Emissions & Aftertreatment Update

Emissions & Aftertreatment Update

June 2, 2010

Mark Szymczak (Zimzak)Cummins WestPowerGen Emissions Solutions

2 Confidential – June 4, 2010

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� 2011 CARB/EPA Stationary Engine Emissions Standards

� ATCM Impact� The Latest From CARB� Aftertreatment Design Considerations� DPF’s: Active vs Passive� Combo DPF / SCR Systems� Questions


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U.S. EPAkW (HP)

0 - 7 (0 - 10)

8 - 18 (11 - 24)

19 - 36 (25 - 48)

37 - 55 (49 - 74)

56 - 74 (75 - 99)

75 - 129 (100 - 173)

130 - 224 (174 - 301)

225 - 449 (302 - 602)

450 - 560 (603 - 751)

>560* (>751)*

a. Applies to portable power generation >1207hp.b. Applies to portable power generation >751hp.

EUROPE kW (HP)

18 - 36 (24 - 48) ( 7.5 ) / 5.5 / 0.6

37 - 55 (49 - 74) ( 4.7 ) / 5.0 / 0.025

56 - 74 (75 - 99) 3.3 / 0.19 / 5.0 / 0.025

75 - 129 (100 - 173) ( 4.0 ) / 5.0 / 0.3 3.3 / 0.19 / 5.0 / 0.025

130 - 560 (174 - 751) ( 4.0 ) / 3.5 / 0.2 2.0 / 0.19 / 3.5 / 0.025 0.4 / 0.19 / 3.5 / 0.025

( 6.4 ) / 3.5 / 0.20

( 6.4 ) / 3.5 / 0.20

9.2 ... 0.543.5 / 0.40 / 3.5 / 0.100.67 / 0.40 / 3.5 / 0.10 a

( 4.0 ) / 3.5 / 0.20

( 4.0 ) / 3.5 / 0.20

( 6.4 ) / 3.5 / 0.203.5 / 0.19 / 3.5 / 0.040.67/ 0.19 / 3.5 / 0.03 b

0.40 / 0.19 / 5.0 / 0.02

2.0 / 0.19 / 3.5 / 0.02 0.40 / 0.19 / 3.5 / 0.02

Tier 2 Tier 3 Tier 4 Interim Tier 4 Final

( 7.5 ) / 5.0 / 0.40

2016 2017

( 7.5 ) / 6.6 / 0.40

( 4.7 ) / 5.0 / 0.03

2012 2013 2014 20152008 2009 2010 20112004 2005 2006 2007

8.0 / 1.5 / 5.5 / 0.8

2009 2010 20112004 2005 2006 2007

7.0 / 1.3 / 5.0 / 0.4 ( 4.7 ) / 5.0 / 0.4

0.4 / 0.19 / 5.0 / 0.025

2016 20172012 2013 2014 20152008

Stage IVStage IIIBStage IIIAStage II

( 6.6 ) / 3.5 / 0.20

( 7.5 ) / 5.5 / 0.60

( 7.5 ) / 8.0 / 0.80

( 7.5 ) / 6.6 / 0.80

( 6.6 ) / 5.0 / 0.30

( 4.0 ) / 3.5 / 0.20

( 4.0 ) / 5.0 / 0.30

( 7.5 ) / 5.5 / 0.30

( 4.7 ) / 5.0 / 0.30( 4.7 ) / 5.0 / 0.40

3.4 / 0.19 / 5.0 / 0.02

6.0 / 1.0 / 5.0 / 0.3

6.0 ... 0.2

NOx / HC(T1) or NMHC(T4) / CO / PM or (NOx+NMHC)/CO/PM [g/kW-hr]


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(gm/kw-hr)Tier 3 (now)

Tier 4i (2011)

T4 (2015) reduction

NOx+HC 4 2.19 0.4 90%Particulates 0.2 0.02 0.02 90%

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(gm/kw-hr)Tier 2 (now)

Tier 4i (2011)

T4 (2015) reduction

NOx+HC 6.4 1.07 1.07 83%Particulates 2.0 1.0 0.03 98%


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PM Standards

HC, NOx, NMHC, CO Standards

* Exemptions for Ag, Fire Pumps, etc

� NOx, HC, and CO, must meet the current off-road standard.

�No exception for Emergency Engines

CaliforniaYes

Other StatesNo


“Hi Mark – We are not able to provide you with any certainty at this time but we can tell you where we are in the process regarding evaluating any potential amendments to the stationary engine air toxic control measure (ATCM). Staff has investigated the feasibility of requiring Tier IV for emergency back up engines and at this point believe SCR is probably not cost-effective in most situations provided the number of hours are typical of what was reported to the survey we conducted during the development of the ATCM – about 22 hours of M&T and 6-8 hours of emergency operation. However, there may be some situations, i.e. an emergency-back-up engines that operates for many hours, where an SCR would provide air quality benefits. ARB staff continues to believe DPFs are cost-effective and feasible for emergency back-up operations but we are open to investigating if the requirement for DPFs should be limited to certain situations such as when an engine is in a populated area, or close to sensitive receptors. Please be aware, that these are only staff’s opinion - we haven’t briefed upper mgt. or taken these ideas through the public process yet. Regarding the timing for any amendments, we are on the Board calendar for the July 2010 hearing. Our first workshop is tentatively planned for March 1st and the notice should be going out in the next week or two. We are also planning on conducting a short survey to collect updated information on back-up engines and typical hours of operation. We are hoping to have this distributed the first week in February.I know this probably doesn’t help you in your discussions with your clients but this is all we can tell you at this point. I believe we will have a better idea of any proposed amendments in the March-April timeframe.

Feb 2010 Communication from CARB


Hi Mark,We have changed our direction somewhat from our last

workshop. ARB staff will propose the following for discussion at the June 22 workshop.

� Align the ATCM’s emission standards for new direct-drive fire pump engines with the standards and implementation schedules required by the NSPS final rule.

� Align the ATCM’s emission standards for new emergency standby engines with the NSPS emission standards for this subset of stationary CI ICEs, except the ATCM will retain a minimum PM emission limit of 0.15 g/bhp-hr (the NSPS requires a less stringent PM standard for CI engines between 50 > hp <175 this hp range).

� We are still investigating the issue we discussed earlier regarding a subset of new emergency standby engines that are near sensitive receptors or multiple engines at one location (e.g., data centers, server banks, etc) that may require a more stringent PM emissionstandard than what is required by the NSPS.

� The ATCM will continue to allow upon district approval emergencystandby engines to operate > 50 hrs for M&T if the engine emits PM at a rate < or equal to 0.01 g/bhp-hr.

� Non-substantive changes to ATCM for clarity.

May 26, 2010 CARB Communication


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�CARB Decision – Slated for September�Consider Engineering in a DPF�Consider Purchase & Permit to Construct in

2010


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Cleaire Emission Controls

Miratech

Johnson Matthey

Harco

Rypos

GT Exhaust

CleanAir Systems

Universal

All offer > 85% PM reduction


Diesel Particulate Filters

Passive Active

CSF CDPFElectrically Regenerated

Fuel Regenerated

On-Line Off-Line

CSF: Catalyzed Soot FilterCDPF: Catalyzed Diesel Particulate Filter (DOC + DPF)

Design Considerations:

Diesel Exhaust DPF Options



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1. Standby Application vs Prime Power2. PM Emissions Reduction Required (25% vs 85%)3. Engine ACFM and Exhaust temp at various loads4. DPF Cost5. Engine Heat / Engine Loading during test runs6. Engine Heat/ Engine Loading during actual emergency7. Engine Backpressure Limit vs Backpressure Added by Aftertreatment and

Exhaust Run8. Mounting Location and Accessibility / Weight, Size & Ease of Installation9. Longevity & Location of App -- SS vs Carbon Steel Housing10. Sound Attenuation Requirements11. Maintenance Requirements of Abatement Device12. BP Monitoring system and datalogging13. Product manufacturer’s warranty, quality, history & support


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� Combo DOC & Filter� Low Cost� Lowest Regen Temp @ 465F� Needs NOx:PM of 20:1� Low Mtc. on Standby App� West Coast Mfg� West Coast Field Support� Trained CWI Technicians� Need Cleaning after 1000hrs of Use

Catalyst

Filter

14 Confidential – June 4, 2010 CRT20-H-BITO-X*JM: 90"w x 137"L x 40"h667359927"QSK78-G6DQKAC2500

CRT20-H-BITO-X*JM: 90"w x 137"L x 40"h779292227"QSK60-G6-NR2DQKAB2000

CRT20-H-BITO-X*JM: 90"w x 137"L x 40"h750292227"QSK60-G6-NR2DQKAA1750

CRT14-H-BITO-X*JM: 90"w x 125"L x 40"h665222027"QSK50-G4-NR2DQGAB1500

CRT14-H-BITO-X*JM: 90"w x 125"L x 40"h625222027"QSK50-G4-NR2DQGAA1250

CRT10-H-BITO-X*JM: 90"w x 110"L x 40"h620149027"QST30-G5-NR2DQFAD1000

CRT10-H-BITO-X*JM: 90"w x 110"L x 40"h583149027"QST30-G5-NR3DQFAC900

CRT10-H-BITO-X*JM: 90"w x 110"L x 40"h557149027"QST30-G5-NR2DQFAB800

CRT10-H-BITO-X*JM: 90"w x 110"L x 40"h553149027"QST30-G5-NR2DQFAA750

CRT4-H-BITO-X*JM: 38"w x 80"L x 40"h595122041"QSK23-G3-NR1DQCA600

CRT3-H-BITO-X*JM: 38"w x 90"L x 24"h74575541"QSX15-G9-NR2DFEK500

CRT3-H-BITO-X*JM: 38"w x 90"L x 24"h73575541"QSX15-G9-NR2DFEJ450

CRT2-H-BITO-X*JM: 38"w x 74"L x 24"h72575541"QSX15-G9-NR2DFEH400

CRT2-H-BITO-X*JM: 38"w x 74"L x 24"h68075541"QSX15-G9-NR2DFEG350

CRT2-H-BITO-X*JM: 38"w x 74"L x 24"h73847041"QSM11-G4DQHAB300

CRT2-H-BITO-X*JM: 38"w x 74"L x 24"h73847041"QSM11-G4DQHAA275

CRT2-H-BITO-X*JM: 38"w x 74"L x 24"h61539941"QSL9-G3-NR3DQDAA250

CRT1-H-BITO-X*JM 36"w x 44"L x 24"h63536441"QSL9-G2-NR3DSHAD230

CRT1-H-BITO-X*JM 36"w x 44"L x 24"h61636441"QSL9-G2-NR3DSHAC200

CRT1-H-BITO-X*JM 36"w x 44"L x 24"h60036441"QSL9-G2-NR3DSHAB175

CRT1-H-BITO-X*JM 36"w x 44"L x 24"h63925040"QSB7-G3-NR3DSGAC150

CRT1-H-BITO-X*JM 36"w x 44"L x 24"h60525040"QSB7-G3-NR3DSGAB125

N/A55425040"QSB7-G3-NR3DSGAA100

With Silencingw/ silencer25% LoadHPBP LimitEngineModel #KW

JM P/NDimensionsTempNameplate

JM 10"� x 36"L


Johnson Matthey

CRT+ Slimline Design

For QST30-G5


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� Extended data logging capability

� Stores up to 24 hours of data

� Continuously logs exhaust temperature & backpressure

� High speed RS-232 communications

� Maintenance alerts� Programmable alarm

settings


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� Standby Engines up to 2000kW� Little to no maintenance� Sintered metal fibers� Active system with diesel

oxidation catalysts� Filter element is the heating

element� Level 3 PLUS CARB Verification

for diesel generators with the following limitations:– Diesel sulfur content < 15 ppm– PM emission level < 0.2 g/bhp-

hr


2x 1.1MW

2MW

2x 600kW

Rypos Active Filter Premium: 60% – 75%


Typical DPF/SCR System

DPF


485F Regen Temps

Johnson Matthey SCRT

Combo DPF & SCR System


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One For 1MW Genset. Two for 2MW Genset

Heater/DPF Section Pressure

Drop 13” wclength 75”

Mixing Section Pressure drop:5” wc Length 71”

SCR Section Pressure Drop 5” wc

Length 90”

Flow

Heater ElementsDPF Catalyst

SCR Catalyst

Injector Location

Evaporator


Snow Summit: (2) 2-megs w/ JM SCRT’s

Lehigh Cement

(5) CAT 1500kw

w/ DPF’s

Chevron: (8) DPF’s on Various size pumps/compressorsCalifornia Water Svc: SCR on a 1250kW


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�Secure a permit to construct in 2010 and pre-order generator.

�Consider designing new standby systems to meet Tier 4i PM requirements. -- DPF in lieu of muffler

�Use CWI as a resource for design assistance and CARB updates

�Consider passive filter if emergency load is over 25% of generator capacity

�Specify thermal blanketing for indoor apps.