Diesel s Guide For Going Green
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1 Diesel s Guide For Going Green 1
2 Content Environmental Protection Agency (EPA) Selective Catalytic Reduction (SCR) Advanced Exhaust Gas Recirculation (A-EGR) Diesel Exhaust Fluid (DEF) DEF Specifications DEF Impurities DEF Consumption DEF Gauge and Tank Options DEF Storage DEF Handling DEF Packaging Styles DEF Pumping Systems
3 Prime Lube, Inc. Prime Lube, Inc., Carteret, NJ was established in 1987 and is currently one of the largest distributors of lubricants, engine oils and anti-freeze in the United States. Our brands are Chevron/Texaco, ExxonMobil BP/Castrol and our own, API certified brands, Prime Plus and Prime Ultra. 3
4 2010 Blue Sky East, LLC Prime Lube, Inc. and Kruse NA, one of the world s largest suppliers of DEF, have come together to form the new Joint Venture, Blue Sky East, LLC., that will manufacture DEF (Diesel Exhaust Fluid) in the Northeast, Mid-Atlantic, Heartland and Southeast U.S. Prime Lube, Inc. and their exclusive marketing partners, will supply DEF to 25 of the United States, as well as Washington D.C. and 2 Canadian Provinces. 4
5 EPA Standards Effective January 1, 2010, the U.S. Environmental Protection Agency (EPA) mandated that all diesel-powered passenger and commercial vehicles produced must have an 83% reduction in NO x emissions from the EPA 2007 emission requirement. EPA 2010 engine emissions must meet a NO level of 0.2 g/bhp-hr. The EPA has formally approved Selective Catalytic Reduction (SCR) technology to meet its 2010 emission standard. x 5
6 EPA Emissions Standards (1994 to 2010) 83% Less NO Than x The EPA 2010 standard requires engine emissions to meet a NO x level of 0.2 g/bhp-hr. 90% Less PM. The EPA 2010 standard lowered PM emissions to 0.01 g/hp-hr. Overall, 96% Less NO Than 1994! x 6
7 What is SCR? Selective Catalytic Reduction (SCR) is an emission control technology designed to inject Diesel Exhaust Fluid (DEF) into the exhaust stream that will convert nitrogen oxides (NO ), with an aid of a x catalyst, into nitrogen (N ) and water (H O). It is the after-treatment technology that treats exhaust gas downstream of the engine. SCR is a system that uses DEF to reduce NO 2 to near zero levels to meet the Environmental Protection Agency (EPA) 2010 emission regulations. 2 x 7
8 SCR Process 1. Diesel engine recycles the exhaust. a) NO and Particulate Matter travel to DPF x 2. Diesel Particulate Filter (DPF) traps the particulate matter and burns off the matter with a low grade heat. (The Filters do need frequent maintenance.) a) DEF is sprayed into the exhaust stream as the NO travels down to the SCR Catalyst. 3. DEF and NO x enter the SCR Catalyst together where they react and are converted to nitrogen and water vapor. 4. Nitrogen and water vapor are then released from the tailpipe. x 8
9 SCR Process 9
10 A-EGR Technology (Temporary Competitive Solution) Advanced Exhaust Gas Recirculation is a temporary competitive solution vs. SCR. Enhanced EGR reduces NOxby increasing the amount of engine exhaust gases recirculatedinto the engine cylinder, slowing and cooling the combustion process. Since the exhaust gases have already combusted, they don t burn again. These gases displace some of the normal intake, slowing and cooling the combustion process, which reduces NOxformation. This process doesn t require introducing DEF into the exhaust stream, but it does require more fuel to be injected into the diesel particulate filter for active regenerations. The increased heat created withthe enhanced EGR approach also requires a much greater cooling capacity for the engine. Navistar/International Truck is the only U.S. engine manufacturer using the EGR solution, combined with EPA carbon credits, to comply with EPA s 2010 NO emissions requirement. The question is, how long will these credits last? Tim Shick, Director of Engine Sales said, Our engines, of course, do not use SCR. We only use Advanced EGR. All of the emissions are handled within the engine itself. Our goal for the 2010 engines was to keep the fuel economy equal to 2007 levels. And we re very happy to say that we were able to improve our fuel economy, particularly with our big bore products. They re 2% to 3% better than the comparable 2007 engines. 10
11 Fuel Economy What are the OEM s saying? Volvo / Mack When we came out with the 2010 systems, we found that our fuel economy was 5% better than our 2007 engines. We are now claiming an 8% improvement in fuel economy for our current trucks. That s quite an accomplishment when you realize that we ve also reduced every regulated emission component by 99%. PACCAR PACCAR Test results, coupled with the experiences of operators, consistently demonstrated a 3% to 5% improvement, not counting the cost of diesel emission fluid, over the company s 2007 counterparts. Cummins - Cummins customers have been satisfied with increased fuel economy, as well as the performance and driveability of their EPA 2010 engines. The company promised a fuel economy improvement of 6% on the ISX15 compared to its 2007 model, and customers are realizing this in their daily operations with many citing even better results. Daimler Mercedes Damler Trucks North America (DTNA) drew on its European experiences in their Detroit Diesel engines. Our 2010 DD 15 increased fuel economy by 5% over a 2007 Series 60 engine. Customers are more than satisfied with the fuel economy they re getting. We have some customers getting upwards of 6%. We have one customer who replaced a number of 2004 engines with 2010 model engines. They reported that they are getting over 10% better fuel economy. 11
12 Fuel Economy What are the Fleets saying? From the Fleets: Darry Stuart, President and CEO of DWS Fleet Management Services, said, Performance has been much better than we feared. In fact, the performance they deliver certainly does not support all the complaining we did earlier. The new engines have offered very few problems. Performance is very good. We ve found them to be trouble-free. As far as operations goes, they have offered very little challenge. It really has been a non-event. Art Trahan, Senior Manager, Ryder Systems, who works closely with engine manufacturers on emissions, said, I almost feel that we should have skipped 07 and moved right into 2010 engines. These new engines are delivering 3% to 5% better fuel economy, as manufacturers told us they would. Performance has come back, eliminating driver complaints about the lack of power and torque. Start ability andgrade ability is acceptable as long as you specify the engine and drive-train for the job. We ve not had any complaints as far as power is concerned. So far it s been a good story. 12
13 Supporters of SCR OEM Diesel Engine Manufacturer using SCR: Cummins Mercedes-Benz Detroit Diesel Hino Mack PACCAR Volvo 13
14 Car Dealerships Using DEF 2010 Audi BMW Chrysler Dodge Ford Mercedes Benz Volkswagen 2011 Chevrolet GMC 14
15 What is DEF? Diesel Exhaust Fluid (DEF) is an ULTRA-PURE UREA solution that acts as a reductant. It is carried in a separate tank, and is then injected into the hot exhaust stream and absorbed onto a catalyst. DEF is an aqueous urea solution whose specifications are regulated by standard ISO It is a non-toxic, nonflammable, non-hazardous and non-explosive substance. might have a slightly pungent odor similar to ammonia. DEF is compounded of 32.5% urea and 67.5% deionized water. Urea is a compound of nitrogen that turns to ammonia when heated. 15
16 DEF Process The ULTRA-PURE UREA used to make Premium ULTRA-PURE DEF is made from liquefied Natural Gas that is refined into the size of pellets, or dry prill. The prill is then liquefied in a strict process with deionized water, into a very precise and exact DEF solution under the guidelines of the ISO, the API, and the EPA. 16
17 DEF Specification Specification-No.: ISO Parameter Value Unit Urea 32,5 ± 0,7 Weight % Density (@ 77 F) lbs/gals Refractive Index (@ 77 F) Alkalinity as NH3 < 0,1 Weight % Biuret < 0,3 Weight % Aldehyd < 5 mg/kg Insolubles < 20 mg/kg Phosphate (PO4) < 0,5 mg/kg Calcium < 0,5 mg/kg Iron < 0,5 mg/kg Copper < 0,2 mg/kg Zinc < 0,2 mg/kg Chromium < 0,2 mg/kg Nickel < 0,2 mg/kg Aluminium < 0,5 mg/kg Magnesium < 0,5 mg/kg Density at 20 C (= +69 F) 1,0870 1,0930 g/cm3 Sodium < 0,5 mg/kg Refractive index at 20 C 1,3814 1,3843 Potassium < 0,5 mg/kg Appearance: colorless, clear liquid 17
18 DEF Impurities Impurities can come from: Urea manufacturer DEF blending, mixing, packaging process and packaging Adding any type of additive during mixing process For example, adding an additive to improve DEF s freezing point Transportation and handling of DEF product Customer storage of DEF product Customer dispensing DEF out of container Customer transferring of DEF product into secondary container From secondary container into DEF tank Contamination of DEF tank on vehicle 18
19 DEF Storage DEF should be stored in a cool, dry, well-ventilated area, out of direct sunlight. DEF is a 32.5% solution and will begin to crystallize and freeze at 12 F (-11 C); which will cause DEF to expand 7% when frozen. So it should be stored between 23 F (-5 C) and 77 F (25 C). At 32.5%, both the urea and water will freeze at the same rate, ensuring that as it thaws, the fluid does not become diluted, or over concentrated. The freezing and unthawing of the DEF will not cause degradation of the product. Prolonged DEF storage above 75 F will reduce the shelf life 19
20 DEF Shelf Life 20
21 DEF Shelf Life vs. Temperature *Each increment in temperature that DEF is exposed to, for prolonged periods of time, decrements the shelf life.* 21
22 DEF Thawing Process DEF truck tanks and lines are equipped with heater systems so start up and normal operations of the vehicle will not be impacted. The DEF tank is warmed by the engine coolant, so while the engine idles during warm-up, the fluid will start to thaw enabling the engine to idle without DEF. Thawing Pace 1 minute 5 minutes 10 minutes 22
23 DEF Material Storage Compatible Storage Materials Stainless Steel Titanium Durable Plastic Rubber Incompatible Storage Materials Aluminum Magnesium Steel 23
24 DEF Consumption DEF consumption will be approximately 2% of the diesel fuel consumed. DEF will be consumed on a 50:1 ration with diesel. (For every 50 gallons of diesel fuel burned, you will use 1 gallon of DEF.) Actual usage will vary with driving conditions & engine performance. Heavy Duty: Annual Mile/Vehicle Annual Total Miles Avg. MPG/Truck Average DEF Tank Size (on Vehicle) Annual Fuel Consumption/G Est. Annual DEF Usage (gallons) allon of fuel Consumption DEF Fill-Ups/year 120, , ,000 2% Medium Duty: Annual Mile/Vehicle Annual Total Miles Avg. MPG/Truck Average DEF Tank Size (on Vehicle) Annual Fuel Consumption/G Est. Annual DEF Usage (gallons) allon of fuel Consumption DEF Fill-Ups/year 50,000 50, ,250 2%
25 DEF / Fuel Gauge Full Tank ¼Full Tank Empty Tank A DEF gauge, similar to a fuel gauge, will indicate the level of DEF remaining in the tank. There are indicators on the dash that will illuminate and alert the driver that the vehicle is low on DEF. If a vehicle is operated such that one would completely run out of DEF, the vehicle will be reduced to 55 MPH, if the tank is not replenished after a certain period of time, the speed will be again reduced, to 5 MPH. 25
26 DEF / Fuel Tank (Pick Up Trucks) Ford Pick Up Truck DEF Tank GM Passenger Van DEF Tank (Picture courtesy of: duramax-diesel-v8-engine.html) 26
27 DEF / Fuel Tank (Freightliner Trucks) *Pictures courtesy of Campbell Freightliner* 27
28 DEF / Fuel Tank (Kenworth Tractor) 28
29 DEF / Fuel Tank (Volvo Tractor) 29
30 DEF / Fuel Tank 30
31 DEF / Fuel Tank 31
32 DEF / Fuel Tank 32
33 DEF / Fuel Tank 33
34 SCR Catalyst *Picture courtesy of Campbell Freightliner* 34
35 DEF Package Availability ½Gallon OEM 1 Gallon Bottle 2.5 Gallon Bottle 55 Gallon Drums 275 Gallon Tote *For Bulk Storage and Dispensing Systems, contact your Prime Lube Representative.* 35
36 ½Gallon OEM Bottles Coupling to filler neck non-destructive and threaded for secure fit After threading onto filler pipe simple pressure on bottles bottom as inverted, opens to top seal to empty seconds to empty. Overflow protected Tamperproof Mercedes BLUETEC 36
37 1 Gallon Bottle Convenient one gallon bottle Packaged four bottles per case Available flex spout Attractive retail packaging Convenient commercial back-up DOT approved 48 cases per pallet 37
38 2.5 Gallon Bottles 2.5 gallon easy pour container Attachable flex spout Available 48 bottles per pallet DOT approved 38
39 55 Gallon Drum Available 4 drums per pallet Easy dispensing of DEF with Poly or Stainless steel hand pump Easy dispensing of DEF with electric pump, hose and filling pistol (valve) 39
40 IBC Totes Available in 275 gallons. IBC containers are stackable to 3 high. IBC is available with either an open or closed system. Container is sealed access caps secured with nylon plastics to expose any possible tampering of product. Easy assembly of Pump, Hose and Filling-pistol (valve). 40
41 Drum Dispensing Pumps 365 DEF Pump Nylon and stainless steel DEF dispensing pump w/o house. Fits 15 through 55 gallon drums with 2 bung opening. Includes bung adapter and discharge spout. Spout can be removed and hose attached. Dispenses 8oz. Per stroke DEF Rotary Pump Plastic Rotary DEF dispensing pump with telescopic down tube. Polypropylene and stainless steel construction. Dispenses 1 gallon per 16 revolutions. 375 DEF Lever Pump Lever style polypropylene and stainless steel DEF dispensing pump. Fits 15 through 55 gallon drums with 2 bung opening. Dispenses 12 oz. per stroke. 41
42 Drum Pump System 42
43 Tote Dispensing System 43
44 Single or Double Tote Storage Features: Insulated to maintain DEF temperature Wide Door access for ease of tote exchange Structure is lockable for security Pre-piped and wired for immediate dispensing Mag-Drive Pump (No seals) Flow meter with resettable totalizer SS Automatic Nozzle Suction Hose with quick connections Suction tube for mounting in Tote Lid Hose Reel for hose storage Options: Stainless Steel Level Probe Lighting available Filter with Polypropylene housing Heavy Duty Chemical Hose Components meet ISO Compliance Standards 44
45 Bulk Storage and Dispensing System Features: Insulated to maintain DEF temperature Pump recirculation for maintaining min. flow Structure is lockable for security Integrally mounted, lockable Fill Box Pre-piped and wired for immediate dispensing External Tank Venting Mag-Drive Pump (No seals) Flow meter with resettable totalizer SS Automatic Nozzle Options: Stainless Steel Level Probe Level Indicator mounted in Fill Box Telemetry for Remote Level monitoring Lighting available Filter with Polypropylene housing Heavy Duty Chemical Hose Components meet ISO Compliance Standards 45
46 Retail Dispensing System Features: Insulated enclosure with total containment Mag-drive pump (no seals) DEF tanks from 525gal to 2000gal Automatic shut-off valve Welded Stainless Steel pipe Stainless steel, lockable refill cabinet W heater with thermostat Compatible with retail dispensers by Dresser Wayne, Gilbarco, Gasboy and Bennett, as well as most standard POS systems Options: Stainless Steel Level Probe Level Indicator mounted in Fill Box Telemetry for Remote Level monitoring Filter with Polypropylene Housing Components meet ISO Compliance Standards 46
47 Retail Dispensing System 47
48 Non-retail Dispensing System 48
49 Retail Dispensing System 49
50 Tom Sensbach National Sales Manager Cell:
51 Q & A 51
Diesel s Guide For Going Green
Diesel s Guide For Going Green Table of Contents Environmental Protection Agency (EPA).............................. 6 Selective Catalytic Reduction (SCR).................................. 8 Advanced Exhaust
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