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FEELING BLUE

AdBlue might be ammonia based, but don't risk putting fertiliser in your Euro-4 trucks. Sharon Clancy investigates.

AdBlue has become the generic name for the urea-based additive that 80% of truck engine manufacturers are using in Selective Catalytic Reduction (SCR) systems to convert oxides of nitrogen (N0x) into nitrogen and water vapour in order to meet the lower emissions limits on Euro-4 and Euro-5 trucks.

The main vehicle components of the SCR system are the SCR catalyst, the AdBlue injection unit, the AdBlue storage tank and the AdBlue dosing control unit.AdBlue is injected into the exhaust pipe upstream of the catalyst where its urea molecules react with heat and water to form the ammonia needed to convert the NOx molecules into nitrogen and water.

Dutch company GreenChem registered the AdBlue name in 20003, but has assigned the rights to the German vehicle manufacturers' association, the VDA.

AdBlue is a water-based solution containing 32.5% pure urea. Urea is manufactured in large quantities, particularly for use in fertilisers, so operators might be tempted to buy urea and make their own solutions. This is not a good idea because any urea solution that does not comply with the DIN standard 07 070 risks poisoning the catalyst and thus invalidating the vehicle's warranty.

Yara's AdBlue expert Paul Norman says:"If potassium and phosphorous levels are above the levels allowed by DIN 07 070 there is a big risk the catalyst will be poisoned. If the catalyst is poisoned it is impossible to regenerate it. You are then faced with an expensive bill to replace the catalyst."

AdBlue's DIN 07 070 specifies a urea concentration of between 31.8% and 33.3% with more than 0.2mg/kg of copper, zinc, chromium and nickel. Levels of phosphate, potassium, calcium and iron are restricted to 0.5mg/kg.

Storage

The good news in terms of storage is that AdBlue is non-toxic and non-hazardous.

The suppliers expect 70% to 80% of operators will have their own supply and will buy emergency supplies as and when needed from retail filling stations. GreenChem says on-board tanks should give a range of 7,000km between fill-ups.

However, there are some downsides. AdBlue is corrosive,so you'll need to be careful when specifying pumping and delivery equipment. It freezes at -11°C, and salt crystals will form at -9°C.

What extra precautions you need to take to prevent AdBlue freezing depends on where you are in the UK and how frequently the temperature is likely to drop low enough to cause problems. Robert Futcher works at Bell Flow Systems, which developed the dispensing equipment used by Yara."We are still exploring what operators actually need," he says,"but we can protect the AdBlue from crystalising or freezing by supplying heated mats that automatically switch on when the temperature drops below freezing, for example, preventing any damage to the pipes or tank.

"Once there are crystals in the solution it can impair the function of the pump. The crystals can also act as an abrasive on the seals, meaning pumps can start failing after just 200,000 litres."

Bell Flow's solution is an impeller pump:the shaft and housing are stainless steel to eliminate any corrosion problems. Futcher says: The impeller spins independently of the motor shaft which means any crystals are dispersed they do not collect around the seals."

Distribution

You might expect ALIBI= to be sold by the fuel and oil companies, but the AdBlue manufacturers are setting up their own independent distribution networks. This is partly designed to build operator confidence in its widespread availability for SCR-equipped vehicles, and partly so they can ensure supplies comply with the DIN standard.

The plan is that eventually the fuel distributors will start offering AdBlue, at least at retail forecourts.

Average AdBlue consumption is predicted to be about 5% volume of diesel consumption for Euro-4 and about 6% for Euro-5; that equates to roughly I .71iti1 00km on the road. From 2010 the manufacturers expect to be selling about 460,000 tonnes a year; shelf life is said to be about a year.

You'll be able to buy AdBlue in various quantities ranging from 5litre containers on fuel station forecourts to 50,000-litre tank containers. It's early days, so everyone is still hedging their bets on how big an AdBlue storage tank operators will need. "Some distributors are talking about very large storage tanks, but taking into account the dosage rate, we expect a 1.000-litre AdBlue tank to be sufficient for a 20,000-litre fuel bunker facility," says Futcher.

Dureal's UK business manager John Fatuhi points out that multi-depot fleets can control the cost of AdBlue installations by allocating their SCR-equipped vehicles to certain depots. -Don't put one or two SCR trucks into 15 sites," he says,"concentrate them in one or two depots."

Dutch company GreenChem is setting up distribution networks in 22 countries and is planning production sites in 13. including one in Mold, through a joint venture with Finnish chemical manufacturer Dynea.

It currently has two production plants, in Rotterdam and Gent, with another due to come online this year in Krems. UK production will start in 2006.

Independent distributors

GreenChem's main route to market will be through independent fuel distributors. although it is also planning a network of 1,5000 retail sites across Europe. GreenChem says its network is virtually ready in five countries, including the UK, and another 17 countries will be onstream by the end of 2005.

Most of GreenChem's competitors are multinational chemical companies which are adding AdBlue production to existing sites. They are teaming up with chemical distribution specialists to deliverAdBlue direct to end users as well as retail fuel distributors.

Norwegian chemical company Yara, for example, has teamed up with Brenntag to set up the Airl AdBlue production and delivery network while Univar has set up a dedicated AdBlue division called Dureal.

Yara claims to be Europe's largest manufacturer of urea and its distributor, Brenntag, claims to be Europe's largest chemical distributor.

Brenntag already supplies AdBlue from more than 60 European sites and guarantees supplies within 48 hours of ordering. A wide variety of delivery options are offered, including 1BCs (intermediate bulk containers of 1,000 litres), permanent mini-bulk units (several cubic metres) and portable canisters.

Pan-European availability

Airl is already in production at Yara's plant in. Brunsbtittel, Germany; preparations are under way to expand capacity at other Yara plants in Europe. Brenntag guarantees panEuropean availability within 48 hours.Yara will sell direct to the largest fleets leaving Brenntag to supply smaller fleets and the retail market.

GreenChem has developed a range of storage tanks under the Greenstar banner. Greenstar 2, for example is a 5,000-litre tank which can be expanded to 30,000 litres;it is designed for fleets of about 15 trucks. With IBC-sized tanks, distributors are expecting operators to rent the storage system and pay for the AdBlue.

All Dureal dispensers are fitted with telemetry that monitors AdBlue levels to avoid running out.The telemetry also monitors and controls temperature to make sure the AdBlue doesn't freeze.

"Operators do not have to worry about dipping tanks to check levels and we can hill monthly only for the actual amounts used,says Fatuhi.

For small and medium size operators Dureal supplies a 12501it base unit which can be expanded with a 1,0001it feeder unit. An insulated cover is available for outdoor use. There's also a starter set based on 2001it drums with an electric or hand pump, and Slit packs to be carried on board for emergency top-ups.

Dureal has come up with a mobile filling kit which it thinks will prove popular with contract-hire and rental companies.

"Rental companies will not have to worry whether customers have an AdBlue refill capacity," Fatuhi explains."Instead, they can deliver one of our mobile units when the trucks are delivered.

"The operator keeps the AdBlue kit for the duration of the contract and returns it with the vehicle. For one-off trucks and short-term rentals, the solution is to put a five-litre container in the truck." • CONTACTS Airl: 01469 554711 Bell Flow Systems: 0800 0277786 Dureal: 0161 741 70465 GreenChem: 31 765 812727 Kemira: 0151 357 5362