Understanding Diesel Retrofit Technologies

Lanny ColeCummins Atlantic LLCFiltration and Emission Sales Manager

North Carolina, South Carolina, and Virginia

704-588-1240 ext 202

Diesel Emission Retrofit Projects

Why Retrofit ?

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Why Reduce Emissions?

Health Effects

Economic Effects

Environmental Effects

EPA estimates that for every $1 spent on retrofit, there is a $13 return on healthcare cost

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Evolution of On-Highway Standards - EPA

0.010.01 0.100.10

0.20.2

1.21.2

2.52.5

4.04.0

5.05.0

EPA 1994

EPA 1998

EPA 2004

PARTICULATE [g/HP-hr]

NO

x [

g/H

P-h

r]N

Ox

[g

/HP

-hr]

Euro 2 1996

EPA 2010*

EPA 2007*

0.0750.075 0.110.110.0150.015

* Aftertreatment Required

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Key Regulated By-products

Nitrogen Oxides – air quality / smog (Ground Level Ozone)

PM - health effects– 56% emitted of PM attributable to diesel engine

– Black smoke

HC / CO / Toxic Hydrocarbons – smell

Retrofitting Existing Diesel Engines with Emission Control Technologies is the primary way to reduce emissions

Diesel Emission Basics

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Engine design changes– Combustion– Air handling– Exhaust gas recirculation (EGR)– Closed Crankcase Ventilation (CCV)

Fuels– Ultra Low Sulfur Diesel– Additives? – Water emulsions?– Biodiesel?

Exhaust after-treatment– Diesel Oxidation Catalysts – >25% PM, > 70%HC and >40% CO reduction– Passive (catalyzed) Filters - >85% PM reductions, HC & >70%CO reduction, – Active (electric, non-catalyzed) Filters - 85% PM reduction – NOx Reducing Catalysts - 85% PM reduction, 25% NOx reduction, HC & CO

reduction– Selective Catalytic Reduction (SCR) 60-90% NOx reduction, HC & CO reduction

CCV

EGRCombustion advances

Ways to Reduce Emissions?

DPF

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Verification What does verified technology mean?

– Process that EPA and CARB use to certify a technology does what the manufacturer claims.

• Identifies application guidelines for each device• Identifies qualified engines and markets for that devices application

Why is using verified technology important?– Verification is required for most publicly funded projects– Enables a standardized understanding and classification of technologies

EPA– http://www.epa.gov/otaq/retrofit/verif-list.htm– EPA lists verified technologies alphabetically by Manufacturer

CARB– http://www.arb.ca.gov/diesel/verdev/vt/vt.htm– CARB lists verified technologies by classification

• Level 1 = >25%• Level 2 = >50%• Level 3 = >85%

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EPA/CARB Verified Product SummaryDOC Passive DPF Active DPF SCR

Design Passive Diesel

Oxygen Catalyst

Passive DOC

with Wall Flow

PM filter

active DPF w/ NO2 decomp cat using fuel as

NO2 reductant

CRT with urea based SCR system and

NH3 slip catalyst

Market Any Pre EGR and EGR engines

EGR engines Pre EGR and EGR engines

Emission

Reduction

PM > 25%,

HC > 70%,

CO > 40%

PM = >85%,

HC =90%,

CO = 70%

PM = 85%,

HC = 90%,

CO = 70%

PM >85%, HC >90%, CO >70%, NOx>65%

Maximum HP

Ratings

600HP 600HP 600 HP 600 HP

Temperature

Requirements

None 240°C @ 40% 240°C @ 40% 240°C @ 40%

Monitor Required No Yes Yes Yes

Maintenance No 60-100K level 1 cleaning

60-100K level 1 cleaning

60-100K level 1 cleaning

Diesel Oxidation Catalyst(DOC)

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Diesel Oxidation Catalyst

The DOC may either replace or be added to the existing vehicle muffler.

Easily installs

Needs no maintenance

Requires no monitoring

Can be used with low-sulfur (500 ppm) or ultra-low sulfur diesel fuels (15 ppm)

Oxidation Catalyst Control Capabilities•PM >25% Reduction•CO >50%•HCs and Toxic HCs -- >70%

Closed Crankcase Ventilation(CCV)

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Crankcase Ventilation Filter Closes the current open crankcase

system by filtering blow-by gases thus removing oil residues and routing the residues and gases back into the engine.

Simple, high efficiency,serviceable

Interval – every3rd to 4th oil change

Additional 10% to 15% reduction in emissions.

ReplaceableReplaceablefilter elementfilter element

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Diesel Oxidation Catalyst + Closed Crankcase Ventilation

Combines the benefits of both for additional emissions reductions.

Applies to many applications

The CCV Kit eliminates 100% of engine compartment blow-by.

Verified as a combination package by the EPA/CARB

Diesel Particulate Filter(DPF)

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Diesel Particulate Filter

The CRT filter is capable of converting > – 90% of Particulate matter– >90% Hydrocarbons– >70% Carbon Monoxide.

Requires Ultra Low Sulfur Fuel – Can use B20 bio-diesel fuel

Maintenance: – Periodic filter cleaning required

Vehicle requires datalogging for approval to retrofit

Retrofit DPFs are generally be installed as a passive system but active systems are available

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Diesel Particulate Filter

Oxidation catalyst with Precious Metal Coating

• Existing exhaust temperatures are used for Passive Regeneration

• Oxidize injected fuel is used to produce heatfor Active Regeneration

Diesel Particulate Filter

PM = 90% reductionHC = >90% reductionCO = >70% reduction

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Heavy Duty Solution

Particulate Filters are required on engines built after Jan1, 2007

2007

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Cooled EGRParticulateFilter

Same as today

SelectiveCatalytic

Reduction

2010

Heavy Duty Solution

15L

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What Technology Where?

DOC DPF Active DPF

Urban Bus Post ’93 already have DOC

Available Available

School / Shuttle Bus

Available,

Some models already have

Available Available

Refuse Available Available Available

Emergency Available Not recommended Not recommended

Construction Available,

Must have LSD

Must have ULSD

Watch space

Available,

Watch space

Planning a Diesel Emission Retrofit Project

Start with the Money

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Retrofit Funding Sources US EPA

– Grants– Santee Cooper consent decree

• Retrofitted 105 school buses, 60 in upstate region

Smartway Program– Rebates to individuals who retrofit

State DAQ– Spartanburg County EPF project

County and City Clean Air Stakeholders State DOT Private Corporations

– Duke Power • Cleaning up power plants and support equipment

Starting A Retrofit Project

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Compile A Fleet List

Why does an accurate up to date fleet list matter?– Not every engine can be retrofitted– There is no “one size fits all” retrofit device

Fleet list is the road map of the project– Allows vehicles to be sorted into emission reduction “buckets”

• Retrofit• Repower• Replace• Rebuild• Refuel

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Fleet List

Equipment Make:___________________Equipment Model:___________________Engine Manufacturer:_________________Engine Model:_______________________Engine Year:________________________Engine Horse Power:_________________EPA Engine Family #:_________________Quantity of Like Units:_________________Muffler Part # or Dimensions:___________

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Vehicle Retrofit Priority

Reduction Goals

Remaining Service Life

Retrofit Device Maintenance– Annual costs and fleet impact

The Right Technology In The Right Place

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Product Decision Tree

1. What is the projects goal?• PM Reduction• NOx Reduction

2. Verification Required ?• (CARB / EPA)• Manufacturers warranty consideration

3. Fuel Type?• ULSD (15 ppm)• Off-road fuel • BioDiesel

4. Engine Age • EPA Certification Year/Emission Tier Level?

5. Duty cycle/temperature of application?• Datalogging needed

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Timing

What is the projects timeline?– Funding Source

• Required Installation due date

Installation:– When are the vehicles available?– When will the retrofit devices be available?– Will installation be done by the retrofit vendor?

• Transportation to and from• Down time

– How long to install the device

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Reminders 1.Funding:

- You cannot receive funding if you do not apply.

- If you do not succeed on your first attempt try again.

- Build and Maintain working relationships with air quality stakeholders.

2. Compiling Fleet Information:

- Maintain a fleet list of potential retrofit equipment.

3. What technology to use:

-The right technology on the right application

4. Vehicle Priority:

-Remaining years of service

-Quantity of vehicles

5.. Cost Considerations:

-Amount and type of reduction you are trying to achieve.

-Maintenance vs. no maintenance technology

6.Timing:

-Funding dealines

-Installation constraints

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Business Case Funding

Technology

Retrofit Success

Thank you