Experience with 7000 Particle Filter Retrofits onroad and offroad in Switzerland. Andreas Mayer / TTM

Transcription

1 Experience with 7000 Particle Filter Retrofits onroad and offroad in Switzerland Andreas Mayer / TTM

2 PM- Emissionen onroad und offroad 60.0% 50.0% 40.0% 30.0% 20.0% 10.0% 0.0% Lieferwagen Schwere Nutzfahrz. Busse Personenwagen Onroad total Rail Navigation Construction machines Agriculture & Forestry Industry Military Offroad total

3 Swiss DPF Regulations 1990 (EJPD): Retrofit only permitted under conditions: - no additional Noise Emission - no Formation of secondary toxic Air Contaminants 1994: SUVA: Diesel-Emissions DME carcinogenic 1998: LRV: Diesel-Soot carcinogenic 1998: Limit for Stationary Engines < 5 mg/m3 2000: SUVA: PFS mandatory underground 2002: BUWAL-BauRLL: PFS mandatory for construction (B-type construction sites) 2003: only VERT approved PFS for onroad vehicles

4 Quality Control Instruments VERT-Standards Homologation Procedure and Field Control

5 Not all Filters are good Filters

6 VERT specifications for particle trap systems New 2000 hrs Filtration efficiency number count Number concentration of solid particles in the size range nm > 95% > 95% Filtration efficiency EC mass EC mass concentration Opacity during free acceleration No increase of limited emissions CO, HC, NOx and PM > 90% 0.12 m -1 85% < 0.12 m -1 No relevant increase of secondary toxic emissions

7 VERT Filter Suitability Test VFT1: PFS new VSET: Secondary Emissions Test (PAH, Nitro-PAH, PCDD/F and total > 150) VFT2: 2000 Operation Hours Field Test VFT3: Repetition of VFT1 after Field Test VERT-Approval BUWAL Filterlist VERT-Approval is lost at a Failure Level > 5 % pa

8 VERT- tested PFS Status 8/2003 Active Regeneration Passive Regeneration Filtration-Efficiency DEUTZ Full Flow Burner 98 old data ECS-UNIKAT Electr.Heating Catalyt.Coating HJS CRT, FBC (Additives) JOHNSON MATTHEY Electr.Heating CRT, FBC HUSS Electr.Heating Standstill-Burner DCL Electr.Heating Intake Throttling FBC, Catalyt.Coating ARVINMERITOR Full Flow Burner ENGELHARD CSF HUG Full Flow Burner Catalyt.Coating INTECO FBC EHC Exchangable TSH Electr.Heating Catalyt.Coating 98.90

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10 Possible Drawbacks: Cost Noise Backpressure Influence on Fuel Economy Risks for the Engine and Vehicle

11 Cost at low and high production volume Retrofit Cost at low volume today 25 kw :125 Fr/kW - 20 % of vehicle cost 100 kw: 100 Fr/kW - 8 % of vehicle cost > 250 kw: 80 Fr/kW - 5 % of vehicle cost Cost Reduction expected - Manufacturing Cost by 1/3 within 2 Years Cost of high volume DPF production - LDV: 2 % of vehicle cost - HDV: 2 % of vehicle cost COST-EFFECTIVENESS 1:4 (10)

12 Influence of Backpressure on Engine Performance limit 200 mbar

13 Impact on Noise

14 Possible Failures Common Failures and Measures/Methods for Quality-Improvement as introduced in Switzerland

15 Spectacular Filter Damage Ring-off-Cracks and Melting of the Cordierite Material source Johnson Matthey

16 Reasons for Failures: Local Temperature Peaks during Regenerations (source IBIDEN) Temperature ( ) Soot load : g (30.0 g/l) Max.temp. :951 Max.temp.grad. :84.5 /cm Regeneration rate : 94.5 % Time(min)

17 Ash Plugging of Filter Cells (source SHELL)

18 Reliability-History of PFS in Switzerland 1990: 230 Filters installed in Buses (DB/M&H-System) 1998: still 200 in Operation 2000: 2400 PFS in Operation, > 6% Failures pa too many Failures urgent measures 2003: > 6500 PFS in Operation - Failures < 2-3 % per year - PFS > km with Trucks and Buses - PFS > Bh with Construction Machines - PFS > Bh on a Ferry Boat 2005: Construction Directive > PFS expected Failure Target: < 1% pa

19 Character of Failures (1) Most Failures immediately after Retrofit Canning Failures of the Ceramic Monolith Material Failures of the Filter Media Cementing Failures with segmented Filters Mechanical Shock: during Transport or Installation Installation: often insufficient Vibration Decoupling Operation: wrong Fuel Sulfur Content too high Application: wrong System selected High Lubrication Oil Consumption

20 Character of Failures (2) Failures rare after long Operation: Backpressure-Alarms not respected Ash-Cleaning unprofessional Engine Maintenance careless Experience proves that VERT-Filters show no aging effects Filtration Quality remains constant

21 Measures to improve Quality introduced in 2000 One Filter Family lost VERT-Approval Introduction of the 2000-hrs Operation Test (VFT2) Electronic On-board-Control Access upstream of PFS for emission diagnosis Use of active Filter-Systems in critical applications Engine Maintenance and Instruction!!! Periodic Emission Control by User Systematic PFS-Selection (CD available) Use low-s fuels and LASP lubrication oils

22 VERT- Datalogger

23 Maintenance Sticker Emission Sticker

24 AKPF-Q-Label for PFS with outstanding Filtration Quality

25 Proper Filter Selection: BUWAL Interactive CD

26 Duty Cycle Analysis: 5 CH Bus-Fleets EFO

27 Planning for Switzerland Retrofits Construction (total ) today: Agriculture (total ) Trucks (total ) Buses (total 5 500) today: Incentives for new Vehicles LD-Vehicles Reduction of Import Tax (4%) HD-Vehicles Reduction of Road Tax LSVA Quality Criterion Ultrafine Particle Number Concentration

28 Summary and Conclusions (1) PFS have excellent emission reduction potential >99% very careful homologation and selection is needed PFS have long life and filtration does not deteriorate PFS are available for all applications PFS-cost is acceptable compared to health cost will soon be further reduced (increasing production and competition)

29 Summary and Conclusions (2) PFS-reliability is acceptable now if carefully controlled can be further improved ( 3% 1 % failure pa) Engine maintenance and periodic checks are very important no risk for the engine is backpressure is < 200 mbar Use of proper fuel and lube oil is important Applications can and will now be extended in Switzerland to HDV onroad, Agriculture Tractors and LDV

30 Thank You for your kind Attention We are ready for Questions now or later