Retrofit Emission Control Technologies Retrofit Emission Control Technologies for On- and Off-Road Diesel Enginesfor On- and Off-Road Diesel Engines
Manufacturers of Emission Controls Association
May 2002
Presentation OutlinePresentation Outline
Introduction
Overview of Retrofit Control Technologies
Examples of Emissions Control Performance
Retrofit Experience
Conclusion
IntroductionIntroduction
Diesel Engines Are a Major Source of NOx, PM, and Toxic Emissions
Even with Tighter Emission Standards Already Promulgated, Existing, High-Emitting Diesel Engines Will Be in Use for the Next 10 to 20 Years
Retrofitting Existing Diesel Engines with Exhaust Control Technologies, Repowering with Clean Diesel Engines, or Converting Diesel Engines to Natural Gas Are Available Strategies to Reduce Emissions
Diesel Particulate FiltersDiesel Particulate Filters
Trapped PMCell Plugs
Exhaust(PM, CO, HC)Enter
Ceramic HoneycombWall
Exhaust (CO2, H2O)Out
Diesel Particulate Filters Are Efficient and Diesel Particulate Filters Are Efficient and Are Developing an Impressive Track RecordAre Developing an Impressive Track Record
Filter Control Capabilities
– PM -- >85% Reduction
– CO and HC -- >90% Reduction
– Toxic HCs -- >90% Reduction
Filter Operating Experience
– Over 50,000 Systems Have Been Retrofitted to HDD Vehicles Worldwide
– Peugeot Selling Filter-Equipped LDVs on Several Models
– Several Other EU OEs Have Announced Plans for Filters
– Over 20,000 Non-Road Engines Equipped (Both OE Installed and Retrofit) Including Both Passive and Active Systems
Diesel Oxidation CatalystDiesel Oxidation Catalyst
PAHC2H2n+2
SO2+H2OMetals
SootCO + 1/2 O2
HC + O2
PAH + O2
Aldehydes + O2
CO2
CO2 + H2OCO2 + H2OCO2 + H2O
Flow through monolithwith catalytic coating
SO2+H2O
Metals
Soot
COAldehydes
HCPAHSO2
NOx
CO2
H2OSO2 /SO3
NOx
Diesel Oxidation Catalysts Are Efficient and Diesel Oxidation Catalysts Are Efficient and Have Excellent Operating ExperienceHave Excellent Operating Experience
Oxidation Catalyst Control Capabilities
– PM -- 20-50% Reduction
– CO and HC -- >90% Reduction
– Toxic HCs -- >70% Reduction
Oxidation Catalyst Operating Experience
– >30,000 Urban Buses in the U.S. and Europe
– >8,000 HD Vehicles in Mexico
– Hong Kong Is Retrofitting 2,000 Urban Buses and >40,000 Medium-Duty Diesel Vehicles
– >250,000 Off-Road Engines
– >1,500,000 Class 1 & 2 Vehicles (Pick-Ups)
– >5,000,000 LDD Vehicles in Europe
Crankcase PM Emissions Can Be ControlledCrankcase PM Emissions Can Be Controlled
blow-by filter &pressure regulatorair filter
turbo
engine
drain to oil sump
breatherport
check valveafter-cooler
Returns Crankcase PM Emissions to the Oil Sump
Eliminates a Significant Source of PM
Retrofit EGR Systems Are Being IntroducedRetrofit EGR Systems Are Being Introduced
EGR Control Capabilities
– >40% NOx Reduction
– Can Be Used in Conjunction with Filter Technology to Provide Substantial PM Reductions As Well
EGR Operating Experience
– Over 400 Systems Installed and Operating on Volvo and Cummins Engines in Europe
– Several Demonstration Programs Being Initiated in US
SCR System SCR System
EDC
diagnose
engine Catalyst
NOx, O2
reducingagent
(NH2) 2CO
purified exhaust gas
N2, H2O
Dosing Unit
ECU DCU
exhaustgas
operating
data
(NH2) 2CO
SCR Has Been Used Successfully on Stationary SCR Has Been Used Successfully on Stationary Sources and Is Now Used for Mobile SourcesSources and Is Now Used for Mobile Sources
SCR Control Capabilities (w/ Integral Oxidation System)
– PM – 20-50% Reduction
– CO and HC -- >90%
– Toxic HCs – >70%
– NOx – 50 to >80%
SCR Operating Experience
– 18 HD Trucks Demonstrated in Europe since 1995 with Mileage Exceeding 200,000 miles
– Over 20 Marine Vessels since mid-1990s
– Some Use on Locomotives
– Several Off-Road Applications
– Several Demonstrations Currently in Process for HDD On-Road
Other Retrofit Options Can Be Used to Reduce Other Retrofit Options Can Be Used to Reduce Emissions on Existing VehiclesEmissions on Existing Vehicles
Active Lean NOx Catalysts with Heat Recuperator and Filter for Reductions in CO, HC, Toxics, NOx, and PM
– Demonstrations in California
– Several systems being validated
Diesel Particulate Filters Are Extremely Diesel Particulate Filters Are Extremely Effective (NYB Cycle)Effective (NYB Cycle)
9.1
13.1
4
6.5
0.6
0.2
3
0.3
7
0
2
4
6
8
10
12
14
THC*10 (g/ mile) CO (g/ mile) PM *10 (g/ mile)
OE w/ LSD DPF w/ ULSD
93-98% Reduction In Excess of a 93% Reduction in PM, CO, and HC Emissions
Diesel Particulate Filters Are Extremely Effective in Diesel Particulate Filters Are Extremely Effective in Controlling Toxic Hydrocarbon Emissions (NYB Cycle)Controlling Toxic Hydrocarbon Emissions (NYB Cycle)
0
50
100
150
200
250
300
350
Form
aldeh
yde
Aceta
ldeh
yde
Aceto
ne
Tota
l
Engine-Out
Filter
89-98% Reduction
In Excess of a 98% Reduction in Total Carbonyl Emissions
SCR Test Results in European & US Steady State Test SCR Test Results in European & US Steady State Test CycleCycle
0
500
1000
1500
2000
2500
1 2 3 4 5 6 7 8 9 10 11 12 13mode
NO
x [g
/h]
NOx before catalyst: 6.79 g/bhphr NOx after catalyst: 1.34 g/bhphr
NOx conversion: 80%
Retrofit ExperienceRetrofit Experience
Mining
Materials Handling
Truck and Bus
– Transit bus, school bus, waste haulers, delivery trucks, utility trucks
Marine Vessels and Locomotives
Stationary Diesel Engines
– Emergency Standby, Peak Shaving, Base Loaded
Overview of Retrofit ProgramsOverview of Retrofit Programs
United States
– ARB Diesel Risk Reduction Plan
– Mandatory Urban Bus Retrofit/Rebuild Program
– U.S. EPA Voluntary Retrofit Program
– Other Programs:
– SCAQMD Rules 1190 –1196, ARCO/ARB/CEC Program Member Retrofits, New York City Transit Retrofit Program, Long Beach Transit Retrofit Program, Seattle’s King County Transit Retrofit Program, WMATA Transit Retrofit Program, MBTA Transit Retrofit Program, School Bus Retrofits (L.A., OR, NY, PA), Seattle DOT, New York City DOT / DOS, NESCAUM/NEP/MECA Nonroad Equipment Pilot Demonstration Program, Boston Central Artery/Tunnel Project Retrofit Program
Overview of Retrofit Programs (cont.)Overview of Retrofit Programs (cont.)
International (cont.)
– Sweden’s Clean Cities Retrofit Program
– London Bus and Truck Program
– German Central City/Tunnel Clean Diesel Program
– Retrofit of Tunnel Construction Equipment in Germany, Austria and Switzerland
– Paris Bus Retrofit Program
– Retrofit Programs in Japan, Korea, Taiwan, Mexico, and Hong Kong
Filter System Retrofitted to a Refuse TruckFilter System Retrofitted to a Refuse Truck
Filter System
Both Oxidation Catalysts and Diesel Particulate Filters Have Both Oxidation Catalysts and Diesel Particulate Filters Have Been Extensively Retrofitted to This Type of Mining VehicleBeen Extensively Retrofitted to This Type of Mining Vehicle
ConclusionsConclusions
A Variety of Demonstrated Retrofit Technologies Are Available to Significantly Reduce PM, NOx, HC, CO, Toxic, Smoke and Odor Emissions from Existing HDDEs
Available Retrofit Control Technologies and Applications Are Expanding
Advanced Control Technologies Are Being Developed, Tested and Commercialized
Successful Retrofit Programs Are Occurring Worldwide