Development of the two-stage SCR control strategy to satisfy ultra-low NOx emission regulation for heavy-duty diesel engine

The emission regulations for heavy-duty diesel engines regarding nitrogen oxide (NOX) are becoming increasingly stringent, particularly in relation to cold start cycles. While the two-stage selective catalytic reduction (SCR) has the potential to achieve ultra-low NOX emissions, several challenges remain, including the accurate prediction of ammonia (NH3) storage mass and the co-control of the two-stage SCR. The first step in this study involved the establishment of a rapid control prototype platform to facilitate the development and validation of a two-stage SCR control strategy. Secondly, an initial method for predicting the NH3 storage based on the mass conservation law was proposed, which was subsequently improved by filling and emptying experiments. The third step involved the development of a two-stage SCR co-control strategy, including obtaining the steady-state NH3 storage target value, dynamic correction for NH3 storage target value, regulation of NH3 storage, and control of the close-coupled SCR urea injector state. Finally, the two-stage SCR urea injection control strategy was certified under the world harmonized transient cycle (WHTC). The results demonstrate that the composite value of engine outlet NOX emissions under cold and hot start WHTC cycles is 13 g/(kW·h). Meanwhile, the composite value of tailpipe NOX emissions under cold and hot start WHTC cycles is 0.065 g/(kW·h), representing only 14% of the EU VI limit value of 0.46 g/(kW·h). Thus, the findings demonstrate that integrating an accurate NH3 storage prediction method with the two-stage SCR co-control function is crucial for heavy-duty diesel engines to achieve ultra-low NOX emissions.