FOCAS® HOT GAS TEST RIG (FOCAS HGTR™)
 

The FOCAS® Hot Gas Test Rig (FOCAS HGTR™) is a high-flow, diesel-fueled, burner-based catalyst aging system which expands on the capabilities of the Southwest Research Institute® (SwRI®) FOCAS aging system. FOCAS is a computer-controlled, gasoline-filled burner system designed to simulate the aging conditions of an engine with or without the presence of lubricating oil-poisoning effects. SwRI designed the rig to accommodate full-sized catalyst systems and provide user-designed programmable aging cycles, allowing users to create aging cycles to meet specific needs.
 

Schematic diagram of FOCAS HGTR™ with a diesel DPF–SCR emissions system installed.

FOCAS HGTRTM Features

• Diesel-fueled exhaust
• Independent control of NO_x concentration (10–1200 ppm)*
• Temperature control (250–1000°C)†
• Flow control (up to 2300 kg/hr)
• Heat recovery, minimized heat loss and dilution for reduced fuel consumption
• 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 *Upper level limited by flow
• Temperature range varies and is a function of total flow

* Upper level limited by flow
† Temperature range varies and is a functionof total flow
 

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

Advantages of Burner-based Diesel Aging

Because most current diesel emission systems involve NO_x control technology, simulating diesel engine NO_x levels is an important part of an aging test stand. Since NO_x formation is closely linked to peak combustion temperatures (which are lower at lower pressures), burner-based aging systems produce lower NO_x levels than engine-based systems. The FOCAS HGTR™ uses a patent-pending method to control the exhaust gas NO_x from diluted burner baseline levels (~10 ppm) to levels up to 1200 ppm. The system uses closed-loop control based on NO_x sensor feedback. Varying NO_x concentration set points can be added to aging cycles, independent of temperature and flow setpoints.
 

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).

This flyer was published in June 2009.  For more information about FOCAS® Hot Gas Test Rig (FOCAS HGTR™), contact Cynthia Webb, Phone (210) 522-5873, or Bruce Bykowski, Phone (210) 522-2937, Engine, Emissions and Vehicle Research Division, Southwest Research Institute,  P.O. Drawer 28510, San Antonio, Texas 78228-0510.

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