A Study about Particle Filter Application on a
State-of-the-Art Homogeneous Turbocharged
2L DI Gasoline Engine
Dr. Ingo Mikulic, Hein Koelman, Steve Majkowski, Paul Vosejpka
Dow Automotive Systems
19. Aachener Kolloquium, 2010
299-51813/11-10
Content
• Introduction & Background
• Results On Roller Chassis:
• Tailpipe Particle Number Emissions
• Gaseous Emissions & Fuel Consumption
• Peak Pressure Drop
• On-road Testing:
• Fuel Consumption
• Soot Accumulation Behavior
• Summary & Path Forward
299-51813/11-10
Dow Powertrain Technologies
Lubricants
(Reduced Ash)
GPF
DPF
(CSF, SCRF)
Li-Ion Cell
Materials
Li-Ion Cells
& Packs (JV)
Waste Heat Recovery
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AERIFYTM Particulate Filters
GPF
Technology Description:
High porosity filters made from
Acicular Mullite crystals
Application Benefits of AERIFY vs competitive substrates:
Reduced fuel penalty
• Low backpressure
Reduces needed packaging
• Downsizing
space & system cost
• Heavy coating / system integration
Euro 6 particulate number limit
• High filtration efficiency
299-51813/11-10
Objective of This Presentation
• State-of-the-art DI Gasoline engines produce low particulate mass
emission but significant nanoparticle emission
• EU legislation will limit tailpipe Particulate Number (PN) tailpipe
emission for Gasoline light passenger cars in 2014-15 timeframe
(Euro 6)
• Current expectation is to apply the PN measurement technique and
limit for Diesel light passenger cars (e.g. 6x1011 #/km)
• OEM are preparing technical solutions:
– Via engine-in means
– Via usage of Gasoline Particulate Filter (GPF):
 Uncoated GPF
 Coated GPF
Topic of this presentation!
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Packaging For Uncoated GPF
Baseline Close-Coupled Concept of Actual Exhaust Systems (w/o GPF)
Engine
TWC TWC
Close-coupled
Integration of Uncoated GPF for Euro 6 Applications
Engine
TWC TWC
Close-coupled
Engine
TWC
TWC
GPF
Close-coupled
GPF
- No modification of TWC concept
- Continuous soot clean-out?
- GPF underfloor in extra canning
Underfloor
- Continuous soot clean out!
- GPF close-coupled in TWC canning
- TWC system must shrink. GPF
length constrained by packaging.
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GPF Performance Requirements
Sufficient PN Filtration in Clean State
(engineering target : ~3x1011 #/km)
Uncoated
GPF
Low p over Filter
(target: ~100 mbar)
Ash Storage
(~200.000 km)
Tested Samples
Material
Acicular Mullite
Acicular Mullite
Acicular Mullite
Acicular Mullite
Acicular Mullite
Acicular Mullite
Acicular Mullite
Diameter,
inch
4.66
4.66
4.66
4.66
4.66
4.66
4.66
Length,
inch
3
4
5
2
3
4
5
Honeycomb structure
DPF
GPF
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Test Vehicle
Audi A5 Coupe
2L TFSI Multitronic
Combustion system
Turbocharged homogeneous
DI Gasoline engine
Displacement
1.984 L
Exhaust system
Close-coupled TWC
Emission compliance
Euro 5
Maximum speed
226 km/h
Max power
132 kW at 4000-6000 rpm
Curb weight
1460 kg
Mileage at test begin
Approx.1500 km
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Underfloor Position of GPF
GPF
TWC
~90cm (isolated)
Engine
Upstream GPF
Downstream GPF
Temperature
Temperature
Pressure
Pressure
Flow and GPF canning were not optimized to deliver lowest
possible backpressure
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Tailpipe PN Emissions in NEDC
Particle Number Tailpipe, #/km
2.0E+12
PN emissions measured
following PMP protocol
1.8E+12
1.6E+12
1.4E+12
1.2E+12
1.0E+12
8.0E+11
Diesel Euro 6
6.0E+11
DPF
4.0E+11
GPF
Engineering Target
2.0E+11
0.0E+00
Empty
1.00
GPF Can
3“L
3.00
4“L 5.00
5“L
2“L 7.00
3“L 4“L 9.00
5“L Repetitions
11.00
AERIFY DPF and GPF deliver PN tailpipe emissions below the
engineering target in fresh state regardless of the filter length
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Online PN Emissions in NEDC
5.0·1011
w/o GPF
W/o
GPF
Optimized
DPF, 4.66“x5“
DPF; 4.66" x 5"
Optimized
DPF; 4.66" x 4"
DPF, 4.66“x4“
Optimized
DPF; 4.66" x 3"
DPF, 4.66“x3“
Optimized
GPF; 4.66" x 5"
GPF, 4.66“x5“
Optimized
GPF; 4.66" x 4"
GPF, 4.66“x4“
Optimized
GPF; 4.66" x 3"
GPF, 4.66“x3“
Optimized
GPF; 4.66" x 2"
GPF, 4.66“x2“
Particle flow / -/s
4.0·1011
3.0·1011
Significant PN emission is
formed in:
2.0·1011
• Cold start
• Catalyst heating
• Rapid accelerations
1.0·1011
0.0·100
Veh. speed
/km/h
120
80
40
0
0
200
400
600
800
Time / s
1000
1200
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NOx, CO2 & Consumption in NEDC
0.035
7.9
Consumption, l/100km
0.03
DPF
0.02
GPF
0.015
0.01
0.005
DPF
GPF
7.7
7.6
7.5
7.4
7.3
0
1.00
3.00
5.00
7.00
9.00
11.00
1.00
3.00
5.00
7.00
9.00
11.00
188
No negative impacts on:
186
DPF
CO2, g/km
NOx, g/km
0.025
7.8
GPF
184
• Tailpipe NOx
• Tailpipe CO2
• Fuel Consumption
182
180
178
in NEDC.
176
1.00
3.00
5.00
7.00
9.00
11.00
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Peak Backpressures
Δp = 95 mbar
Δp = 88 mbar
1360
Δp = 127 mbar
1400
Δp = 188 mbar
1440
Δp = 171 mbar
1480
Δp = 178 mbar
Abs. Pressure upstr. TWC, mbar
1520
1320
1280
1240
Original
Empty
1.00
2.00
GPF Can
3“L
3.00
4“L
4.00
DPF
5“L
5.00
3“L
6.00
4“L
7.00
5“L
8.00
GPF
Total exhaust pipe backpressure after ~80 sec in free full load acceleration.
AERIFY GPF delivers p < 100 mbar at 4 and 5 inch length.
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Onroad Low Load Cycle
Exhaust gas tem perature / °C
450
Standardized Cycle
400
350
Average Speed
22 km/h
Maximum Speed
33 km/h
Cycle Length
10 km
Maximum temperature
upstream GPF
~420 °C
300
250
Upstream GPF
Downstream GPF
Vehicle speed / km /h
200
35
30
25
20
15
10
5
0
• No pressure drop increase
observed after 532 km nonstop
cruising in low load cycle.
• The GPF inlet face was white
or slightly grey after de-canning.
0
500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Time / s
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Onroad Fuel Consumption Cycle
800
Exhaust gas temperature / °C
Standardized Cycle
700
600
500
400
300
Upstream GPF
Downstream GPF
200
Vehicle speed / km/h
100
140
120
100
80
60
40
20
0
Average Speed
67 km/h
Maximum Speed
131 km/h
Cycle Length
258 km
Maximum temperature
upstream GPF
~720 °C
• No pressure drop increase
observed after 806 km nonstop
cruising in fuel consumption
cycle.
• The GPF inlet face was white
or slightly grey after de-canning.
0
2000
4000
6000 8000 10000 12000 14000
Time / s
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Onroad Fuel Consumption Cycle
8.5
7.73
7.80
7.90
7.60
7.80
7.80
7.5
7.77
No relevant penalty
8
7.60
Fuel consumption / l/100km
GPF, 4.66“x3“
Optimized
GPF; 4.66" x 3"
W/o
GPF
w/o GPF
7
6.5
#1
#2
#3
Mean value
Consumed fuel measured by weighing refilled quantities. Variations may occur
caused by daily traffic variations. No relevant difference in average
consumption observed (w/ GPF versus w/o GPF).
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Fuel Penalties at Constant Speed
25
17.8
17.3
20.1
20.4
2-3% penalty
20
11.1
11.2
14
13.7
15
6.5
6.4
5
5.6
5.5
7.8
7.8
9.1
9
10
4.9
5.1
Fuel consumption / l/100km
W/o
w/o GPF
21.4
21.3
Optimized
GPF; 4.66" x 3"
GPF, 4.66“x3“
0
60
80
100
120
140
160
180
200
Vmax Vmax
(D)
(S)
Vehicle speed /km/h
Fuel consumption data from ECU. Increase of 2-3% found for vehicle speeds
of 180 – 200 km/h. No relevant increase at lower vehicle speeds.
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Summary
• The anticipated Euro 6 PN limit of 6x1011 #/km and its engineering
target (e.g. 50%) can be safely demonstrated by application of
AERIFY honeycomb filters
• AERIFY GPF delivers excellent PN filtration and very low pressure
drop regardless of its length
• No fuel consumption increase observed up to 180 km/h constant
cruising with the given test vehicle
• No soot accumulation oberserved in standardized onroad cycles
with the given test vehicle
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Path Forward
•
Sufficient PN Filtration in Clean State
(engineering target : ~3x1011 #/km)
Uncoated
GPF
Ash Storage
(~200.000 km)
•
Low p over Filter
(target: ~100 mbar)
Onroad ash accumulation in progress to investigate ash production, ash
storage, and pressure drop behavior over filter lifetime.
299-51813/11-10
Thank You
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