SwRI: FOCAS Hot Gas Test Rig accommodates full-sized catalyst systems

  image of a schematic diagram of FOCAS HGTR with a diesel DPF-SCR emissions system installed
 

A schematic diagram of FOCAS HGTR with a diesel DPF-SCR emissions system installed. Click image to enlarge.

The FOCAS® Hot Gas Test Rig (HGTR™) is a high-flow, diesel-fueled burner-based catalyst aging system that expands on the capabilities of the Southwest Research Institute (SwRI) FOCAS aging system.

 

FOCAS is a computer-controlled, gasoline-fueled burner system designed to simulate the aging conditions of an engine with or without the presence of lubricating oil-poisoning effects.

 

SwRI designed the hot gas test rig to accommodate full-sized catalyst systems and provide user-designed programmable aging cycles, allowing users to create aging cycles to meet specific needs.

 

FOCAS HGTR Features

  image of chart showing measured NOx and CO concentration data as a function of NOx control signal on FOCAS HGTR
 

Measured NOx and CO concentration data as a function of NOx control signal on FOCAS HGTR.

  • Diesel-fueled exhaust

  • Independent control of NOx concentration (100 to 1,200 ppm)

  • Temperature control (250 to 1,000°C)*

  • Flow control (up to 2,700 kg/hr)

  • Heat recovery, minimized heat loss and dilution for reduced fuel consumption compared to an engine

  • Separate burner and dilution air controls

  • Full FMEA (failure modes and effects analysis) safety monitoring and response

  • Ability to add oil component to aging

  • Ability to add water vapor

*Temperature range is a function of total flow.

 

Advantages of FOCAS Burner-Based Diesel Aging

 

Fuel Cost Savings
  image of chart showing examples of the impact of burner dilution, heat recovery, and heat loss on fuel savings.
  image of chart showing examples of the impact of burner dilution, heat recovery, and heat loss on fuel savings.
 

Examples of the impact of burner dilution, heat recovery, and heat loss on fuel savings. The FOCAS HGTR will utilize heat recovery and dilution for fuel cost savings compared to engine aging. The real fuel savings will be directly related to real burner outlet temperature (which is affected by heat loss) and the level of dilution that can be utilized (which will be affected by required catalyst inlet temperature, efficiency of heat loss recovery, and burner heat loss efficiency.

Because most current diesel emission systems involve NOx control technology, simulating diesel engine NOx levels is an important part of an aging test stand. Since NOx formation is closely linked to peak combustion temperatures (which are lower at lower pressures), burner-based aging systems produce lower NOx levels than engine-based systems. The FOCAS HGTR uses a patent-pending method to control the exhaust gas NOx from burner baseline levels to levels as high as 1,200 ppm.

 

The FOCAS HGTR system uses closed-loop control based on NOx sensor feedback. Varying NOx concentration set points can be added to aging cycles, independent of temperature and flow setpoints.

 

For more information about the FOCAS Hot Gas Test Rig (HGTR) capabilities at SwRI or how you can contract with SwRI, please contact Cynthia Webb at cwebb@swri.org, (210) 522-5873, or Bruce Bykowski at bbykowski@swri.org or (210) 522-2937.


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Southwest Research Institute® (SwRI®) is an independent, nonprofit, applied engineering and physical sciences research and development organization with 12 technical divisions using multidisciplinary approaches to problem solving. The Institute occupies more than 1,200 acres and provides nearly two million square feet of laboratories, test facilities, workshops, and offices for more than 3,300 employees who perform contract work for industry and government clients.