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

Overview of Retrofit Control TechnologiesOverview of Retrofit Control Technologies

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

EGR SystemEGR System

Courtesy of Southwest Research Institute

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

Emissions Control PerformanceEmissions Control Performance

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

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 TruckFilter System Retrofitted to a Truck

Filter System

Filter System Retrofitted to a Refuse TruckFilter System Retrofitted to a Refuse Truck

Filter System

Integrated Converter MufflerIntegrated Converter Muffler

Muffler Replacement

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