降低车用柴油机NOx排放的SCR技术控制策略研究
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摘要
柴油机由于具有动力性强、耗油率低等优势,在中/重型客、货车上得到了广泛的应用,但柴油机的主要排放物NO_x和PM无法像汽油机排放物那样可以通过采用三效催化转化器有效地解决,因此,在发展现有柴油机机内排放控制新技术的基础上,研究、开发适合于柴油机的先进排气后处理技术是柴油机生存和发展的关键。在商用车满足欧Ⅳ、欧Ⅴ排放法规技术路线中,目前国际上普遍采用如下两种技术路线,一是通过燃烧系统优化降低机内颗粒物的生成量,然后采用选择性催化还原(SCR)后处理技术降低NO_x的排放;其二是通过废气再循环(EGR)降低机内NO_x生成量,然后采用颗粒物后处理技术降低颗粒物的排放。
以尿素为还原剂的SCR(Selective Catalytic Reduction)技术由于具有可以通过优化缸内燃烧来改善燃油消耗和较强的抗硫中毒能力等优点,作为控制车用柴油机尾气排放的重要手段在欧洲等发达国家和地区已经得到了广泛的应用,对于改善由柴油汽车尾气造成的大气污染发挥了重要作用。由于我国排放法规体系等效采用欧洲法规体系,考虑到我国的国情和技术的移植便利性,我国各主要整车厂和柴油机企业也倾向于采用SCR技术作为满足未来更严格排放要求的主要技术措施。
目前,虽然国内几家主要车用柴油机企业已经在柴油机领域开展了SCR技术的研究,但基本上以国外技术引进应用为主,核心技术仍主要掌握在国外相关厂家手中,这成为我国该技术推广和应用的主要瓶颈,而我国随着道路运输的快速增长,车用柴油机需求量也正在迅速增加,其污染物的治理刻不容缓,急需成本低廉、性能高效的SCR排气后处理技术和装置。因此,有关SCR技术的国产化研究日益紧迫,对于SCR技术从催化剂性能研究、催化转化器优化设计到尿素喷射系统的控制策略的研究与应用、OBD系统的开发和标定,再到整个系统在整车上的集成和匹配应用的研究非常必要。
本课题针对SCR技术在WP12系列柴油机上的开发、匹配、标定为基础,采用试验评价、理论分析、数值模拟和试验验证相结合的方法对SCR技术实际应用进行了研究。主要内容包括:SCR催化反应系统的研究、尿素喷射控制策略和尿素喷射量标定的研究、SCR技术OBD系统的开发与标定、SCR系统在寒冷地区使用过程中存在的主要问题和解决措施。
首先,本文对SCR催化反应系统中DeNO_x效率的影响因素进行了研究,包括载体和催化剂的优化筛选、催化转化器结构的设计和优化、尿素喷射段管路内液滴粒子的分布等三个方面的内容。通过催化剂和载体的对比试验结果表明,规格为400/7的载体虽然压力损失最大,但影响并不明显,从成本和产业化的角度,可以选择其作为试验用催化剂载体;催化剂样品(2)无论在DeNO_x效率还是防止氨气逃逸方面都优于样品(1),且经过老化试验后性能也未明显下降,因此,选择催化剂样品(2)作为下一步试验的催化剂。设计了适用于重型车用发动机的箱式SCR催化转化器,并利用CFD技术进行了优化设计。对几种催化转化器设计方案的计算结果表明,入口管串孔区域长度和开孔区域角度范围分别存在一个最佳长度和角度范围可以使得各载体流量的分配最均匀;另外,在入口管底部设置一多孔式导流板可以消除底部的涡流,有利于改善流动效果,减少压力损失。利用CFD技术对尿素喷嘴的布置位置、角度和排气管直径大小进行了多种方案的对比计算和分析,并根据计算结果确定了合适的喷嘴安装位置和喷嘴安装角度,为SCR排气管段的设计提供了理论指导和参考,也为SCR系统与发动机的匹配试验打下了良好的基础。
良好的喷射策略不仅可以缩短标定周期,提高工作效率,而且能够在满足排放目标的前提下节省尿素的消耗。本文以SCR系统在WP12柴油机上的开发、匹配和标定为基础,在发动机台架上对SCR技术尿素喷射系统进行了试验研究,实现了通过对尿素喷射量的控制既满足国Ⅳ排放法规要求,又避免过量的氨气逃逸。这对制定科学的尿素喷射控制策略和高效、合理的SCR匹配、标定能够起到积极的促进作用。研究内容包括:尿素喷射的控制策略、尿素喷射量的优化标定、催化转化器动态温度修正等方面。在对尿素喷射策略研究分析的基础上,根据对标定经验的总结,并参照相关技术资料提出了稳态测试条件下尿素喷射量的优化标定方法,并建立了可以在ESC测试循环标定过程中对NO_x综合排放量进行估算的标定估算模型,在SCR尿素喷射量的标定过程中,可以对NO_x的控制有的放矢。实践证明该方法可以明显提高工作效率、节省标定时间、缩短标定周期。通过对尿素喷射策略和催化转化器动态温度修正的研究,及ESC和ETC测试循环试验结果表明,开启动态修正后在保证NO_x排放量满足要求的前提下能够有效减少尿素消耗量;在瞬态工况下,还可以有效降低NH_3逃逸造成的二次污染;同时,稳态工况下的尿素喷射量还需要进一步的合理优化,尽量减少动态修正的比例,提高SCR系统的利用效果。另外,应在优化SCR催化转化器结构的前提下进一步缩小催化剂载体体积,以减小载体的储热总量,提高催化转化器在发动机工况发生变化时对温度的瞬态响应能力。
由于从国家第Ⅳ阶段开始要求必须安装OBD系统,所以对OBD系统的控制策略和控制算法的研究、系统开发及标定等工作就非常必要。本文根据OBD系统的检测功能原理和检测技术要求,在应用SCR技术的WP12重型车用柴油机上进行了OBD1+NO_x控制阶段的开发和标定,并通过了认证试验,表明所开发的OBD故障诊断和排放监控策略满足对发动机在线监测和诊断的要求。
最后,由于我国地域辽阔,在寒冷季节南北地区气温相差比较大,北方地区冬季可达到-30℃以下,而尿素溶液在温度低于-11℃时会出现结冰或固态化等现象,导致SCR的尿素供给系统无法正常工作,造成配置SCR系统的车辆在这些地区的使用受到一定的限制。这一问题可以通过对尿素存储单元和流动沿程管路进行有效的加热来解决。为了确保SCR系统在北方地区寒冷季节的正常运行,在对尿素存储单元和尿素沿程管路加热过程中,必须确保加热系统的加热能力合理分配,使尿素溶液保持在结冰点之上,但又不加热过度,以免造成无谓的能量浪费。因此,有必要对SCR系统的加热功能进行理论分析和实际应用状态下的研究。本文利用传热学和热力学等方面的知识,在对尿素流动沿程管路尿素溶液、管路和环境空气之间传热分析的基础上,对尿素管路散热量进行了计算,提出了解决尿素存储单元和尿素管路结冰问题的解决措施,为尿素管路的选型和加热功率的选择提供理论指导;通过在低温试验室内的模拟试验对加热管路进行了不同功率的对比选型;最后将该系统配置在整车上进行了寒冷地区的试验测试,以确保SCR系统能够满足在我国寒冷地区正常使用的要求。研究结果表明,尿素存储单元采用水加热方式、尿素供给单元和尿素管路采用电加热方式可以有效解决SCR系统在寒冷地区使用过程中出现的结冰问题。
总之,本文研究结果对开发满足国Ⅳ排放商用柴油机具有一定的参考价值,对我国降低商用车柴油机排放、减少大气污染具有现实的社会意义。
As the aggravation of environmental pollution caused by vehicles, a series of legislations are put out to reduce emissions from automobile engines and more stringent. The after-treatment technology is one of the major measures to meet the emerging stringent emission legislation limits. Because of its advantage of higher power performance and lower oil consumption, diesel engines are widely applied in medium/heavy trucks and passenger carriages. However, the NOx and PM, which are the main emissions of diesel, can't be effectively solved for lean burn engines through TWC (Three-Way Catalysts) technology as gasoline engines due to the low NO_x conversion in the presence of oxygen. Thus, it is the time for diesel engines to develop appropriate exhaust after-treatment technology. In all the technology routes studied by diesel engine manufacturers to deal with Euro IV and Euro V standards two methods are concluded, which one is reducing NOx emissions with SCR (Selective Catalytic Reduction) technology on the basis of combustion optimization for diesel engines to reduce PM, and the other to debase NOx emissions with EGR (Exhaust Gas Recirculation) and PM with DPF.
The Selective Catalytic Reduction (SCR), using urea as reducing agent, because of the advantage of low oil consumption and strong resistibility, is presently considered the most promising technique for the removal of nitrogen oxides from the exhaust of heavy-duty diesel vehicles. It has contributed to control the emissions from vehicles in Europe. Due to our emission standard system is equivalent to the Europe standard system, in view of China's conditions and the convenience of technology explanting, manufacturers of vehicle and diesel engine are inclined to adopting the SCR technology as the major technology to meet the more stringent exhaust emission standards in future.
However, the study about Urea-SCR technology is not self-dependent currently in our country although the native manufacturers have been starting the application in SCR technology on heavy-duty diesel engines. Due to the key technology and patents for SCR system which are held by manufacturers abroad, they have been becoming the bottle-neck of the SCR techonogy extending and application in China. With the diesel vehicles are increasing significantly in our country, it is very urgent to reduce the pollutants from vehicles, and it has a rapidly increasing demand of the advanved SCR catalysts. Therefore, it is urgent for the domestic research of the relative SCR technology and is necessary to have a totally understand of them to prepare for the further study and domestically manufacture. So, it is more and more necessary to research the SCR technology, from the catalyst, the catalyst box design, the urea dosing control strategy and the OBD system, to the entire system in the vehicle integrating and matching.
In this paper, it's based on the SCR technology's developing, matching, calibration on diesel engine WP12, and the actually application of the SCR technology is deeply studied with the integration methods of experimental evaluation, theoretical analysis, numerical simulation and the experimental verification. The paper includes: the study of SCR catalyst reaction system, the study of urea dosing control strategy and calibration of urea dosing quality, the development and calibration of OBD system, the main problems and solution measures when the SCR system using in cold area. The following are the brief description and introduce of this paper in writing orders.
Firstly, the influence factors of DeNOx efficiency of the SCR catalyst reaction system are totally studied, include optimizing screening of substrate and catalyst, designing and optimizing of catalyst box structure and dripping distribution of exhaust pipe where dosing urea. As the result of contrast test to substrate and catalyst shows, through substrate 400/7 has the biggest pressure loss, it's not obviously and can be the substrate of catalyst in the test temporary from the view of cost and mass production; catalyst sample (B) is superior to catalyst sample (A) both in DeNOx efficiency and preventing NH3 disclosure, and after degradation testing its performance does not decrease obviously, therefore, catalyst sample (B) is chosen as the catalyst for the further test. SCR catalyst converters of box-type which are suitable for heavy-duty engines are designed and optimized by CFD. As the calculation result of the design schemes to several catalyst converters shows, there is a optimum length for inlet pipe area with holes and a optimum angle scale for the area with holes at which every substrate have the most even flow distribution; Furthermore, a flow guidance panel at the bottom of inlet pipe can remove the vortex in the base, and is in favor of improving flow effect and reducing pressure loss. CFD technology is used to have contrast calculation and analysis to the position and angle of the urea dosing system, and the diameter of exhaust pipe of different schemes.
Secondly, good dosing strategy not only can shorten calibration period, improve work efficiency, but also save urea consumption at the premise of satisfying emission limits. This paper has testing study about the SCR urea dosing system on the engine test bench, based on the developing, matching, calibration of SCR system on diesel engine of WP12, and aims at verify the system can satisfy China IV emission standard at the condition of dosing reasonable quality of urea and avoiding excessive NH3 escape. It has positive function for making scientific dosing control strategy and efficient and reasonable SCR matching and calibration. The contents of study include the following: urea dosing control strategy, optimum calibration of urea dosing quantity, catalyst dynamic temperature correction and so on. In the foundation of in-depth studying and analyzing of urea dosing strategy, according to the summary of calibration experience, and referring to relative technical material, the method of optimum calibration of urea dosing quality under steady testing state is put forward, the calibration calculation model estimating synthetical NOx emission during ESC test cycle is also established, which might help to control the NOx with a clear goal during SCR urea dosing quantity calibrating. Practice proved that this method can obviously improve working efficiency, save calibration time. Study of urea dosing strategy and dynamic temperature correction of catalyst converter, and ESC and ETC test result indicate that opening dynamic correction can effectively reduce urea consumption at the premise of satisfying emission limits. Under transient state, the secondary pollution caused by leakage of NH3 can also be effectively reduced. But at the same time, urea dosing quality should be optimized fatherly under steady state, so as to reduce the ratio of dynamic correction and improve the utilization effectiveness of SCR system as far as possible. In addition, the volume of catalyst substrate should be further reduced in order to reduce the total amount of substrate thermal storage and improve the catalyst converser's response ability to temperature change under the transient state.
Once more, due to the OBD system must be installed during stage IV, the study of control strategy, control algorithm and system development and calibration of OBD system is very necessary and time presses. Based on detection theory and the testing technical requirements of the OBD system, the development and the calibration of OBD1+NOx control stage on the WP12 heavy diesel engine which applied SCR technology is introduced in this paper, and certification test has been passed, which can indicate that the developed OBD fault diagnosis and emission monitoring strategies satisfy the online monitor and diagnosis request to engine.
At last, because the vast territory of China, the temperature difference is quite large between north and south in winter, and it may achieve -30℃below in north of Yellow River. Urea will freeze when the environment temperature is lower than -11℃, leading to the disable of SCR system urea supplying, resulting in restriction to the use of vehicle which apply the SCR system in these areas. But this problem can be solved effectively by heating the urea storage unit and flowing pipeline. With the purpose of ensuring the normal running of SCR system in north cold area, heating ability of the heating system must be distribute reasonably during the process of heating urea storage unit and pipeline, so as to maintain temperature of urea above the freezing point but not over-heating. Therefore, it is necessary to have a theoretical analysis and study in practical application condition to the heating function of SCR system. First, mathematical model estimating heat dissipating capacity is established by using heat transfer theory and thermodynamics knowledge, and referring to the relative technical material, which provides reference for the selection of urea pipeline and heating power; And then contrast selection under different heating power is done through simulation test in the cooled lab; At last, the whole system in the vehicle is tested in cold area to ensure the normal running request of the system in cold area of China. The study result of urea heating system indicates that urea tank heating by engine cooling water, urea supply module and pipeline heating by electric can solve the freezing problem of SCR system in cold area of China.
The study results have reference value to develop commercial diesel engine which can satisfy China IV emission limits, and have realistic social meaning to China for reducing commercial automobile diesel engine emissions and air pollution.
以尿素为还原剂的SCR(Selective Catalytic Reduction)技术由于具有可以通过优化缸内燃烧来改善燃油消耗和较强的抗硫中毒能力等优点,作为控制车用柴油机尾气排放的重要手段在欧洲等发达国家和地区已经得到了广泛的应用,对于改善由柴油汽车尾气造成的大气污染发挥了重要作用。由于我国排放法规体系等效采用欧洲法规体系,考虑到我国的国情和技术的移植便利性,我国各主要整车厂和柴油机企业也倾向于采用SCR技术作为满足未来更严格排放要求的主要技术措施。
目前,虽然国内几家主要车用柴油机企业已经在柴油机领域开展了SCR技术的研究,但基本上以国外技术引进应用为主,核心技术仍主要掌握在国外相关厂家手中,这成为我国该技术推广和应用的主要瓶颈,而我国随着道路运输的快速增长,车用柴油机需求量也正在迅速增加,其污染物的治理刻不容缓,急需成本低廉、性能高效的SCR排气后处理技术和装置。因此,有关SCR技术的国产化研究日益紧迫,对于SCR技术从催化剂性能研究、催化转化器优化设计到尿素喷射系统的控制策略的研究与应用、OBD系统的开发和标定,再到整个系统在整车上的集成和匹配应用的研究非常必要。
本课题针对SCR技术在WP12系列柴油机上的开发、匹配、标定为基础,采用试验评价、理论分析、数值模拟和试验验证相结合的方法对SCR技术实际应用进行了研究。主要内容包括:SCR催化反应系统的研究、尿素喷射控制策略和尿素喷射量标定的研究、SCR技术OBD系统的开发与标定、SCR系统在寒冷地区使用过程中存在的主要问题和解决措施。
首先,本文对SCR催化反应系统中DeNO_x效率的影响因素进行了研究,包括载体和催化剂的优化筛选、催化转化器结构的设计和优化、尿素喷射段管路内液滴粒子的分布等三个方面的内容。通过催化剂和载体的对比试验结果表明,规格为400/7的载体虽然压力损失最大,但影响并不明显,从成本和产业化的角度,可以选择其作为试验用催化剂载体;催化剂样品(2)无论在DeNO_x效率还是防止氨气逃逸方面都优于样品(1),且经过老化试验后性能也未明显下降,因此,选择催化剂样品(2)作为下一步试验的催化剂。设计了适用于重型车用发动机的箱式SCR催化转化器,并利用CFD技术进行了优化设计。对几种催化转化器设计方案的计算结果表明,入口管串孔区域长度和开孔区域角度范围分别存在一个最佳长度和角度范围可以使得各载体流量的分配最均匀;另外,在入口管底部设置一多孔式导流板可以消除底部的涡流,有利于改善流动效果,减少压力损失。利用CFD技术对尿素喷嘴的布置位置、角度和排气管直径大小进行了多种方案的对比计算和分析,并根据计算结果确定了合适的喷嘴安装位置和喷嘴安装角度,为SCR排气管段的设计提供了理论指导和参考,也为SCR系统与发动机的匹配试验打下了良好的基础。
良好的喷射策略不仅可以缩短标定周期,提高工作效率,而且能够在满足排放目标的前提下节省尿素的消耗。本文以SCR系统在WP12柴油机上的开发、匹配和标定为基础,在发动机台架上对SCR技术尿素喷射系统进行了试验研究,实现了通过对尿素喷射量的控制既满足国Ⅳ排放法规要求,又避免过量的氨气逃逸。这对制定科学的尿素喷射控制策略和高效、合理的SCR匹配、标定能够起到积极的促进作用。研究内容包括:尿素喷射的控制策略、尿素喷射量的优化标定、催化转化器动态温度修正等方面。在对尿素喷射策略研究分析的基础上,根据对标定经验的总结,并参照相关技术资料提出了稳态测试条件下尿素喷射量的优化标定方法,并建立了可以在ESC测试循环标定过程中对NO_x综合排放量进行估算的标定估算模型,在SCR尿素喷射量的标定过程中,可以对NO_x的控制有的放矢。实践证明该方法可以明显提高工作效率、节省标定时间、缩短标定周期。通过对尿素喷射策略和催化转化器动态温度修正的研究,及ESC和ETC测试循环试验结果表明,开启动态修正后在保证NO_x排放量满足要求的前提下能够有效减少尿素消耗量;在瞬态工况下,还可以有效降低NH_3逃逸造成的二次污染;同时,稳态工况下的尿素喷射量还需要进一步的合理优化,尽量减少动态修正的比例,提高SCR系统的利用效果。另外,应在优化SCR催化转化器结构的前提下进一步缩小催化剂载体体积,以减小载体的储热总量,提高催化转化器在发动机工况发生变化时对温度的瞬态响应能力。
由于从国家第Ⅳ阶段开始要求必须安装OBD系统,所以对OBD系统的控制策略和控制算法的研究、系统开发及标定等工作就非常必要。本文根据OBD系统的检测功能原理和检测技术要求,在应用SCR技术的WP12重型车用柴油机上进行了OBD1+NO_x控制阶段的开发和标定,并通过了认证试验,表明所开发的OBD故障诊断和排放监控策略满足对发动机在线监测和诊断的要求。
最后,由于我国地域辽阔,在寒冷季节南北地区气温相差比较大,北方地区冬季可达到-30℃以下,而尿素溶液在温度低于-11℃时会出现结冰或固态化等现象,导致SCR的尿素供给系统无法正常工作,造成配置SCR系统的车辆在这些地区的使用受到一定的限制。这一问题可以通过对尿素存储单元和流动沿程管路进行有效的加热来解决。为了确保SCR系统在北方地区寒冷季节的正常运行,在对尿素存储单元和尿素沿程管路加热过程中,必须确保加热系统的加热能力合理分配,使尿素溶液保持在结冰点之上,但又不加热过度,以免造成无谓的能量浪费。因此,有必要对SCR系统的加热功能进行理论分析和实际应用状态下的研究。本文利用传热学和热力学等方面的知识,在对尿素流动沿程管路尿素溶液、管路和环境空气之间传热分析的基础上,对尿素管路散热量进行了计算,提出了解决尿素存储单元和尿素管路结冰问题的解决措施,为尿素管路的选型和加热功率的选择提供理论指导;通过在低温试验室内的模拟试验对加热管路进行了不同功率的对比选型;最后将该系统配置在整车上进行了寒冷地区的试验测试,以确保SCR系统能够满足在我国寒冷地区正常使用的要求。研究结果表明,尿素存储单元采用水加热方式、尿素供给单元和尿素管路采用电加热方式可以有效解决SCR系统在寒冷地区使用过程中出现的结冰问题。
总之,本文研究结果对开发满足国Ⅳ排放商用柴油机具有一定的参考价值,对我国降低商用车柴油机排放、减少大气污染具有现实的社会意义。
As the aggravation of environmental pollution caused by vehicles, a series of legislations are put out to reduce emissions from automobile engines and more stringent. The after-treatment technology is one of the major measures to meet the emerging stringent emission legislation limits. Because of its advantage of higher power performance and lower oil consumption, diesel engines are widely applied in medium/heavy trucks and passenger carriages. However, the NOx and PM, which are the main emissions of diesel, can't be effectively solved for lean burn engines through TWC (Three-Way Catalysts) technology as gasoline engines due to the low NO_x conversion in the presence of oxygen. Thus, it is the time for diesel engines to develop appropriate exhaust after-treatment technology. In all the technology routes studied by diesel engine manufacturers to deal with Euro IV and Euro V standards two methods are concluded, which one is reducing NOx emissions with SCR (Selective Catalytic Reduction) technology on the basis of combustion optimization for diesel engines to reduce PM, and the other to debase NOx emissions with EGR (Exhaust Gas Recirculation) and PM with DPF.
The Selective Catalytic Reduction (SCR), using urea as reducing agent, because of the advantage of low oil consumption and strong resistibility, is presently considered the most promising technique for the removal of nitrogen oxides from the exhaust of heavy-duty diesel vehicles. It has contributed to control the emissions from vehicles in Europe. Due to our emission standard system is equivalent to the Europe standard system, in view of China's conditions and the convenience of technology explanting, manufacturers of vehicle and diesel engine are inclined to adopting the SCR technology as the major technology to meet the more stringent exhaust emission standards in future.
However, the study about Urea-SCR technology is not self-dependent currently in our country although the native manufacturers have been starting the application in SCR technology on heavy-duty diesel engines. Due to the key technology and patents for SCR system which are held by manufacturers abroad, they have been becoming the bottle-neck of the SCR techonogy extending and application in China. With the diesel vehicles are increasing significantly in our country, it is very urgent to reduce the pollutants from vehicles, and it has a rapidly increasing demand of the advanved SCR catalysts. Therefore, it is urgent for the domestic research of the relative SCR technology and is necessary to have a totally understand of them to prepare for the further study and domestically manufacture. So, it is more and more necessary to research the SCR technology, from the catalyst, the catalyst box design, the urea dosing control strategy and the OBD system, to the entire system in the vehicle integrating and matching.
In this paper, it's based on the SCR technology's developing, matching, calibration on diesel engine WP12, and the actually application of the SCR technology is deeply studied with the integration methods of experimental evaluation, theoretical analysis, numerical simulation and the experimental verification. The paper includes: the study of SCR catalyst reaction system, the study of urea dosing control strategy and calibration of urea dosing quality, the development and calibration of OBD system, the main problems and solution measures when the SCR system using in cold area. The following are the brief description and introduce of this paper in writing orders.
Firstly, the influence factors of DeNOx efficiency of the SCR catalyst reaction system are totally studied, include optimizing screening of substrate and catalyst, designing and optimizing of catalyst box structure and dripping distribution of exhaust pipe where dosing urea. As the result of contrast test to substrate and catalyst shows, through substrate 400/7 has the biggest pressure loss, it's not obviously and can be the substrate of catalyst in the test temporary from the view of cost and mass production; catalyst sample (B) is superior to catalyst sample (A) both in DeNOx efficiency and preventing NH3 disclosure, and after degradation testing its performance does not decrease obviously, therefore, catalyst sample (B) is chosen as the catalyst for the further test. SCR catalyst converters of box-type which are suitable for heavy-duty engines are designed and optimized by CFD. As the calculation result of the design schemes to several catalyst converters shows, there is a optimum length for inlet pipe area with holes and a optimum angle scale for the area with holes at which every substrate have the most even flow distribution; Furthermore, a flow guidance panel at the bottom of inlet pipe can remove the vortex in the base, and is in favor of improving flow effect and reducing pressure loss. CFD technology is used to have contrast calculation and analysis to the position and angle of the urea dosing system, and the diameter of exhaust pipe of different schemes.
Secondly, good dosing strategy not only can shorten calibration period, improve work efficiency, but also save urea consumption at the premise of satisfying emission limits. This paper has testing study about the SCR urea dosing system on the engine test bench, based on the developing, matching, calibration of SCR system on diesel engine of WP12, and aims at verify the system can satisfy China IV emission standard at the condition of dosing reasonable quality of urea and avoiding excessive NH3 escape. It has positive function for making scientific dosing control strategy and efficient and reasonable SCR matching and calibration. The contents of study include the following: urea dosing control strategy, optimum calibration of urea dosing quantity, catalyst dynamic temperature correction and so on. In the foundation of in-depth studying and analyzing of urea dosing strategy, according to the summary of calibration experience, and referring to relative technical material, the method of optimum calibration of urea dosing quality under steady testing state is put forward, the calibration calculation model estimating synthetical NOx emission during ESC test cycle is also established, which might help to control the NOx with a clear goal during SCR urea dosing quantity calibrating. Practice proved that this method can obviously improve working efficiency, save calibration time. Study of urea dosing strategy and dynamic temperature correction of catalyst converter, and ESC and ETC test result indicate that opening dynamic correction can effectively reduce urea consumption at the premise of satisfying emission limits. Under transient state, the secondary pollution caused by leakage of NH3 can also be effectively reduced. But at the same time, urea dosing quality should be optimized fatherly under steady state, so as to reduce the ratio of dynamic correction and improve the utilization effectiveness of SCR system as far as possible. In addition, the volume of catalyst substrate should be further reduced in order to reduce the total amount of substrate thermal storage and improve the catalyst converser's response ability to temperature change under the transient state.
Once more, due to the OBD system must be installed during stage IV, the study of control strategy, control algorithm and system development and calibration of OBD system is very necessary and time presses. Based on detection theory and the testing technical requirements of the OBD system, the development and the calibration of OBD1+NOx control stage on the WP12 heavy diesel engine which applied SCR technology is introduced in this paper, and certification test has been passed, which can indicate that the developed OBD fault diagnosis and emission monitoring strategies satisfy the online monitor and diagnosis request to engine.
At last, because the vast territory of China, the temperature difference is quite large between north and south in winter, and it may achieve -30℃below in north of Yellow River. Urea will freeze when the environment temperature is lower than -11℃, leading to the disable of SCR system urea supplying, resulting in restriction to the use of vehicle which apply the SCR system in these areas. But this problem can be solved effectively by heating the urea storage unit and flowing pipeline. With the purpose of ensuring the normal running of SCR system in north cold area, heating ability of the heating system must be distribute reasonably during the process of heating urea storage unit and pipeline, so as to maintain temperature of urea above the freezing point but not over-heating. Therefore, it is necessary to have a theoretical analysis and study in practical application condition to the heating function of SCR system. First, mathematical model estimating heat dissipating capacity is established by using heat transfer theory and thermodynamics knowledge, and referring to the relative technical material, which provides reference for the selection of urea pipeline and heating power; And then contrast selection under different heating power is done through simulation test in the cooled lab; At last, the whole system in the vehicle is tested in cold area to ensure the normal running request of the system in cold area of China. The study result of urea heating system indicates that urea tank heating by engine cooling water, urea supply module and pipeline heating by electric can solve the freezing problem of SCR system in cold area of China.
The study results have reference value to develop commercial diesel engine which can satisfy China IV emission limits, and have realistic social meaning to China for reducing commercial automobile diesel engine emissions and air pollution.
引文
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