1 Santiago BUS-DPF-Retrofit Swiss Contributions and Lessons of the Pilot Project 2004 Andreas Mayer / TTM
Emission Reduction Potential of DPF 2 120 100 80 60 40 20 0 Russ PAH Asche CO HC NOx krebserzeugende Substanzen
Principles for DPF-Retrofits 3 There must be a Will at involved levels HE-motivated Vehicles must be well maintained Low S-Fuel and LASP-lube oil available Drivers and Mechanics instructed Periodic Controls in place DPF must be VERT-certified and OBC-equipped Only DPF-manufacturer with specific experience Local Partners, well trained and local service support Financial, guarantee, data transfer issues solved at Start
Swiss Contributions 4 Consult and Discuss Overall Concept of the Program Type Approval and Quality Control - Criteria and Methods Selection and Evaluation of DPF-Candidates/Manufacturers Provide Dataloggers: Installation and Data Evaluation Particle Measurement: Instruments and Instruction Selection of Filter Systems for Pilot Test Evaluation of Pilot Test Data General Information on DPF- Experience Worldwide Advice on Methodology for Large Scale Retrofit
5 Concept of the Pilot Program Select 10 representative Vehicles Check on emissions, noise, fuel economy, oil consumption Select DPF-candidates based on Principles Monitor 10 candidate vehicles over 2 month duty cycle Install DPF and run 1. Emission Control on Chassis Dyno Field Test over 2 month / 10 000 km with data acquisition logbook, fuel and lube controls and detailed reporting on any event of malfunctioning 2. Emission Control on Chassis Dyno Based on Data and Information Approval for LS-Retrofit
6 Schedule of the Pilot Program 01.02.04: 1.Meeting Pilot Program Concept (Santiago) 19.03.04: Meeting with AKPF Filter Manufacturers (Zürich) 15.05.04: Datalogger installed 31.06.04: Datalogging w/o DPF complete 01.07.04: low S-Fuel (DIESEL CIUDAD PLUS) available! 05.07.04: DPF-System-Selection (Santiago) 16.08.04: ETH-conference; meetings (Zürich) 17.08.04: Start Retrofit last scheduled retrofit 10.09.04 06.09.04: First emission Test with Nanoparticle analysis (Me&TSI) 30.11.04: Second emission measurements concluded 13.12.04: Pilot Phase concluding meeting (Santiago) Impressive: how perfect this program has been managed by 3CV!
Vehicles and DPF Candidates 7
8 Monitoring - Datalogging Not only during Pilot Program Data Monitor is part of each Filter System
Installation with noise attenuation, heat insulation, vibration decoupling, access for measurements 9
Emission Control 10 Chassis Dynamometer NOx, CO, HC, PM = limited emissions Smoke during free acceleration Ultrafine Particles: SMPS and NanoMet Noise Field (road)- Control Smoke during free acceleration (not sensitive) Engine Dynamometer NOx, CO, HC, PM = limited emissions Smoke during free acceleration Ultrafine Particles: SMPS and NanoMet Size specific metal particle analysis Secondary emissions
11 Some Representative Data without/with Filter Exhaust-Temperatures Filter-Backpressures Exhaust-Emissions
Monitored History with Particle Filter Vehicle: TT 2191 Filter: Engelhard 1 12
Monitored History with Particle Filter Vehicle: NR 4362 Filter: Engelhard 2 13
Monitored History with Particle Filter Vehicle: TE 3776 Filter: HJS-CRT 1 14
Monitored History with Particle Filter Vehicle: SZ 5875 Filter: HUSS 2 15
Monitored History with Particle Filter Vehicle: TF 5204 Filter: ADASTRA 16
Monitored History with Particle Filter Vehicle: RR 1547 Filter: AIRMEEX 17
Monitored History with Particle Filter Vehicle: TZ 7737 Filter: Clean Air 18
Monitored History with Particle Filter Vehicle: UZ 2582 Oxidation Catalyst Südchemie 19
Average Exhaust Temperatures w/wo Filter for the whole Fleet 20 Chile: Transsantiago Pilot Project, Loggerdata Evaluation Status: 03.12.2004 Vehicles: 12 Measurements: 13.04.04 Ð 14.11.04 Average Exhaust Temperature [¼C] Sampling Interval 60 s Sampling Interval 4 s Overall Evaluation Sampling Interval 60 s; T Ð 50 ¼C Sampling Interval 1 s * 400 without / with Trap 350 Average 300 250 200 150 * * * * * * * * * * * * * * * * * 100 50 0 LD 8523 NR 4362 RR 1547 SZ 5875 TB 8691 TE 3776 TF 5204 TT 2191 TZ/UK/UY UZ 2582
21 Temperatures and Pressure w/wo Filter Vehicle: TT 2191 Filter: Engelhard 1 Vehicle: TT 2191. Status: 03.12.2004 400 350 300 250 200 150 100 50 0 Sampling Interval 1 s Sampling Interval 60 s Pressure Max. Sampling Interval 4 s Sampling Interval 60 s; Ð50¼C T Pressure Average without / with Trap Average 600 525 450 375 300 225 150 75 0
22 Temperatures and Pressure w/wo Filter Vehicle: NR 4362 Filter: Engelhard 2 Vehicle: NR 4362. Status: 03.12.2004 400 350 300 250 200 150 100 50 0 Sampling Interval 1 s Sampling Interval 60 s Pressure Max. Sampling Interval 4 s Sampling Interval 60 s; Ð50¼C T Pressure Average without / with Trap Average 600 525 450 375 300 225 150 75 0
0 0 23 Temperatures and Pressure w/wo Filter Vehicle: TE 3776 Filter: HJS CRT 1 Vehicle: TE 3776. Status: 03.12.2004 400 350 300 250 200 150 100 50 Sampling Interval 1 s Sampling Interval 60 s Pressure Max. Sampling Interval 4 s Sampling Interval 60 Ð50¼C s; T Pressure Average without / with Trap Average 600 525 450 375 300 225 150 75
0 0 24 Temperatures and Pressure w/wo Filter Vehicle: SZ 5875 Filter: HUSS 2 Vehicle: SZ 5875. Status: 03.12.2004 400 350 300 250 200 150 100 50 Sampling Interval 1 s Sampling Interval 60 s Pressure Max. Sampling Interval 4 s Sampling Interval 60 Ð50¼C s; T Pressure Average without / with Trap Average 600 525 450 375 300 225 150 75
25 Temperatures and Pressure w/wo Filter Vehicle: RR 1547 Filter: AIRMEEX 400 350 300 250 200 150 100 50 0 Vehicle: RR 1547. Status: 03.12.2004 Sampling Interval 1 s Sampling Interval 60 s Pressure Max. Sampling Interval 4 s Sampling Interval 60 Ð50¼C s; T Pressure Average without / with Trap Average 600 525 450 375 300 225 150 75 0
0 0 26 Temperatures and Pressure w/wo Filter Vehicle: TF 5204 Filter: ADASTRA Vehicle: TF 5204. Status: 03.12.2004 400 350 300 250 200 150 100 50 Sampling Interval 1 s Sampling Interval 60 s Pressure Max. Sampling Interval 4 s Sampling Interval 60 Ð50¼C s; T Pressure Average Average without / with Trap 600 525 450 375 300 225 150 75
0 0 27 Temperatures and Pressure w/wo Filter Vehicle: TZ 7737 Filter: Clean Air Vehicles: TZ 7737 / UK 8319 / UY 5202. Status: 03.12.2004 400 350 Sampling Interval 60 s Sampling Interval 60 s; Ð50¼C T with Trap Pressure Max. Pressure Average 600 525 300 450 250 375 200 300 150 225 100 150 50 75
Filtration Efficiency Aftertreatment Licence plate Filtration Adastra DPF VERT TF 52 04 99.909 % Airmeex DPF VERT RR 15 47 99.377% Engelhard DPF VERT NR 43 62 98.249% Engelhard DPF VERT TT 21 91 99.777% HJS DPF VERT TE 37 76 99.954% HJS DPF VERT TJ 92 89 98.588% HJS DPF VERT VF 37 42 99.975% Huss DPF VERT LD 85 23 99.998% Huss DPF VERT SZ 58 75 99.994% DOC DOC ZU 25 82 4.402% Filter X DPF UK 83 19 39.942% Filter Y DPF UY 52 02 34.143%
29 Filter-System Failures 2 Engelhard: no failure or malfunctions 4 HJS: 1 filter plugged/exchanged due to engine TC-failure 2 Huss: 1 filter plugged due to engine TC-failure 1 Airmeex: filter plugged/cleaned/survived during engine failure 1 Adastra filter plugged due to additiv dosing stop /cleaned/survived 1 CleanAir no failure or malfunctions All Filters and System Elements survived although 3 engines had major problems, Filtration after test was as good as before
Engine Failures 30 2 Engine TC-failures: quite unusual high amount of lube oil can plug the CRT-catalyst and when soaked by the filter damages the filter structure due to high regeneration exotherms. 1 Engine Piston-rod-bearing failures: followed by heavy piston seizing massive oil leakage to the exhaust combined with high smoke emission filter plugged DPF can not trigger such failures if backpresssure is under control backpressure monitoring, alarm if backpressure 200 mbar is exceeded.
Conclusions from Pilot Program 31 The Pilot Program has provided all required information: Emission reduction potential proved to be excellent Operating conditions are favorable for regenerations Installations, although tailor-made, survived Local companies can pick-up the retrofit-technology Enough filter systems approved to insure competition However: Engine failures are annoying improve maintenance Reporting on malfunctions must be improved Instruction on filter technology is now urgent First LS-retrofit phase must be very carefully supervised Emission control should be very frequent in first period
Recommendations for Large-Scale Retrofit-Phase 32 All Filters with electronic onboard control OBC with alarms Measurement before/after retrofit in each case by filter manufacturer (local partner) copy of protocol to 3 CV Filter Manufacturer must report every 3 month on number of retrofits, failures, malfunctions, guarantee cases 10 representative vehicles out of each group closely followed ( 1 year) by 3CV with frequent emission checks First 25 retrofits of each manufacturer be checked by 3 CV Introduce: LASP-Oils, Maintenance-Label, Emission-Label 2-year warranty for all filter elements and proper functioning
Truck-Installation in place of Muffler 33
34 Maintenance Label Emission Label
Low-S-Fuel and LASP-Lube Oils) 35
36 Thank You for your kind Attention We are ready for Questions now or later ttm.a.mayer@bluewin.ch