Emission Control System

EAT system (Exhaust After Treatment System)

 

Increasingly stringent emission standards are driving engineers to develop top-performing exhaust aftertreatment systems (EAT systems) that are not only compliant with future emission standards but also fit into minimal spaces. Proventia provides full-scale emission knowhow and expertise in integration. We provide selective catalytic reduction (SCR), diesel particulate filter (DPF), diesel oxidation catalyt (DOC), urea/ AdBlue®/ DEF mixing technologies and components integrated into a fully tailored system to meet present and future Euro, Stage and Tier standards.

We design and engineer emission control systems in close co-operation with engine manufacturers, using their own emission control concepts and certified components and combining them with Proventia´s own innovations and products for urea mixing or thermal management. Selective catalytic reduction (SCR) technology and urea mixing are Proventia´s key competences in EAT systems.

 

 Our strengths

 

  • Long experience of various engines, applications and their usage in challenging environments
  • Specific SCR and urea/ AdBlue®/ DEF mixing expertise
  • Proven track record of EAT system development
  • Own innovations combined to proven technology platforms
  • Genuinely agile engineering process

SuperTornado urea mixing technology

 

SCR technology uses ammonia in the form of a urea-water solution (DEF/ AdBlue®) as a reducing agent for catalytic reactions. Particularly if an airless injector is used, the urea solution has a tendency to form deposits (urea crystallization) in the process of evaporation and decomposition into ammonia.

 

To prevent the build-up of deposits and to obtain good uniformity in the catalyst cell, an efficient mixer is needed. Particularly in limited-space applications and in real driving cycles that include slow driving with low loads, the high NOx reduction targets of today´s regulations cannot be reached without efficient urea mixing. The key to solving mixing problems is to have an effective urea mixer, such as the Proventia SuperTornado™.

More urea at low temperatures

 

As a rule, the longer the mixing length is, the easier it is to achieve optimal urea mixing. In diesel engines, particularly in those applications that require a compact design, there is no space available for longer pipelines.

 

Proventia SuperTornado will allow injecting more urea solution at low temperatures and in minimal pipe lengths. Proventia SuperTornado mixer technology contributes to even ammonia (NH3) distribution and improves overall SCR performance by inducing turbulence and enhancing ammonia (NH3) mixing within the exhaust gas.

Applicability of SuperTornado urea mixing technology

 

Proventia SuperTornado urea mixing technology is a flexible platform that can be used with various urea dosing systems to solve deposit problems and improve SCR performance in many applications with different engine sizes and in a variety of operating environments. The Proventia SuperTornado™ enables the design of compact EAT systems for applications that have limited space requirements. The system can be integrated with DPF substrates if the chosen emission strategy requires DPF.

 

Proventia designs the SuperTornado urea mixing technology to fit the customer´s application and to meet any specific needs and provides support in dosing strategy calibration as well.

How does it work?

 

The Proventia SuperTornado urea mixer has two separate swirling concentric flows. Urea is injected into the central flow, where the small droplets evaporate and bigger droplets travel further down the mixer to where the two flows meet. When the droplets reach the stronger outer flow, the velocity difference between flow and droplet rises rapidly, resulting in a high evaporation rate. With SuperTornado, evaporation and mixing is effective, leading to ammonia uniformity values exceeding 0.99, allowing more precise amounts of urea to be injected into the exhaust gas – even at lower temperatures – which eventually results in increased NOx reduction and the best possible use of SCR catalyst chemistry.

Key features

 

The greatest benefit from the mixing technology is for SCR performance and NOx reduction at low temperatures in real driving circumstances.

 

  • Ensures optimal reaction with ammonia
  • Allows increased urea solution injection even at low exhaust temperatures
  • Allows shorter mixing pipes to be used
  • Gives even NH3 distribution
  • Required NOx reductions also in real driving emission (RDE) tests

For more information Download PDF

DPF (Diesel Particulate Filter)

 

Diesel particulate filters are precious-metal-coated wall-flow filters. World-leading coating technologies of the filters we use guarantee a one-of-a-kind purification performance with over 90% PM reduction and long-term chemical durability.

 

How does it work?

 

Diesel particulate filters collect the particulate matter on the surface and inside the filter. Collected particulates are removed from the filter through active or passive regeneration.

dpf

Diesel oxidation catalysts (DOC)

 

Diesel oxidation catalyst (DOC) technology reduces effectively hydrocarbon (HC) and carbon monoxide (CO) emissions as well as the soluble organic fraction of the particulate matter (PM).

 

How does it work?

 

HC and CO as well as PM emissions are oxidised into harmless products such as carbon dioxide (CO2) and water (H2O) over a precious-metal-coated catalyst. The choice of catalyst formulation depends on the duty cycles and the temperature conditions of the application. Particulate matter is oxidised through reactions with nitrogen dioxide.

Doc

Selective Catalytic Reduction (SCR)

 

The use of selective catalytic reduction (SCR) technology for reducing emissions of nitrogen oxides (NOx) in diesel engine applications is growing as emission standards like Stage 5 come into force. SCR is an effective and reliable technology that is suitable for a broad range of diesel engines and applications.

How does it work?

 

SCR uses urea (AdBlue®/ DEF) to reduce NOx over an SCR catalyst. An SCR system consists of an SCR catalyst, urea dosing system, urea tanks, urea mixer, urea lines, various sensors and a control unit that controls the whole SCR operation. Other technologies such as DOC or DPF for reducing particulate matter (PM) can be integrated into the system, if the engine manufacturer´s chosen emission strategy requires this.

SCR and Stage 5 emission standard

 

The proposed Stage 5 regulations for non-road applications in the EU will require highly advanced PM and NOx emissions reduction technologies. This means that SCR technology is increasingly being used in diesel applications. Manufacturers of smaller diesel machines in particular will face a challenge with the stringent emission standards, as the lack of space is obvious, yet SCR technology requires a number of EAT system components to be fitted into a machine’s design. Stage 5 exhaust systems require integrating and optimizing all components; and this is what we do best. Proventia also has ultra-compact EAT design platforms that fit even the tightest space requirements.

 

To comply with Stage 5, manufacturers of bigger diesel machines are expected to combine an SCR system and a diesel particulate filter (DPF). High NOx reduction targets mean that the SCR performance needs to be improved in every possible way, and this is where we can offer our best knowhow with engineering services, urea mixing expertise and thermal management skills.

Exhaust Accessories (Mixing pipes, exhaust pipes)

 

Single components and accessories can play a significant part in the operation of today´s complex exhaust systems. We provide our engine, exhaust and emission know how also on a component level. We design and develop key exhaust system components such as urea mixers, mixing pipes, exhaust piping that help our customers´ engines fulfill emission requirements.

We design flex pipes, elbows, clamps and fittings. We design and develop integrated thermal components to protect any heat sensitive engine parts. Our advanced design tools enable us to optimize all components and support cost-efficiency in product development and manufacturing of the components. We are a one-stop shop for OE manufacturers, providing all the necessary components and accessories related to exhaust after treatment systems.

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