The California Demonstration Program for Control of PM from Diesel Backup Generators (BUGs) U.S. Department of Energy s 9th Diesel Engine Emissions Reduction Conference Newport, Rhode Island August 24-28, 2003 J. Wayne Miller, Kent Johnson, John Lee, Marla Mueller, Bonnie Soriano, Bill Welch Supporting contributors: David R. Cocker III, Kathalena Cocker, Jim Lents, Don Pacocha, Sandip Shah, Alex Santos, Peggy Taricco University of California, Riverside Bourns College of Engineering
Today s Topics Background on California PM demonstration program for diesel backup generators Approach to measurement of PM emissions Emission results for: Uncontrolled sources Controlled sources
Today s Topics Current state of understanding about emissions from diesel backup generators. Approach to measurement of PM emissions. Background on California PM demonstration program for diesel backup generators. Emission results for: Uncontrolled sources Controlled sources Future work
EPA s AP-42 Emission Factors - Small Diesel SMALL DIESEL (< 600 hp) Emission Factor Emission Factor Emission Factor Emission (lb/hp-hr) (g/kw-hr) (lb/mmbtu) Factor Pollutant (power output) (power output) (fuel input) Rating NOx 0.031 18.85 4.41 D CO 6.68E-03 4.06 0.95 D SOx 2.05E-03 1.25 0.29 D PM 10 2.20E-03 1.34 0.31 D CO 2 1.15 699.20 164 B Aldehydes 4.63E-04 0.28 0.07 D TOC 0.00 Exhaust 2.47E-03 1.50 0.35 D Evaporative 0.00 0.00 0.00 E Crankcase 4.41E-05 0.03 0.01 E Refueling 0.00 0.00 0.00 E
UCR s Mobile Emission Lab
Schematic of UCR s Heavy-duty Mobile Emission Laboratory (MEL) Diluted Exhaust: Temperature, Absolute Pressure, Throat P, Flow. GPS: Pat, Long, Elevation, # Satellite Precision. CVS Turbine: 1000-4000 SCFM, Variable Dilution. Secondary Probe. Gas Sample Probe. Secondary Dilution System* PM (size, Mass). Drivers Aid. Gas Measurements: CO 2 %, O 2 %, CO ppm, NO x ppm, THC ppm, CH 4 ppm. Other Sensor: Dew Point, Ambient Temperature, Control room temperature, Ambient Baro, Trailer Speed (rpm), CVS Inlet Temperature. Dilution Air: Temperature, Absolute Pressure, Throat P, Baro (Ambient), Flow, Dew Point (Ambient). Exhaust: Temperature, P (Exhaust-Ambient), Flow. Engine Broadcast: Intake Temperature, Coolant Temperature, Boost Pressure, Baro Pressure, Vehicle Speed (mph), Engine Speed (rpm), Throttle Position, Load (% of rated).
Schematic of Secondary Sampling System Primary Tunnel
Inside the Mobile Laboratory
Verification of Secondary System for Measuring PM Verification testing performed at CARB HDDT test facility March 19, 2002 2000 Freightliner Tractor, CAT C-15 CARB provided the difference in measurements between CARB/UCR labs Test Cycle THC CO NO x CO 2 PM Hot UDDS 12% 18% 8% 2.7% 0.1%
Objectives for Diesel Backup Generator (BUGs) Project Cooperative project of the California Energy Commission and the California Air Resources Board Measure emissions from representative BUGs based on: Size (>300kw) Market share Age/emission standards Measure real world emissions Regulated gaseous emissions Regulated particulate matter (PM 2.5 ) emissions Speciated VOCs and SVOCs, including toxics for selected units Develop emission factors for AP-42. Uncontrolled and controlled emission factors.
PM Demonstration-Test Matrix Size Ranges 15 engines (300 to 750 kw) 3 engines (1000 to 2000 kw) Age Ranges Pre 1987 1987-1996 Post 1996 Manufacturers Caterpillar Cummins Detroit Diesel Corporation
PM Control Technologies Selected for Demonstration Emulsified Fuel Diesel Oxidation Catalysts Passive Filters Active Filter
Field Testing of Backup Generators (BUGs)
600 kw load bank 600 kg Steps: 1kw @ 415volt
Testing Protocol for Backup Generators 1. Cold start/idle for 30 minutes 2. ISO-8178B -- Type D2 constant speed Mode 1 2 3 4 5 Speed rated speed Load 100% 75% 50% 25% 10% Weighting Factor 0.05 0.25 0.3 0.3 0.1 Example: Where: GAS GAS M P i x GASi x n M W GASi i= 1 = n Pi WFi i= 1 Fi = overall emission factor of a given pollutant (lb/hp-hr or g/kw-hr) = emission factor of given pollutant at Mode i = load value at Mode i + auxiliary loads
Cold Start Emissions for the Detroit 92 at VAF NOx ppm CO ppm THC ppm 45 1000 40 Cold Start Emissions for the Detroit 92 at VAF (first 100 seconds) 900 NOx (ppm) 35 30 25 20 15 10 5 0-5 NOx (ppm) NOx ppm CO ppm THC ppm 45 1000 40 900 35 800 700 30 600 25 500 20 400 15 300 10 200 5 100 0 0 0 10 20 30 40 50 60 70 80 90 100-5 -100 Time (sec) 0 0 200 400 600 800 1000 1200 1400 1600 1800 800 700 600 500 400 300 200 100-100 Time (sec) CO and THC (ppm) CO and THC (ppm)
PM 2.5 Emission Factors 0.35 AP42 =1.34 g//kw-hr 0.3 0.25 PM (g/kwhr) 0.2 0.15 0.1 0.05 0 1 11C 3 7 9 9C 12 10 10C 4 5 2 6 Bug ID Number
BUG Emissions with Fuel Change
PM 2.5 Emission Factors: Diesel-water Emulsion with Newer BUG Baseline LUBRIZOL 0.9 0.8 0.7 0.6 PM g/kwhr 0.5 0.4 0.3 0.2 0.1 0.0 M10 M25 M50 M75 M100
PM 2.5 Emission Factors: Diesel-water Emulsion with Older BUG Baseline LUBRIZOL 40 35 30 25 PM g/hr 20 15 10 5 0 M10 M25 M50 M75 M100
BUG Emissions with Control Device
Maintenance Cycle Cold Start Temp Profile for a 3406C CAT BUG Exh Temp Coolant Temp Logger Temp Ambient Temp Back Pres 450 400 Cold Start Count = 12 49 44 350 39 Temperature (F) 300 250 200 150 34 29 24 19 14 Back Pressure (inh20) 100 9 50 4 0-1 2/5 2/6 2/7 2/8 2/9 2/10 2/11 2/12 2/13 Month/Day
Diesel Oxidation Catalyst
PM 2.5 Emission Factors with Diesel Oxidation Catalyst Baseline DOC 0.9 0.8 0.7 0.6 PM g/kwhr 0.5 0.4 0.3 0.2 0.1 0.0 M10 M25 M50 M75 M100
Measurement of Elemental and Organic Carbon 4 3.5 3 EC/OC 2.5 2 1.5 1 0.5 0 0% 20% 40% 60% 80% 100% % Load 1999 M1 2000 M3
Passive Diesel Particle Filter
Control of New BUG with DPF 0. 8 0. 7 0. 6 0. 5 0. 4 0. 3 0. 2 0. 1 g/kw-hr Uncont ol l ed Wi th DPF 0 10% 25% 50% 75% 100% Per cent Load
Active Diesel Particle Filter System
Control of Older Two-stroke BUG
Control of Older BUG EC & OC for Uncontrolled Old BUG 0.50 g /kw-hr 0.40 0.30 0.20 OC EC 0.10 0.00 100 75 50 25 10 Percent load
Control of Older BUG Effect of DOC on PM 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 g/kw-hr 100 75 50 25 10 Percent Load PM -uncontrolled PM with DOC
Looking Ahead Test larger (>1,000 hp) BUGS in uncontrolled mode. Complete demonstration of PM control for ongoing activities including: Control of older 2-stroke diesel engines with a fuel borne catalyst and diesel oxidation catalyst. Control with fuel borne catalyst additive and bare filter. Demonstrate combined system of PM control plus selective catalytic reduction (SCR) for control of PM and NOx. Transition of data to EPA s AP-42 tables for general use.
Conclusions Results showed that emission factors for the uncontrolled BUGs were less than in the AP-42 tables. With control technology, the PM emissions can be reduced from 15% to 99.8+%. Selection of the control technology depends on a number of factors, including PM characterization.
Thank You Sponsors! US Environmental Protection Agency (US EPA) California Air Resources Board (CARB) California Energy Commission (CEC) South Coast Air Quality Management District (AQMD) Detroit Diesel Corporation International Truck & Engine Caterpillar Cummins Mack Volvo