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Voluntary Diesel Emission Voluntary Diesel Emission Reduction ProgramsReduction Programs

Steve AlbrinkSteve AlbrinkRetrofit ProgramRetrofit Program

Office of Transportation and Air QualityOffice of Transportation and Air Quality

HD Rule/HD Rule/RetrofitRetrofit

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8 Hour Ozone Nonattainment Areas

Counties Exceeding PM2.5 NAAQS

8 Hour Ozone Nonattainment AND PM 2.5 NAAQS Exceedances

Federal Class I Areas (Visibility)Air quality data derived from AQS (PM 2.5: 2000-2002 data;

8 Hour Ozone: 2001-2003 data) with data handling per Agency guidance.

Need for Air Pollution ReductionNeed for Air Pollution ReductionFine particles from diesel exhaust can remain in the atmosphere for weeks, and carry over hundreds of miles

Diesel exhaust is likely to be carcinogenic to humans

Ozone has been shown to reduce yields of vegetables and field crops

Clean Air Act requires EPA to take steps to remedy regional haze in 156 pristine “Class I” areas

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2007 Highway HDE Program2007 Highway HDE Program

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Nationwide Heavy-DutyNationwide Heavy-DutyPM EmissionsPM Emissions

with new standards

without new standards

Calendar Year

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Nationwide Heavy-DutyNationwide Heavy-DutyNOx EmissionsNOx Emissions

Calendar Year

without new standards

with new standards

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Estimated Costs and Benefits Estimated Costs and Benefits

• Health benefitsHealth benefitsThe program will prevent annually:The program will prevent annually:

Over 8,300 premature deathsOver 8,300 premature deathsOver 750,000 respiratory illnessesOver 750,000 respiratory illnesses1.5 million lost work days1.5 million lost work days

• Benefits are 16 times greater than costsBenefits are 16 times greater than costs Monetized benefits: $70.3 billion/yearMonetized benefits: $70.3 billion/year Compliance costs: $4.3 billion/yearCompliance costs: $4.3 billion/year

– Estimated at $1,200-1,900 per engineEstimated at $1,200-1,900 per engine– About 5 cents per gallon of fuelAbout 5 cents per gallon of fuel

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2007 HDE Program 2007 HDE Program Key Elements Key Elements

• Applies new NOx and PM standards to Applies new NOx and PM standards to heavy-duty engines and vehiclesheavy-duty engines and vehicles

–90%+ emission reductions90%+ emission reductions–Phase-in of NOx standards 2007-2010Phase-in of NOx standards 2007-2010–Incentives for early technology introductionIncentives for early technology introduction

•Reduces diesel fuel sulfur levels nationwideReduces diesel fuel sulfur levels nationwide–Enables use of aftertreatment technologyEnables use of aftertreatment technology–Highway diesel fuel sulfur cap of 15 ppmHighway diesel fuel sulfur cap of 15 ppm–Transitional flexibilities 2006-2010Transitional flexibilities 2006-2010–Small Refiner FlexibilitySmall Refiner Flexibility

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Valuable to StatesValuable to States

• States will be counting on heavy-duty diesel States will be counting on heavy-duty diesel emission reductions to meet National Ambient emission reductions to meet National Ambient Air Quality Standards.Air Quality Standards.

•Nonattainment Areas for PM2.5 and 8-hour Nonattainment Areas for PM2.5 and 8-hour Ozone will be designated this year.Ozone will be designated this year.

•State Implementation Plans (SIP) will include State Implementation Plans (SIP) will include these reductions.these reductions.

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VOLUNTARY DIESEL VOLUNTARY DIESEL RETROFIT PROGRAMRETROFIT PROGRAM

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What is the Voluntary Diesel What is the Voluntary Diesel Retrofit Program?Retrofit Program?• A voluntary program designed to install pollution-A voluntary program designed to install pollution-reducing technology on existing diesel vehicles reducing technology on existing diesel vehicles and equipmentand equipment

–Existing diesel engines can last 20-35 yearsExisting diesel engines can last 20-35 years–2007 Highway & Proposed Nonroad rules address 2007 Highway & Proposed Nonroad rules address only future enginesonly future engines

• We are building a market for clean diesel We are building a market for clean diesel conceptsconcepts

–Accelerating the delivery of ULSDAccelerating the delivery of ULSD–Forging business partnerships and relationshipsForging business partnerships and relationships–Investing EPA resources to accelerate market growthInvesting EPA resources to accelerate market growth

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• The Diesel Retrofit Program works best when:The Diesel Retrofit Program works best when:

–EPA HQ and Regional offices create partnerships with EPA HQ and Regional offices create partnerships with local leadershiplocal leadership–Local leadership is in the best position to:Local leadership is in the best position to:

•Create expanding retrofit programs (as opposed to a single Create expanding retrofit programs (as opposed to a single demo)demo)•Work with local fleet management and decision makersWork with local fleet management and decision makers•Know how to secure local and regional fundingKnow how to secure local and regional funding

• EPA will supply technical support:EPA will supply technical support:–Engine manufacturersEngine manufacturers–Retrofit manufacturersRetrofit manufacturers–Fuel refineries and suppliersFuel refineries and suppliers

Successful Retrofit Program ModelSuccessful Retrofit Program Model

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EPA Funded ProjectsEPA Funded Projects

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The Role of Diesel FuelThe Role of Diesel Fuel

•ULSD is becoming more widely available ULSD is becoming more widely available throughout the countrythroughout the country

–Several fuel companies can distribute ULSD today in specific Several fuel companies can distribute ULSD today in specific regionsregions

•The foundation of many retrofit projects will be The foundation of many retrofit projects will be the fuel supplythe fuel supply

–Many technologies require Ultra Low Sulfur Diesel (ULSD) FuelMany technologies require Ultra Low Sulfur Diesel (ULSD) Fuel–Some can operate on current fuel but can not achieve full Some can operate on current fuel but can not achieve full emission reduction potentialemission reduction potential–Generally, PM filter with ULSD achieve PM reductions over 90%Generally, PM filter with ULSD achieve PM reductions over 90%

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ULSD AvailabilityULSD Availability

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What is Retrofit Technology?What is Retrofit Technology?• Retrofit technology can be:Retrofit technology can be: any change to an engine any change to an engine system above and beyond what is required by EPA system above and beyond what is required by EPA regulations that improves the engine’s emission regulations that improves the engine’s emission performance: performance:

•Catalyst or filterCatalyst or filter

•Engine upgradeEngine upgrade

•Early engine replacementEarly engine replacement

•Use of cleaner fuels or additivesUse of cleaner fuels or additives

•Idling control equipmentIdling control equipment

•Combination of aboveCombination of above

• Retrofit Web site maintains a list of manufacturers Retrofit Web site maintains a list of manufacturers and verified technologyand verified technology

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Retrofit Technology VerificationRetrofit Technology Verification

• Objective:Objective: Evaluate the emission reduction Evaluate the emission reduction effectiveness of retrofit technologyeffectiveness of retrofit technology

- Verification provides stakeholders with confidence that - Verification provides stakeholders with confidence that these technologies will achieve quantifiable emission these technologies will achieve quantifiable emission reductionsreductions

• Verification consists of the following:Verification consists of the following:- Appropriate Testing Protocols- Appropriate Testing Protocols- Statistical Sampling Methods- Statistical Sampling Methods- Durability Requirements- Durability Requirements

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•14 Technologies Currently EPA-Verified 14 Technologies Currently EPA-Verified

–DPFs, DOCs, Crankcase Filtration, Emulsified Fuel, DPFs, DOCs, Crankcase Filtration, Emulsified Fuel, Biodiesel, Cetane EnhancersBiodiesel, Cetane Enhancers

•Recent VerificationRecent Verification

–Caterpillar, DOCCaterpillar, DOC

–Engine Control Systems, DPFEngine Control Systems, DPF

–Donaldson, DOC & Crankcase ControlDonaldson, DOC & Crankcase Control

–Clean Diesel Technology, DOC & Fuel Borne CatalystClean Diesel Technology, DOC & Fuel Borne Catalyst

•Several Verifications in ProcessSeveral Verifications in Process

Retrofit Technology VerificationRetrofit Technology Verification

Diesel Retrofit Technologies: Diesel Retrofit Technologies: An OverviewAn Overview

• Existing emission controls systems can greatly Existing emission controls systems can greatly reduce diesel particulate matter (PM) emissionsreduce diesel particulate matter (PM) emissions– Diesel oxidation catalysts and diesel particulate filtersDiesel oxidation catalysts and diesel particulate filters

• Existing and developing emission control systems Existing and developing emission control systems can greatly reduce NOx and PM emissionscan greatly reduce NOx and PM emissions– Lean NOx catalysts, EGR, SCR and combined Lean NOx catalysts, EGR, SCR and combined

systemssystems

• Technologies to control crankcase emissionsTechnologies to control crankcase emissions• Advanced fuelsAdvanced fuels

– Low sulfurLow sulfur

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Diesel Retrofit Technologies: An Diesel Retrofit Technologies: An OverviewOverview

• Integrated emission control systems will Integrated emission control systems will allow diesel engines to meet future allow diesel engines to meet future emission challengesemission challenges

• Integration will involve the entire vehicle Integration will involve the entire vehicle including:including:– The engineThe engine– The emission control systemThe emission control system– The fuelThe fuel

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Diesel Oxidation CatalystsDiesel Oxidation Catalysts

CarbonCarbon

SOFSOF

NOxNOx

COCO

HCHC

CarbonCarbon

NOxNOx

WaterWater

Oxidation catalysts oxidize carbon monoxide (CO), Oxidation catalysts oxidize carbon monoxide (CO), hydrocarbons (HCs) and the soluble organic fraction hydrocarbons (HCs) and the soluble organic fraction (SOF) to reduce particulate matter (PM), CO, HCs, and (SOF) to reduce particulate matter (PM), CO, HCs, and toxic emissions toxic emissions

Diesel Oxidation Catalysts Are Diesel Oxidation Catalysts Are EfficientEfficient

and a Proven Technologyand a Proven Technology• Hundreds of thousands have been retrofitted Hundreds of thousands have been retrofitted

since the 1960s on highway, mining, since the 1960s on highway, mining, materials handling and construction vehiclesmaterials handling and construction vehicles

• Durabilities in excess of 10,000 hours of Durabilities in excess of 10,000 hours of operationoperation

• Diesel oxidation catalyst control capabilitiesDiesel oxidation catalyst control capabilities– PM 20 to 30% reductionPM 20 to 30% reduction– CO > 40%CO > 40%– HCs > 50%HCs > 50%

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Diesel Particulate Filter Diesel Particulate Filter TechnologyTechnology

Trapped SootCell Plugs

Exhaust In(Soot, CO, HC)Enter

Exhaust (CO2, H2O)Out

Diesel Particulate Filters Are Diesel Particulate Filters Are Efficient and Are Developing Efficient and Are Developing an Impressive Track Recordan Impressive Track Record

• Filter control capabilitiesFilter control capabilities

– PM 80% to 90% reductionPM 80% to 90% reduction

– CO > 75%CO > 75%

– HCs > 85%HCs > 85%

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• Typical test filter – Typical test filter – current standardscurrent standards

• Test filter – 2007 Test filter – 2007 standardsstandards

• Unused test filterUnused test filter

PM Emissions PM Emissions with Trapwith Trap

Diesel Particulate Filter Retrofit Diesel Particulate Filter Retrofit ExperienceExperience

• Retrofitting existing diesel engines with diesel Retrofitting existing diesel engines with diesel particulate filters is an available strategy to particulate filters is an available strategy to reduce emissions including PM, CO, and HCsreduce emissions including PM, CO, and HCs

• A growing number of programs and A growing number of programs and applications have been successfully completed applications have been successfully completed on highway, non-road and stationary engineson highway, non-road and stationary engines

• More than 25,000 filter systems have been More than 25,000 filter systems have been installed on highway vehiclesinstalled on highway vehicles

• Retrofit technology development continues to Retrofit technology development continues to expand the range of applications availableexpand the range of applications available

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Filter Regeneration Strategy: Filter Regeneration Strategy: Some ConsiderationsSome Considerations

• Application and duty cycleApplication and duty cycle• Engine out emissionsEngine out emissions• Vehicle/engine conditionVehicle/engine condition• Fuel sulfur levelFuel sulfur level• Maintenance and operational proceduresMaintenance and operational procedures

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Filter Regeneration Strategies Filter Regeneration Strategies Used to Date In Retrofit Used to Date In Retrofit

ApplicationsApplications

• Engine reliant Engine reliant

• Catalyst-assistedCatalyst-assisted

• Electric heater-assistedElectric heater-assisted

• Fuel burner-assistedFuel burner-assisted

• Off-board regeneration Off-board regeneration

• Intake/exhaust throttlingIntake/exhaust throttling

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Overview of Filter Retrofit Overview of Filter Retrofit ProgramsPrograms

• The number and scope of retrofit programs The number and scope of retrofit programs are rapidly growingare rapidly growing– North America (California, New York, New North America (California, New York, New

England, Mexico, and elsewhere)England, Mexico, and elsewhere)– Europe (Austria, Finland, France, Germany, Europe (Austria, Finland, France, Germany,

Sweden, Switzerland, and United Kingdom)Sweden, Switzerland, and United Kingdom)– Asia (Hong Kong, Korea, Japan, and Taiwan)Asia (Hong Kong, Korea, Japan, and Taiwan)– Latin America (El Salvador and Nicaragua)Latin America (El Salvador and Nicaragua)

• Over 50,000 filters retrofitted worldwide on Over 50,000 filters retrofitted worldwide on highway and non-road vehicleshighway and non-road vehicles

Other Control TechnologiesOther Control Technologies

• Emulsified Fuel- up to 50% PMEmulsified Fuel- up to 50% PM, 10 to 15% , 10 to 15% NOxNOx

• Biodiesel (B-20 up to 7% PMBiodiesel (B-20 up to 7% PM, 4% NOx, 4% NOx))• DOC w/ fuel borne catalyst (41-50% PMDOC w/ fuel borne catalyst (41-50% PM))• DOC w/ crankcase filtration (25+% PMDOC w/ crankcase filtration (25+% PM))• Lean-NOx catalysts Lean-NOx catalysts • Exhaust gas recirculation (EGR)Exhaust gas recirculation (EGR)• Selective catalytic reduction (SCR)Selective catalytic reduction (SCR)

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Lean NOx CatalystsLean NOx Catalysts

• Used on passenger cars in Europe and Used on passenger cars in Europe and on some heavy-duty engines as original on some heavy-duty engines as original equipmentequipment

• Have been retrofitted on a limited scaleHave been retrofitted on a limited scale• Can achieve modest NOx reductions, 5-Can achieve modest NOx reductions, 5-

15%15%• Hydrocarbon injection can increase Hydrocarbon injection can increase

control capabilitiescontrol capabilities

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Exhaust Gas Recirculation (EGR)Exhaust Gas Recirculation (EGR)

• A portion of the engine’s exhaust is A portion of the engine’s exhaust is recirculated to the turbocharger inlet or intake recirculated to the turbocharger inlet or intake manifoldmanifold

• Cooled, recirculated gases lower combustion Cooled, recirculated gases lower combustion temperatures and reduce NOx formationtemperatures and reduce NOx formation

• Particulate filters are an important part of Particulate filters are an important part of EGR systems, preventing PM from being EGR systems, preventing PM from being recirculated to the enginerecirculated to the engine

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Exhaust Gas Recirculation (cont.)Exhaust Gas Recirculation (cont.)

• EGR systems have been installed on EGR systems have been installed on some newer enginessome newer engines

• Technology demonstration programs of Technology demonstration programs of retrofits have been conducted in retrofits have been conducted in Houston and Los Angeles; more Houston and Los Angeles; more programs are planned for other citiesprograms are planned for other cities

• EGR can achieve NOx reductions of EGR can achieve NOx reductions of >40%>40%

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Selective Catalytic Reduction Selective Catalytic Reduction (SCR)(SCR)

• Used extensively on stationary sourcesUsed extensively on stationary sources• Has been applied to marine vessels and Has been applied to marine vessels and

locomotives and in truck and passenger car locomotives and in truck and passenger car demonstration programsdemonstration programs

• Involves use of a catalyst, a reagent (usually Involves use of a catalyst, a reagent (usually a solution of urea, sometimes ammonia) a solution of urea, sometimes ammonia) and dosing equipment to inject the reagent and dosing equipment to inject the reagent into the exhaust streaminto the exhaust stream

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Selective Catalytic Reduction Selective Catalytic Reduction (cont.)(cont.)

• SCR control capabilitiesSCR control capabilities

– PM – 30 to 50% reductionPM – 30 to 50% reduction

– CO and HC – >80% CO and HC – >80%

– NOx – 60 to 80%NOx – 60 to 80%

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Key Considerations for Retrofit Key Considerations for Retrofit ProgramsPrograms

• How long the vehicle is going to remain in How long the vehicle is going to remain in serviceservice

• The condition of the engine is an important The condition of the engine is an important factor in making a decision whether to install factor in making a decision whether to install retrofit control technologyretrofit control technology

• Retrofit at the time of engine rebuild can be Retrofit at the time of engine rebuild can be advantageousadvantageous

• For filter retrofit, one must consider: vehicle For filter retrofit, one must consider: vehicle application, exhaust temperature (duty cycle), application, exhaust temperature (duty cycle), engine-out PM emissions, fuel sulfur level, and engine-out PM emissions, fuel sulfur level, and the regeneration strategy to be followedthe regeneration strategy to be followed

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Key Considerations for Retrofit Key Considerations for Retrofit ProgramsPrograms

• Retrofit Technology Check ListRetrofit Technology Check List– Model YearModel Year

• Generally, only 1994 and newer should get PM filtersGenerally, only 1994 and newer should get PM filters• Some newer engines came with DOCs from the factorySome newer engines came with DOCs from the factory

– SizeSize• Properly sized control systems ensure low back pressure and Properly sized control systems ensure low back pressure and

maximum performancemaximum performance

– Vehicle IntegrationVehicle Integration• Space, accessibility and exhaust temperature are important Space, accessibility and exhaust temperature are important

vehicle integration issuesvehicle integration issues• Devices are often installed in-line or as a muffler replacement Devices are often installed in-line or as a muffler replacement

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Key Considerations for Retrofit Key Considerations for Retrofit ProgramsPrograms

• Retrofit Technology Check List (cont.)Retrofit Technology Check List (cont.)

– Fuel TypeFuel Type• For PM control, <15 ppm sulfur fuel allows for For PM control, <15 ppm sulfur fuel allows for

maximum emission control performance (even for maximum emission control performance (even for DOCs) and best filter regeneration characteristicsDOCs) and best filter regeneration characteristics

– MaintenanceMaintenance• Vehicles to be retrofitted should be properly and Vehicles to be retrofitted should be properly and

regularly maintained—key factor for successregularly maintained—key factor for success• Retrofit technologies should be maintained per Retrofit technologies should be maintained per

their manufacturer’s recommended procedures their manufacturer’s recommended procedures

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Frequently Asked Questions Frequently Asked Questions Concerning Retrofit ProgramsConcerning Retrofit Programs

• CostsCosts– Costs depend on many factors including:Costs depend on many factors including:

• Number of vehicles retrofitted (sales volume)Number of vehicles retrofitted (sales volume)• Retrofit technology used (oxidation catalyst, filter, etc.)Retrofit technology used (oxidation catalyst, filter, etc.)• Engine size (displacement) Engine size (displacement) • Engine out emissionsEngine out emissions• Fuel qualityFuel quality• Exhaust temperature and duty cycle (These factors will Exhaust temperature and duty cycle (These factors will

affect which retrofit technology will be appropriate.)affect which retrofit technology will be appropriate.)

– Costs are expected to decrease as the market Costs are expected to decrease as the market expandsexpands

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Frequently Asked Questions Frequently Asked Questions Concerning Retrofit Programs Concerning Retrofit Programs

(cont.)(cont.)Technology Cost per Device/System ($)

Diesel Oxidation Catalysts (DOC) 425 to 1,150

Diesel Particulate Filters (DPF) 3,000 to 5,500Combined Lean NOx Catalyst/DPF Systems 5,000 to 10,000

EGR Systems 13,000 to 15,000

SCR Systems 10,500 to 50,000

Notes: DPF costs are higher for active systems and systems that include backpressure monitoring.

Year 2000 data.

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Frequently Asked Questions Frequently Asked Questions Concerning Retrofit Programs Concerning Retrofit Programs

(cont.)(cont.)• DrivabilityDrivability– Properly selected retrofit technologies do not Properly selected retrofit technologies do not

impair driving performanceimpair driving performance

• MaintenanceMaintenance– Oxidation and lean NOx catalysts are virtually Oxidation and lean NOx catalysts are virtually

maintenance freemaintenance free– Filters require very little maintenance (ash removal)Filters require very little maintenance (ash removal)– SCR maintenance, as per manufacturer’s SCR maintenance, as per manufacturer’s

specificationsspecifications

• Effects on Engine LifeEffects on Engine Life– Properly maintained engines and retrofit control Properly maintained engines and retrofit control

systems do not shorten engine lifesystems do not shorten engine life

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Frequently Asked Questions Frequently Asked Questions Concerning Retrofit Programs Concerning Retrofit Programs

(cont.)(cont.)• Fuel PenaltiesFuel Penalties

– Most oxidation and lean NOx catalysts Most oxidation and lean NOx catalysts have no effect on fuel consumptionhave no effect on fuel consumption

– Most filters have no effect on fuel Most filters have no effect on fuel consumption consumption

– Urea consumption in SCR systems results Urea consumption in SCR systems results in an equivalent fuel penalty of 3-5% in an equivalent fuel penalty of 3-5%

• WarrantiesWarranties– Manufacturers provide various warranties Manufacturers provide various warranties

as part of a purchase agreementas part of a purchase agreement

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ConclusionsConclusions• A wide variety of retrofit options are available A wide variety of retrofit options are available

for diesel engines to reduce HC, CO, PM and for diesel engines to reduce HC, CO, PM and toxic emissionstoxic emissions

• NOx retrofit controls are emergingNOx retrofit controls are emerging• A growing number of retrofit programs are A growing number of retrofit programs are

being successfully implementedbeing successfully implemented• Technology development continues to Technology development continues to

expand the range of applications available for expand the range of applications available for retrofitretrofit

• A successful retrofit program must be A successful retrofit program must be properly designed and implementedproperly designed and implemented

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Some Diesel Retrofit Web SitesSome Diesel Retrofit Web Sites

• EPA’s Voluntary Diesel Retrofit Program:EPA’s Voluntary Diesel Retrofit Program:– http://www.epa.gov/otaq/retrofithttp://www.epa.gov/otaq/retrofit

• The Manufacturers of Emission Controls Association:The Manufacturers of Emission Controls Association:– http://www.meca.org http://www.meca.org – Click on “Publications” to access MECA fact sheets and Click on “Publications” to access MECA fact sheets and

technical documents on diesel retrofittechnical documents on diesel retrofit

• The Diesel Technology Forum:The Diesel Technology Forum:– http://www.dieseltechnologyforum.com/http://www.dieseltechnologyforum.com/

• The California Air Resources Board’s Diesel Risk The California Air Resources Board’s Diesel Risk Reduction Program:Reduction Program:– http://www.arb.ca.gov/diesel/dieselrrp.htmhttp://www.arb.ca.gov/diesel/dieselrrp.htm