Retrofit Emission Controls for On- and Off-Road Diesel Engines Manufacturers of Emission Controls Association May 2006 www.meca.org DOCs and DPFs Form the Technology Base for Reducing PM Emissions from New and In-use Diesel Engines Diesel Oxidation Catalysts CO Aldehydes HC PAH SO 2 NOx CO 2 H 2 O SO 2 /SO 3 NOx Flow through monolith with catalytic coating Applicable to nearly all diesel engines; significant retrofit & OE experience base PM control through SOF oxidation significant reduction of toxic HCs Diesel Particulate Filters Standard on all on-road heavy-duty engines for 2007; > 1 million vehicles LDD in Europe; > 200,000 retrofits DOCs & DPFs can be combined with Crankcase Filters for additional PM control
Experience with DOC and DPF Retrofits Spans a Variety of On-Road Vehicle Applications Retrofit Experience is Expanding to Off-Road Vehicle Applications
Precious Metal Optimization/Placement Provides an Opportunity for Minimizing Catalyzed DPF NO 2 Emissions Example: Zoned Precious Metal Placement NO 2 emissions cut by more than 50% with zone coating CDPF with normal coating CDPF with zone coating, 65% less PGM SAE Paper No. 2006-01-1091 Retrofit DPF Options for PM Control Expanding Filter system options with active regeneration for cool exhaust applications emerging Diesel fuel combustion across a DOC provides regeneration heat source (similar to many 2007 heavy-duty OEM applications) Other active DPF options: electric heaters, fuel burners Heat DPF DOC Fuel Injection Unit Diesel vapor Exhaust gas
Active DPF Retrofits Include Locomotive and Marine Applications Burner-based active regeneration at 5g/liter soot Extruded SiC DPF SVR = 5 to maintain <30 mbar P Particulate Filters with Electric Regeneration Uncatalyzed wall-flow filter Electrically regenerated 1-8 hour regeneration cycle On- and off-road applications
Flow-Thru or Partial Filter Technologies Verified for Diesel Retrofits Metal Substrate with Sintered Metal Sheets 50-75% PM reduction Can be catalyzed, used with a DOC, or a fuel-borne catalyst Have applicability on older engines Resistant to plugging DOC + Partial Filter Retrofit Performance % Reduction - Hot FTP Test 100 90 80 70 60 50 40 30 20 10 0 HC - '91 Cummins N14 PM - '91 Cummins N14 HC - '89 Cummins C8.3 PM - '89 Cummins C8.3 De-greened DOC De-greened DOC + partial filter Aged DOC + partial filter (3600 hours of field aging on a 93 refuse hauler) Reference: SAE Paper No. 2006-01-0213
Integrated Solutions for Combined PM/NOx Reductions Available for Retrofit Lean NOx Cat. + DPF 25-35% NOx reduction DOC + SCR 70-80% NOx reduction Exhaust gases SCR catalyst Slip catalyst Precatalyst NH3 injection Emulsified Diesel Fuel + DOC or DPF 15-40% NOx reduction Low Pressure EGR + DPF 40-60% NOx reduction DPF+SCR Systems Are On the Road Verified Systems Expected Soon 15 L Engine: 74-82% NOx Reduction thru 75,000 mi 12 L Engine: 81-91% NOx Reduction thru 2 years of operation Reference: SAE Paper No. 2004-01-1289 10 trucks operated for more than 2 million cumulative miles (2 refuse, 8 tractors; 3 emission tested) 45 liters of SCR cats./engine (200 cpsi) Reference: SAE Paper No. 2005-01-1861
Key Considerations for Successful Retrofit Programs Application engineering matching the right technology to the vehicle or equipment Proper professional installation On-vehicle monitors provide important user feedback on performance Maintenance vehicles & retrofit equipment require frequent inspections and maintenance; variety of filter cleaning machines available (see MECA Filter Maintenance White Paper at www.dieselretrofit.org or www.meca.org) Successful Retrofits Require a Team Effort Between Fleet Owners, Operators, and Technology Providers Exhaust Temperature/Duty Cycle Assessment: Critical to Retrofit Technology Selection Raw Temperature Data Data Analysis Data imported into supplier database for analysis and storage Analysis/assessment for proper temperature criteria Feedback Response Documented to Customer Temperature Plot
Example On-Vehicle Monitor System: Provides End-User with Operational Feedback Diesel Particulate Filters Include Modular Designs to Accommodate Installation & Maintenance Most feature a removable filter centerbody for maintenance DPF Centerbody is heavy proper support is vital Inlet and Outlet Sections rotate to facilitate fit
Proper Retrofit Installation Critical for Safe Operation Filter Maintenance: DPFs Accumulate Inorganic Ash Materials and Require Regular Cleaning Ash captured in the filter... collected in filter bag using recommended cleaning practices... sealed in containers... and sent to the appropriate waste facility
Growing Diversity in U.S. Retrofit Projects: More than 250 projects documented in recent report prepared for EPA Retrofit experience report available at: www.epa.gov/cleandiesel/publications.htm Regional Diesel Collaboratives Promote Retrofit Initiatives Nationwide
New Retrofit Resource: www.dieselretrofit.org JUST ADDED: Updated Diesel Retrofit Technology Report & Case Studies for Retrofits on Construction Equipment Verified Closed-Loop TWC Retrofit System for SI LPG Fork Lifts Now Available ECM Wiring Harness Fuel Regulator Converter Muffler Reduces HC+NOx exhaust emissions from 12 g/bhp-hr (uncontrolled engine) to 1 g/bhp-hr, > 90% system efficiency
Diesel Retrofit Technology - Summary Retrofit technology options and application ranges continue to expand in the U.S. and other major world markets Efficient and well resourced ARB & EPA verification processes important to delivering proven retrofit technologies to the market State and federal funding programs provided needed incentives for diesel retrofits