Program Overview
This program provides engineering and technical teams with a deep, application-focused understanding of Selective Catalytic Reduction (SCR) systems used in modern BS-VI/Euro-VI engines. Covering NOx formation, SCR reaction chemistry, DEF/urea injection, catalyst selection, temperature window management, ammonia slip, OBD diagnostics, and common field failure modes, the course blends conceptual clarity with real-world OEM and fleet case studies. Participants gain situational awareness of practical integration challenges, sensor behaviour, dosing errors, catalyst ageing, and regulatory constraints. Through structured calculations, diagnostic exercises, and simulation-based scenarios, attendees learn to analyse emission data, identify root causes, and implement corrective actions that improve SCR performance, compliance, and durability.
Features
- Interpret NOx formation mechanisms and apply SCR reaction chemistry for effective NOx reduction
- Diagnose SCR system issues including dosing errors, catalyst ageing, ammonia slip, and sensor failures
- Optimise catalyst temperature windows, DEF usage, and mixing strategies using real emission data
- Apply root-cause analysis and recommend corrective actions for SCR performance and compliance issues
Target audiences
- Engine development, aftertreatment & emissions engineering professionals
- Calibration, OBD, diagnostics & ECU controls engineers
- R&D, design & testing teams working on BS-VI/Euro-VI platforms
- Quality, validation, durability & warranty engineering teams
- Operations, plant technical, and fleet/maintenance professionals handling SCR-equipped engines
Curriculum
- 6 Sections
- 42 Lessons
- 1 Day
Expand all sectionsCollapse all sections
- Fundamentals of NOx Formation & Emission Challenges9
- 1.1NOx formation in engines
- 1.2Thermal NOx, fuel NOx, prompt NOx
- 1.3Effect of AFR, temperature, pressure, load
- 1.4BS-VI / Euro-VI NOx limits
- 1.5Why NOx is critical vs HC/CO/PM
- 1.6OEM challenges: transient cycles, aftertreatment warm-up
- 1.7Sector examples: CV, HCV, off-road, gensets
- 1.8Case Based Learning- NOx spike in cold conditions; NOx under high-altitude operation; Field warranty issues linked to NOx sensor failure
- 1.9Activity: Interpret NOx emission data from a real drive cycle
- SCR System Architecture & Chemical Principles9
- 2.1Fundamentals of SCR Urea; ammonia; reduction reactions
- 2.2Reduction mechanisms: Standard SCR, Fast SCR, Slow SCR
- 2.3Case Based Example: Impact of exhaust temperature window
- 2.4Uniformity index & mixing efficiency challenges
- 2.5Impact of sulphur, contaminants, and DEF quality
- 2.6Exercise: Map catalyst type vs temperature window using a sample scenario
- 2.7Case Based Learning: Ammonia storage/availability issue in cold climates
- 2.8Cross-industry catalyst poisoning cases
- 2.9Activity: Map catalyst type vs temperature window using a sample scenario
- DEF / Urea Handling, Injection & Ammonia Generation8
- 3.1SCR reducing agents (DEF/AUS32)
- 3.2Urea decomposition; ammonia generation (from Ammonia Generation from Urea)
- 3.3Case Based Example: DEF freezing, crystallisation, contamination
- 3.4Spray atomisation issues, injector clogging
- 3.5OBD requirements for dosing
- 3.6Case study: Under-dosing vs over-dosing
- 3.7Case Based Learning: Ammonia slip events during high-load operation
- 3.8Activity: Analyse a DEF dosing vs NOx reduction dataset
- Catalyst Types, Reactions & Temperature Window Optimisation7
- 4.1V2O5-based, Cu/Fe-zeolite catalysts
- 4.2Reaction pathways & optimal windows
- 4.3Ageing behaviour & sulphur sensitivity
- 4.4Case Based Example: Catalyst durability, thermal shock, long-term performance
- 4.5Real challenges: high-temp tolerance, ammonia slip, deactivation
- 4.6Case Based Learning: Catalyst ageing in high-load HCV; SCR deterioration in stop-start urban buses
- 4.7Activity: Temperature window selection for given real-world duty cycle
- Full SCR System Operation, Diagnostics & Troubleshooting7
- 5.1SCR system components (from SCR Operation & System Components)
- 5.2Sensors: NOx (upstream/downstream), temp, ammonia sensors, DEF quality sensor
- 5.3Regeneration & control strategies
- 5.4Typical failure modes- clogging, low conversion efficiency, NH₃ slip
- 5.5Impact of poor mixing: ammonia distribution & uniformity index
- 5.6Case Based Learning: OEM case of excessive ammonia slip, SCR overheating during regen events, Sensor drift leading to false diagnosis
- 5.7Activity: Root-cause analysis of an SCR failure event
- Integrated Industry Case Study & Simulation Workshop2
- 6.1Real SCR system scenario: Engine struggling to meet NOx limits; Ammonia slip detected during transient operation; DEF consumption unusually high; Catalyst performance degrading after ageing
- 6.2System-level diagnosis; Reaction mechanism mapping; Identify dosing fault / uniformity index issues; Recommend corrections (hardware + software + calibration)
Instructor
