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Stationary Diesel Generator / Catalytic Converter Emission

Control Evaluation

Power Systems Division

Naval Surface Warfare Center, Crane, IN.

Cinergy Ventures, Cincinnati, OH

Presenter: Brian Fillingim, NSWC Crane

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Emission Limitation

• Federal Standards for NonRoad Emission Requirements – Tier I Phase - 1996 to 2000– Tier 2 / Tier 3 Phase - 2000 to 2008– Limited Annual Hours to Remain With In

Air Polution Standards for Total Emissions

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Method of Reduction

• Selective Catalytic Reduction (SCR) Process

• Exhaust Catalyst with Anhydrous Ammonia (NH3) Injection “Proof of Concept”

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SCR Process

SCR Reaction Chemistry

4NO + 4NH3 + O2 = 4N2 + 6H2O

6NO2 + 8NH3 + O2 = 7N2 + 12H2O

High Temp and Excess NH3

4NH3 + 5O2 = 4NO + 6H2O

4NH3 + 3O2 = 2N2 + 6H2O

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Test Setup

• Caterpillar Model 3306 Diesel Generator Set - 250 Kilowatt (kW)

•  Catalytic Converter in place of Stock Muffler– Catalyst Design and Formulation by Catalytic

Solutions Inc., Oxnard, CA– Catalyst Housing and Integration by

ArvinMeritor Inc, Columbus, IN

• Manual Setting for NH3 Injection Flow Rate into Engine Exhaust

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Caterpillar Model 3306

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Muffler vs Catalytic Converter

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Test Procedure

• Daily Six to Nine Hour Runs

•  Four to Six Samples per Test Run of:

O2, CO, NO, NO2, SO2

• Temperature (Pre Converter, Post Converter, Catalyst and Ambient)

• Third Party Verification of Emission Measurements by GE Energy Serivces Inc

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Results

• 556 Engine Hours • 476 Hours with NH3 Injection•  Final 350 Hours at 90 percent Load (225

kW) with NH3 Injection•  Maximum NOx Reduction with 13 to 16

standard liters per minute (slpm) NH3 injection (0.8 NH3/NOx) at 90 percent Load

• GE Energy Services Inc. measured Comparable Data and No Indications of Secondary Emissions

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Conclusions

• NH3 Injection and Catalyst Combination Reduced NOx by Approximately 90 percent

•  Further Evaluation in Colder Ambient Temperatures Indicated

•  Further Development and Evaluation of NH3 Controllers is Indicated

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For More Details Contact:

• Raj Malyala - Catalytic Solutions Inc., Oxnard, CA (805) 486-4649 x1727 Rmalyala@catsolns.com

• Jim Lefeld - Cinergy, Cincinnati, OH 513-287-2435 jlefeld@cinergy.com

• Brian Fillingim - NSWC Crane, IN 812-854-2361 brian.fillingim@navy.mil