1. Atlas Copco Compressors LLC
Introduction – IT4
Scott Ellinger
NOTES

2. EPA Tier 4 Regulations Focused on Reducing PM & NOx emissions
Two-Phase Introduction: INTERIM & FINAL
Focused on Reducing PM & NOx emissions
Introduction Timing varies by HP Band
US, Canada, EU & Japan will be Broadly Aligned

3. Construction and Ag - 2012 75 -751 HP Engines 2 4 4 2 4 3 2
Unregulated
Tier 1 / Stage I
Tier 2 / Stage II
Tier 3 / Stage IIIA
Tier 4 Interim / Stage IIIB
Tier 4 Final / Stage IV

4. EPA Mobile Tier 4 Nonroad Standards
(1) Compliance with optional ‘Option 1’ 0.30 g/kW-hr PM limit in 2008 allows 1-year delay of T4 until 2013.
Option 1 engines in 2008 are T4i engines, not T3 engines.

5. Tier 4 Challenge
Tier 4 Final brings a 90% reduction in emissions compared to Tier 3
Achieving near zero emissions by 2014
6.8
Tier 1 / Stage 1 (1996)
Tier 1 / Stage 1 (1996)
Representative of most stringent emission levels: hp ( kW)
4.8
NOx g/hp-hr
Tier 2 / Stage II (2001)
Tier 2 / Stage II (2001)
3.0
Tier 3 / Stage IIIA (2005)
Tier 3 / Stage IIIA (2005)
45% lower
1.5
Tier 4 Interim / Stage IIIB (2011)
90% lower
0.3
Tier 4 Final / Stage IV (2014)
0.015
0.15
0.4
PM g/hp-hr
90% lower

6. Emissions & EPA Compliance

7. Achieving ‘Near-Zero’ Emissions
Emissions from 25 x Tier 4 Final machines will be equivalent to just 1 x Tier 1 machine
Cummins Confidential

9. Terms and Key Words – IT4 Applications
Regeneration: The process of eliminating built up soot from the exhaust system
Two types of Regeneration
Active Regeneration:
Using a hydrocarbon (fuel) to elevate exhaust gas temperatures above 1100 F in order to remove built up soot from the exhaust filter
Passive (Natural) Regeneration:
Using temperature alone to burn soot by elevated exhaust temperature
Can be controlled by temperature management of the exhaust stream
Can be achieved by maintaining exhaust gas temperature
Can also be achieved by control valves that effect exhaust backpressure
At some point Active Regeneration must be used

10. Terms and Key Words – DOC and DPF
Diesel Particulate Filter (DPF)
Diesel Oxidation Catalyst (DOC)

11. Diesel Oxidation Catalyst (DOC)
Open cell substrate flow though device
Reduces HC and CO significantly
Reduces Pm 10 to 30%
Converts NO to NO2 for passive regeneration of the DPF
Oxidizes HC (diesel fuel) as part of active regeneration strategy
No servicing required
Requires use of low sulfur diesel or ULSD
Typically element is ~100% of engine displacement in size

12. Diesel Particulate Filter (DPF)
Wall flow, high filtration efficiency (>95%)
Traps ash, soot and any particles
Needs periodic regeneration / cleaning
Periodic ash cleaning required
No muffler required in the vast majority of applications

13. Regeneration Active Regeneration
Particulate matter left in the filter system is burned off extending the lifetime of the filter.
Uses a fuel burner in the exhaust stream that intermittently raises the temperature above 600°C (1112°F)
Converts particulate matter to CO2 & Ash.

14. Terms and Key Words Soot
Incomplete combustion of hyrdocarbons in the exhaust stream
Can be purged from the DPF by re-generation
Ash
Incomplete combustion of some hydrocarbon by-products
CANNOT be purged from the DPF by re-generation
EPA Mandated that DPF must withstand 4500 hrs before ash cleaning is needed
HPCR
High pressure common rail fuel system
System pressures up to 30,000 psi
Allows mulitple injection events to take place reduce emmisions
VGT
Variable Geometry Turbocharger
Inlet guide vanes can adjust to provide exact boost pressure to work in conjunction with the EGR

15. Terms and Key Words ULSD Low ash Engine oil
Ultra low sulfur fuel (less than 15 ppm)
Must be used on all IT4 machines
Normal diesel fuel will kill an EGR and DOC within a few tank fulls
Low ash Engine oil
Must be used on all IT4 machines to reduce the formation of ash accumulating in the DPF
CANbus – Method of communication between controllers or networks. All of Atlas Copco controllers use SAE J1939 Can communication

16. Emissions & EPA Compliance - EGR
EGR: Exhaust Gas Recirculation
Exhaust gases are cooled and injected back into the engine cylinders to reduce NOx.
Result:
Lower peak combustion temperature generates less NOx but more particulate matter
Heat rejection to radiator increases

17. Interim Tier 4 PowerTech Plus Technology
HC (fuel) Injection
DOC
DPF
Exhaust Gas
Cooled Air from Intercooler
Variable Geometry Turbocharger (VGT)
Air Inlet
EGR
Cooler
EGR Valve
NOx reduction with additional cooled EGR – building on Tier 3 PT+
VGT turbocharger
Larger EGR cooler and valve
Hydrocarbon (HC) and some Particulate Matter (PM) control with Diesel Oxidation Catalyst (DOC)
Majority of PM reduction via Diesel Particle Filter (DPF)
Active Regeneration System for DPF
Compressed Air from Turbocharger

18. Regeneration Stratagy

19. DPF Regeneration ECU controls active regeneration
Diesel fuel added to system for 10 minutes every 5 to10 hrs
Raises temperature into DPF to ~600°C (~1112°F)
Soot Level

20. Exhaust Filter Cleaning & Maintenance
Designed for extended maintenance free operation but ash accumulation does occur.
Minimum maintenance interval for ash removal, as defined by the EPA, is 4500 hours.
This service interval can be increased depending on duty cycle
DPF must be removed from unit and placed in specialized equipment for cleaning by a John Deere service technician.
John Deere has set up a remanufactured filter program where the user buys a remanufactured filter & gives the core to the dealer/service center for cleaning.

21. DPF Information - Indicators

22. Exhaust Filter Cleaning & Maintenance
Several ways to extend service intervals
Reduce idle time
Enable auto cleaning
Operate in high load condition when possible
Use only Ultra low sulfur diesel fuel
Use only approved low ash oil

23. Other IT4 items
Preheat is controlled by John Deere without any control or parts from our side
Engine contains the relay, fuse, and all necessary wiring to the glow pugs
Preheat timing amount is a function of the fuel temperature
Timing is calculated by the engines ECU
All exhaust piping is Stainless steel
Exhaust piping wrapped with insulation
Exhaust bellows can be leakage points and should be occasionally inspected for distortion

24. Contact Numbers Main Number Atlas Copco Technical Support
Option 3
Clayton Jones - Hurricane Boosters/Compressors - Supervisor
direct & mobile
Andrew Stevenson – Compressors: Low Pressure
direct & mobile
Will Hudson – Generators/Compressors
Ext & mobile
Andrew Calendar – Compressors: High Pressure
direct & mobile
Jon Monaco - Hydraulic Att./Handheld Tools
Ext & mobile
Brandon Dyer – Compressors: Low Pressure/Hydraulic Att.
direct & mobile
Scott Ellinger – Compressors
direct & mobile

25. Committed to Sustained Productivity.25
NOTES