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What is SCR?
SCR Lay out./ movie!!!!!
What is Urea?
Urea Use / Application/ availability/supply & consumption
Basic Components in the System
SCR System principle
Installation
What is SCR ?
SCR - Selective Catalytic Reduction
NOx reduction is achieved using SCR catalysts with the reductant
ammonia
SCR technology has been used in stationary applications since the
1970s for NOx reduction
SCR relies on complex chemical, mechanical and electrical systems to
obtain high NOx conversion efficiencies.
Usage around
5% of Fuel
Urea Pump
Compressed
Air supply
Dosing Unit
N 2 + H 2O
Nox Sensor
2007
Temperature Sensors
Tailpipe
SCR Brick
Urea
Injection
Decomposition
Area
Turbo
Exhaust
What is Urea ?
NOxCare (Urea) is a high-purity 32.5 % (by weight)
aqueous urea solution
Hot urea melt is drawn directly from the plant and diluted
with demineralised water
To secure high-quality NOx Care in accordance with the
DIN V 70 070 standard, production is batch-wise
Urea Use
Agriculture
Chemical Industry
raw material for:
UF-resins
Urethanes
and many others
Other industries
auxiliaries in:
chipboard industry
textile industry
coolant lindustry
cosmetics industry
fertilizer
feed
UREA
Medical and pharmaceutics
for the production of:
Water industry
nutritive substance for the
biological treatment of
waste water
Food processing
for chewing gum production
Power industry
reducing agent for
exhaust gas
barbiturates
diuretics
special injury bandages
Chemical distributors
BRENNTAG
Distributors
central depots
Direct supply
Urea plant
Tanks for
dilution with
demineralised
water
Sampling for
quality control
HYDRO
Transport
companies
(home depots)
End users
Reagent (Safety)
.
Skin
Wash off with soap and water, mild irritation may occur.
Eyes
Irrigate eyes with large amount of water
Ingestion
If conscious immediately give large amounts of water. Obtain medical attention.
Fire Non-combustible, if heated water evaporate and ammonia will be released
Spillage
Major releases Absorb large spills in sand or other absorbent. Avoid contamination of drains or
water course, inform authorities if contamination occurs
IN CABINE:
Urea gauge
MIL lamp ( not showed)
OBD connector
BMC TRAINING CENTER
Motorola
design
3
Air cooled
SCR dosing control and On Board Diagnostics is integrated into the CM 850
Module
1
2
3
AD Blue/ Urea
Starts to freeze @ - 11 degr. Celcius (32,5 %
Urea solution)
Notes:
Level sensor has 14 resistance steps
operated by reed switches it is important
to reference first and last resistor for
calibration. Maximum distance per step is
21mm
Float
Level
MIN Urea Level
Gap ~ 5mm
BMC TRAINING CENTER
Float
Temperature Thermister
Heater (water) in
70 Micron
Air Filter
Extruded Head
UDS Performance
The digital electronic doser control makes the Urea Dosing
System extremely fast to achieve the desired flow.
The suction flow is pulsated with a max peak flow about 25
litres/hours what ever the dosing demand is.
The suction flow pulse frequency increases with the dosing
volume.
4. Urea In
Welded
Injector pipe is welded to
injector nozzle body
Ceramic Insulation
Causion do not drop
4 Angled spray holes
Spray hole diameter 0.55mm +\0.05mm
BMC TRAINING CENTER
CATALYST/ Muffler
Catalyst
Muffler - robust construction - compact packaging - optimum ammonia dispersion
13 Litre Brick
O ring - wire mesh
Flow Distribution
S
less
n
i
a
t
S
09 B
t eel 4
ody
CATALYST
Catalyst (EGC)
The Catalyst is typically twice the size of the current exhaust muffler.
The Catalyst comprises of two sections
1) Sound deadening
2) The SCR brick
Catalyst
FULL Catalyst - no precious metal - good NH3 absorption - good Nox conversion
Flat Fibreglass Paper with pleats
Chemistry
- VO5
- WO3
- TO2
- NH3
Inhalation
Very unlikely unless exposed to dry residue , Obtain medical attention
Skin
Wash off with soap and water, mild irritation may occur.
Eyes
Irrigate eyes with large amount of water
Ingestion
If conscious immediately give large amounts of water. Obtain medical attention.
Fire
Non-combustible, if heated water evaporate and ammonia will be released
Spillage
Major releases Absorb large spills in sand or other absorbent. Avoid contamination of drains or
water course, inform authorities if contamination occurs
Thermistors
There are two Thermistors on the EGP
One inlet thermistor and one outlet thermistor.
. They are monitoring the Catalyst temperature.
Component
Location
400
150
350
300
250
200
100
50
0 0
2.8
10
Time in Minutes
25
28
32
33.5
Component Location:
The aftertreatment outlet NOx sensor location can vary depending on engine application.
It is usually located in the exhaust system at the outlet of the aftertreatment catalyst.
Description
The aftertreatment outlet nitrogen oxides (NOx) sensor is a smart device and
receives commands from the engine
Electronic control module (ECM) via the J1939 datalink. The aftertreatment
outlet NOx sensor performs its own Internal diagnostics and reports
malfunctions back to the primary ECM using the J1939 datalink.
The NOx sensor is permanently attached to the NOx control module. They are
serviced as single component and can not be replaced individually.
The aftertreatment outlet NOx sensor is used to measure the outlet NOx
emissions from the engine.
Urea Gauge
Must be located on dash (regulations)
Data comes from J1939
BMC TRAINING CENTER
OBD Connector
System Principle.
The SCR system operates on the principle of Selective Catalytic Reduction (SCR).
The SCR system converts the Nitrogen Oxides produced by the engine (exhaust) into
Nitrogen and Water.
Liquid urea is injected upstream of a catalyst in the exhaust system using a very
accurate dosing pump.
The amount of urea injected by the pump is controlled by the engine ECM.
Under normal operation the Dosing pump has three control Phases:
1.
2.
3.
Priming
Dosing
Purging.
System Priming
Key on engine not running dosing pump in parking situation!
Every time the Engine is RUNNING the dosing pump will go into the PRIMING phase.
Urea solution is circulated through the pump and back to the tank purging air
from the system.
If the PRIMING phase is successful you will hear the Doser Motor operate at 100%
for 30 seconds, an air solenoid will operate at the end of this phase.
If the PRIMING phase is not successful first time, the air solenoid will de-energize and
the motor will run at 100% for another 30 seconds.
This sequence can be repeated up to 20 times before ERROR 1682 SCR Pump State
Control Doser Error is displayed.
System Priming.
System Dosing
At the end of the PRIMING phase the Air Solenoid Valve opens and the pump motor
stops. The pump is now ready to DOSE. The DOSING phase is controlled by the
engine ECM depending on the NOx produced by the engine and the exhaust
temperature.
The pump will not start dosing Urea unless both exhaust temperature sensors
reach 200 degrees, however air will be continuously dosed through the
Dosing Pump, Injector Supply line & Injector while the engine is running.
In the DOSING phase air regulated to 4 bar continuously passes and through the air
solenoid to the injector.
The air has two functions:
1. Acts as a transport media for the urea
2. Prevents the injection nozzle from becoming blocked.
System Dosing 1
Air Only ..Engine Running
In the DOSING phase air regulated to 4 bar continuously passes and through the air solenoid to the injector.
System Dosing 2
Air & Urea ..Engine Running
The pump will not start dosing Urea unless conditions are met.
System Purging.
When the Key Switch is turned to the OFF position the system enters the PURGING
phase.
Compressed air flows through the injector and the pump. The air removes any urea
droplets from the system that could otherwise block the pump valves or the injection
nozzle.
The phase lasts for 30 seconds then the system switches off.
Purging is performed with every key off cycle.
If a SCR system Fault becomes active, then the SCR system will switch off, but first
purge the system with air to clean the system from Urea.
System
Purging.
Stop Mode
2
3
A
A.
B.
C.
D.
UDS limits
11
10
7
8
OBD
AIR UNIT
9
MIXING VALVE
MEMBRANE PUMP
UREA TANK
UDS limits
PRIMING MODE
UREA TANK
UDS limits
P
DOSING MODE, AIR ONLY, ENGINE RUNNING
Air open (air solenoid on)
Pump stopped
Air injected to nozzle
Pressure switch not activated
UREA TANK
UDS limits
DOSING MODE, UREA & AIR
Air open (air solenoid on)
Pump working at required capacity
Urea injected in nozzle line
Pressure switch activated
P
OBD
UREA TANK
UDS limits
PURGING MODE
Air open (air solenoid on)
Pump stopped (0l/h)
Only air injected in nozzle line
Pressure switch activated
P
OBD
UREA TANK
UDS limits
STOP MODE
UREA TANK