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Understanding Diesel Retrofit Technologies

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Presentation on theme: "Understanding Diesel Retrofit Technologies"— Presentation transcript:

1 Understanding Diesel Retrofit Technologies
Lanny Cole Cummins Atlantic LLC Filtration and Emission Sales Manager North Carolina, South Carolina, and Virginia ext 202

2 Diesel Emission Retrofit Projects
Why Retrofit ?

3 Environmental Effects
Why Reduce Emissions? Economic Effects Environmental Effects Health Effects EPA estimates that for every $1 spent on retrofit, there is a $13 return on healthcare cost

4 Evolution of On-Highway Standards - EPA
Euro EPA 1994 5.0 EPA 1998 4.0 EPA 2004 NOx [g/HP-hr] 2.5 1.2 EPA 2007* * Aftertreatment Required 0.2 EPA 2010* 0.01 0.015 0.075 0.10 0.11 PARTICULATE [g/HP-hr]

5 Key Regulated By-products
Nitrogen Oxides – air quality / smog (Ground Level Ozone) PM - health effects 56% emitted of PM attributable to diesel engine Black smoke HC / CO / Toxic Hydrocarbons – smell Retrofitting Existing Diesel Engines with Emission Control Technologies is the primary way to reduce emissions

6 Diesel Emission Basics

7 Ways to Reduce Emissions?
Engine design changes Combustion Air handling Exhaust gas recirculation (EGR) Closed Crankcase Ventilation (CCV) Fuels Ultra Low Sulfur Diesel Additives? Water emulsions? Biodiesel? Exhaust after-treatment Diesel Oxidation Catalysts – >25% PM, > 70%HC and >40% CO reduction Passive (catalyzed) Filters - >85% PM reductions, HC & >70%CO reduction, Active (electric, non-catalyzed) Filters - 85% PM reduction NOx Reducing Catalysts - 85% PM reduction, 25% NOx reduction, HC & CO reduction Selective Catalytic Reduction (SCR) 60-90% NOx reduction, HC & CO reduction CCV Combustion advances EGR DPF

8 Verification EPA CARB What does verified technology mean?
Process that EPA and CARB use to certify a technology does what the manufacturer claims. Identifies application guidelines for each device Identifies qualified engines and markets for that devices application Why is using verified technology important? Verification is required for most publicly funded projects Enables a standardized understanding and classification of technologies EPA EPA lists verified technologies alphabetically by Manufacturer CARB CARB lists verified technologies by classification Level 1 = >25% Level 2 = >50% Level 3 = >85%

9 EPA/CARB Verified Product Summary
DOC Passive DPF Active DPF SCR Design Passive Diesel Oxygen Catalyst Passive DOC with Wall Flow PM filter active DPF w/ NO2 decomp cat using fuel as NO2 reductant CRT with urea based SCR system and NH3 slip catalyst Market Any Pre EGR and EGR engines EGR engines Pre EGR and EGR engines Emission Reduction PM > 25%, HC > 70%, CO > 40% PM = >85%, HC =90%, CO = 70% PM = 85%, HC = 90%, PM >85%, HC >90%, CO >70%, NOx>65% Maximum HP Ratings 600HP 600 HP Temperature Requirements None 40% Monitor Required No Yes Maintenance 60-100K level 1 cleaning

10 Diesel Oxidation Catalyst (DOC)

11 Diesel Oxidation Catalyst
The DOC may either replace or be added to the existing vehicle muffler. Easily installs Needs no maintenance Requires no monitoring Can be used with low-sulfur (500 ppm) or ultra-low sulfur diesel fuels (15 ppm) Oxidation Catalyst Control Capabilities PM >25% Reduction CO >50% HCs and Toxic HCs -- >70%

12 Closed Crankcase Ventilation (CCV)

13 Crankcase Ventilation Filter
Closes the current open crankcase system by filtering blow-by gases thus removing oil residues and routing the residues and gases back into the engine. Simple, high efficiency, serviceable Interval – every 3rd to 4th oil change Additional 10% to 15% reduction in emissions. Replaceable filter element

14 Diesel Oxidation Catalyst + Closed Crankcase Ventilation
Combines the benefits of both for additional emissions reductions. Applies to many applications The CCV Kit eliminates 100% of engine compartment blow-by. Verified as a combination package by the EPA/CARB

15 Diesel Particulate Filter (DPF)

16 Diesel Particulate Filter
The CRT filter is capable of converting > 90% of Particulate matter >90% Hydrocarbons >70% Carbon Monoxide. Requires Ultra Low Sulfur Fuel Can use B20 bio-diesel fuel Maintenance: Periodic filter cleaning required Vehicle requires datalogging for approval to retrofit Retrofit DPFs are generally be installed as a passive system but active systems are available

17 Diesel Particulate Filter
Oxidation catalyst with Precious Metal Coating Existing exhaust temperatures are used for Passive Regeneration Oxidize injected fuel is used to produce heat for Active Regeneration PM = 90% reduction HC = >90% reduction CO = >70% reduction

18 Particulate Filters are required on engines
Heavy Duty Solution 2007 Particulate Filters are required on engines built after Jan1, 2007

19 2010 Heavy Duty Solution 15L Selective Catalytic Reduction Particulate
For 2010, Cummins will be building on the technology that we currently have in the market place. Building on our successes with Exhaust Gas Recirculation (EGR) introduced in 2002 and the Cummins Particulate Filter technology introduced in 2007, Cummins will meet the 2010 emissions standards with the addition of Nitrogen Oxide (NOx) aftertreatment using SCR. Please note….this slide is not to scale. Particulate Filter Cooled EGR Same as today

20 Some models already have
What Technology Where? DOC DPF Active DPF Urban Bus Post ’93 already have DOC Available School / Shuttle Bus Available, Some models already have Refuse Emergency Not recommended Construction Must have LSD Must have ULSD Watch space

21 Planning a Diesel Emission Retrofit Project
Start with the Money

22 Retrofit Funding Sources
US EPA Grants Santee Cooper consent decree Retrofitted 105 school buses, 60 in upstate region Smartway Program Rebates to individuals who retrofit State DAQ Spartanburg County EPF project County and City Clean Air Stakeholders State DOT Private Corporations Duke Power Cleaning up power plants and support equipment

23 Starting A Retrofit Project

24 Compile A Fleet List Fleet list is the road map of the project
Why does an accurate up to date fleet list matter? Not every engine can be retrofitted There is no “one size fits all” retrofit device Fleet list is the road map of the project Allows vehicles to be sorted into emission reduction “buckets” Retrofit Repower Replace Rebuild Refuel

25 Fleet List Equipment Make:___________________
Equipment Model:___________________ Engine Manufacturer:_________________ Engine Model:_______________________ Engine Year:________________________ Engine Horse Power:_________________ EPA Engine Family #:_________________ Quantity of Like Units:_________________ Muffler Part # or Dimensions:___________

26 Vehicle Retrofit Priority
Reduction Goals Remaining Service Life Retrofit Device Maintenance Annual costs and fleet impact The Right Technology In The Right Place

27 Product Decision Tree What is the projects goal?
PM Reduction NOx Reduction Verification Required ? (CARB / EPA) Manufacturers warranty consideration Fuel Type? ULSD (15 ppm) Off-road fuel BioDiesel Engine Age EPA Certification Year/Emission Tier Level? Duty cycle/temperature of application? Datalogging needed

28 Timing What is the projects timeline? Installation: Funding Source
Required Installation due date Installation: When are the vehicles available? When will the retrofit devices be available? Will installation be done by the retrofit vendor? Transportation to and from Down time How long to install the device

29 Reminders 1.Funding: - You cannot receive funding if you do not apply.
- If you do not succeed on your first attempt try again. - Build and Maintain working relationships with air quality stakeholders. 2. Compiling Fleet Information: - Maintain a fleet list of potential retrofit equipment. 3. What technology to use: -The right technology on the right application 4. Vehicle Priority: -Remaining years of service -Quantity of vehicles 5.. Cost Considerations: -Amount and type of reduction you are trying to achieve. -Maintenance vs. no maintenance technology 6.Timing: -Funding dealines -Installation constraints

30 Business Case Funding Retrofit Success Technology

31 Thank you

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