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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 ?
3
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
4
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
5
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
7
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
8
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%
9
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)
11
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)
13
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
14
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)
16
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
17
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
18
Heavy Duty Solution
Particulate Filters are required on engines built after Jan1, 2007
2007
19
Cooled EGRParticulateFilter
Same as today
SelectiveCatalytic
Reduction
2010
Heavy Duty Solution
15L
20
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
22
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
24
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
25
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:___________
26
Vehicle Retrofit Priority
Reduction Goals
Remaining Service Life
Retrofit Device Maintenance– Annual costs and fleet impact
The Right Technology In The Right Place
27
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
28
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
29
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
30
Business Case Funding
Technology
Retrofit Success
Thank you