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

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Presentation on theme: "Understanding Diesel Retrofit Technologies Lanny Cole Cummins Atlantic LLC Filtration and Emission Sales Manager North Carolina, South Carolina, and Virginia."— 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 3 Why Reduce Emissions? Health Effects Economic Effects Environmental Effects EPA estimates that for every $1 spent on retrofit, there is a $13 return on healthcare cost

4 4 Evolution of On-Highway Standards - EPA EPA 1994 EPA 1998 EPA 2004 PARTICULATE [g/HP-hr] NOx [g/HP-hr] Euro EPA 2010* EPA 2007* * Aftertreatment Required

5 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 7 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 EGR Combustion advances Ways to Reduce Emissions? DPF

8 8 Verification 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 –http://www.epa.gov/otaq/retrofit/verif-list.htmhttp://www.epa.gov/otaq/retrofit/verif-list.htm –EPA lists verified technologies alphabetically by Manufacturer CARB –http://www.arb.ca.gov/diesel/verdev/vt/vt.htmhttp://www.arb.ca.gov/diesel/verdev/vt/vt.htm –CARB lists verified technologies by classification Level 1 = >25% Level 2 = >50% Level 3 = >85%

9 9 EPA/CARB Verified Product Summary DOCPassive DPFActive DPFSCR DesignPassive 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 MarketAnyPre EGR and EGR engines EGR enginesPre EGR and EGR engines Emission Reduction PM > 25%, HC > 70%, CO > 40% PM = >85%, HC =90%, CO = 70% PM = 85%, HC = 90%, CO = 70% PM >85%, HC >90%, CO >70%, NOx>65% Maximum HP Ratings 600HP Temperature Requirements 40% Monitor RequiredNoYes MaintenanceNo60-100K level 1 cleaning

10 Diesel Oxidation Catalyst (DOC)

11 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 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 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 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 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 Diesel Particulate Filter PM = 90% reduction HC = >90% reduction CO = >70% reduction

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

19 19 Cooled EGR Particulate Filter Same as today Selective Catalytic Reduction 2010 Heavy Duty Solution 15L

20 20 What Technology Where? DOCDPFActive DPF Urban BusPost 93 already have DOC Available School / Shuttle Bus Available, Some models already have Available RefuseAvailable EmergencyAvailableNot recommended ConstructionAvailable, Must have LSD Must have ULSD Watch space Available, Watch space

21 Planning a Diesel Emission Retrofit Project Start with the Money

22 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 24 Compile A Fleet List 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 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 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 27 Product Decision Tree 1. What is the projects goal? PM Reduction NOx Reduction 2. Verification Required ? (CARB / EPA) Manufacturers warranty consideration 3. Fuel Type? ULSD (15 ppm) Off-road fuel BioDiesel 4. Engine Age EPA Certification Year/Emission Tier Level? 5. Duty cycle/temperature of application? Datalogging needed

28 28 Timing What is the projects timeline? –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 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 30 Business CaseFunding Technology Retrofit Success

31 Thank you


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