrate more than 90% durable reduction in particulate matter (PM) and NOx emissions on a light-duty truck application, based on the FTP-75 drive cycle. Very low sulfur diesel fuel (<15 ppm-wt) enabled lower PM emissions, reduced fuel economy penalty due to the emission control system and improved long-term system durability. Significant progress was made toward a durable system to meet Tier 2 Bin 5 emission standards on a 6000 lbs light-duty truck. A 40% reduction in engine-out NOx emissions was achieved with a mid-size prototype diesel engine through engine recalibration and increased exhaust gas recirculation. Use of a rapid warm-up strategy and urea SCR provided over 90% further NOx reduction while the CDPF reduced tailpipe PM to gasoline vehicle levels. Development work was conducted to separately improve urea SCR and CDPF system durability, as well as improved oxidation catalyst function. Exhaust gas NOx and ammonia sensors were also developed further. While the final emission control system did not meet Tier 2 Bin 5 NOx after 120k mi of aging on the dynamometer, it did meet the standards for HC, NMOG, and PM, and an improved SCR catalyst was shown to have potential to meet the NOx standard, assuming the DOC durability could be improved further. Models of DOC and SCR function were developed to guide the study of several key design factors for SCR systems and aid in the development of urea control strategy for maximum NOx reduction with minimum NH3 slip. A durable co-fueling system was successfully built and tested, with the help of service station nozzle and dispenser manufacturers, for simultaneous delivery of diesel fuel and aqueous urea to the vehicle. The business case for an aqueous urea infrastructure in the US for light-duty vehicles was explored.
- Research Organization:
- Ford Motor Company, Detroit, MI (United States)
- Sponsoring Organization:
- USDOE
- DOE Contract Number:
- FC26-01NT41103
- OSTI ID:
- 898797
- Country of Publication:
- United States
- Language:
- English
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