DECEMBER 4, 2014 — Tenneco (NYSE: TEN) has introduced a complete urea dosing control, fluid handling and catalyst solution for selective catalytic reduction (SCR) aftertreatment, enabling large engines to meet EPA Tier 4 and IMO Tier III regulations. The company is showcasing the complete system at the this week's Workboat Show in New Orleans.
The system is designed specifically for high-horsepower engines in the marine, stationary and locomotive markets, providing precise and reliable delivery of liquid urea. It includes a proprietary, high-performance injector design, a precision mechatronic fluid delivery pump and customizable remote monitoring and controls.
"We're excited to introduce an advanced SCR system specifically designed and purpose-built for large engine applications," said Timothy Jackson, chief technology officer, Tenneco. "The system provides a turnkey dosing solution which is compatible with a wide range of engine and aftertreatment architectures, and is supported by Tenneco's extensive full systems integration expertise."
Tenneco's large engine SCR system is designed to meet the requirements of major classification societies. The system is currently being validated with marine and large engine customers, and is expected to be ready for production in 2015.
Tenneco says that the system's modular design enables seamless integration for a broad range of engine sizes and works with electrically or mechanically controlled engines. It has been validated for durability and all components are easy to maintain and service without the need for special tools.
The fluid delivery system with dosing control software is capable of managing multiple injection points and sensors. The system can support urea flows up to 120 meters, which enables a wide array of installation options. Airless urea injection provides high dosing accuracy and consistency.
The system's unique Human Machine Interface (HMI) can be accessed on the front of the fluid delivery box or remotely via a touch screen tablet. It features an easy-to-use interface to access onboard diagnostic functions and to monitor and control all system parameters, including but not limited to NOx reduction performance and urea concentration levels in real time.
Tenneco's says that its SCR system has demonstrated effective NOx reduction in bench and field testing. In laboratory validation, the system achieved average NOx reduction efficiency levels of more than 90 percent.
In addition to effective emissions reduction, field testing highlighted how the system's form, fit, function and performance capabilities can be easily integrated into a vessel's engine and control architecture.
Field tests were conducted on a 224 ft Great Lakes training vessel powered by four 800 horsepower, circa 1984 Tier 0 engines. In a series of validation tests, including the ISO 8178 E2 cycle, when outfitted with the aftertreatment system, the 1984 Tier 0 engines met all criteria for IMO Tier III and EPA Tier III compliance including NOx, HC and SOx.
Tenneco has also tested the same SCR aftertreatment technology in a stationary diesel generator set, demonstrating the system's flexibility and scalability across multiple applications. When installed on a 970 horsepower, Tier II engine running ISO 8178 D2 cycle, the engine met all criteria for marine EPA Tier IV compliance.
Full Suite of Technologies and Integration Capabilities
In addition to liquid urea injection, dosing and control solutions, Tenneco's full suite of technologies for aftertreatment includes custom-engineered SCR catalysts and catalyst substrates. Along with joint development partner Cormetech, Inc. ( a leading manufacturer of honeycomb catalysts), Tenneco offers an ultra-large diameter substrate for marine engine applications. In addition to the 24" diameter catalyst developed with Cormetech, Tenneco's solutions can be integrated with other substrate sizes, including 13" round coated substrates and 6" extruded square substrates.
Tenneco offers industry-leading expertise designing proprietary mixing technology to efficiently convert injected urea droplets into the desired ammonia without the formation of deposits, especially in low temperature applications. For applications incorporating high-sulfur diesel fuel, Tenneco also offers soot blowers, which can be easily incorporated into the SCR system and integrated with the dosing control unit.
In addition to the design, development, engineering and manufacturing of components and systems, Tenneco also offers customers a collaborative approach to complete systems integration to help maximize efficiency and performance for each individual application.
Through its global network of emission control technical centers, the company offers design and integration capabilities, including computer modeling of exhaust, spray, mixing and cone geometry to help reduce development time and cost.