Transcript Retrofit Presentation - Maryland Dept. Of The Environment

Voluntary Diesel Emission
Reduction Programs
HD Rule/Retrofit
Steve Albrink
Retrofit Program
Office of Transportation and Air Quality
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Need for Air Pollution Reduction
Fine particles from diesel exhaust can
remain in the atmosphere for weeks,
and carry over hundreds of miles
Diesel exhaust is
likely to be
carcinogenic to
humans
Ozone has been shown
to reduce yields of
vegetables and field
crops
8 Hour Ozone Nonattainment Areas
Counties Exceeding PM2.5 NAAQS
Clean Air Act requires EPA to
take steps to remedy regional
haze in 156 pristine “Class I”
areas
8 Hour Ozone Nonattainment AND PM 2.5 NAAQS Exceedances
Federal Class I Areas (Visibility)
Air quality data derived from AQS (PM 2.5: 2000-2002 data;
8 Hour Ozone: 2001-2003 data) with data handling per Agency guidance.
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2007 Highway HDE Program
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Nationwide Heavy-Duty
PM Emissions
without new
standards
with new
standards
Calendar Year
4
Nationwide Heavy-Duty
NOx Emissions
without new
standards
with new
standards
Calendar Year
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Estimated Costs and Benefits
• Health benefits
The program will prevent annually:
Over 8,300 premature deaths
Over 750,000 respiratory illnesses
1.5 million lost work days
• Benefits are 16 times greater than costs
 Monetized benefits: $70.3 billion/year
 Compliance costs: $4.3 billion/year
– Estimated at $1,200-1,900 per engine
– About 5 cents per gallon of fuel
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2007 HDE Program
Key Elements
• Applies new NOx and PM standards to
heavy-duty engines and vehicles
–90%+ emission reductions
–Phase-in of NOx standards 2007-2010
–Incentives for early technology introduction
•Reduces diesel fuel sulfur levels nationwide
–Enables use of aftertreatment technology
–Highway diesel fuel sulfur cap of 15 ppm
–Transitional flexibilities 2006-2010
–Small Refiner Flexibility
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Valuable to States
• States will be counting on heavy-duty diesel
emission reductions to meet National Ambient
Air Quality Standards.
•Nonattainment Areas for PM2.5 and 8-hour
Ozone will be designated this year.
•State Implementation Plans (SIP) will include
these reductions.
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VOLUNTARY DIESEL
RETROFIT PROGRAM
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What is the Voluntary Diesel
Retrofit Program?
• A voluntary program designed to install pollutionreducing technology on existing diesel vehicles
and equipment
–Existing diesel engines can last 20-35 years
–2007 Highway & Proposed Nonroad rules address
only future engines
• We are building a market for clean diesel
concepts
–Accelerating the delivery of ULSD
–Forging business partnerships and relationships
–Investing EPA resources to accelerate market growth
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Successful Retrofit Program Model
• The Diesel Retrofit Program works best when:
–EPA HQ and Regional offices create partnerships with
local leadership
–Local leadership is in the best position to:
•Create expanding retrofit programs (as opposed to a single
demo)
•Work with local fleet management and decision makers
•Know how to secure local and regional funding
• EPA will supply technical support:
–Engine manufacturers
–Retrofit manufacturers
–Fuel refineries and suppliers
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EPA Funded Projects
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The Role of Diesel Fuel
•ULSD is becoming more widely available
throughout the country
–Several fuel companies can distribute ULSD today in specific
regions
•The foundation of many retrofit projects will be
the fuel supply
–Many technologies require Ultra Low Sulfur Diesel (ULSD) Fuel
–Some can operate on current fuel but can not achieve full
emission reduction potential
–Generally, PM filter with ULSD achieve PM reductions over 90%
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ULSD Availability
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What is Retrofit Technology?
• Retrofit technology can be: any change to an engine
system above and beyond what is required by EPA
regulations that improves the engine’s emission
performance:
•Catalyst or filter
•Engine upgrade
•Early engine replacement
•Use of cleaner fuels or additives
•Idling control equipment
•Combination of above
• Retrofit Web site maintains a list of manufacturers
and verified technology
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Retrofit Technology Verification
• Objective: Evaluate the emission reduction
effectiveness of retrofit technology
- Verification provides stakeholders with confidence that
these technologies will achieve quantifiable emission
reductions
• Verification consists of the following:
- Appropriate Testing Protocols
- Statistical Sampling Methods
- Durability Requirements
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Retrofit Technology Verification
•14 Technologies Currently EPA-Verified
–DPFs, DOCs, Crankcase Filtration, Emulsified Fuel,
Biodiesel, Cetane Enhancers
•Recent Verification
–Caterpillar, DOC
–Engine Control Systems, DPF
–Donaldson, DOC & Crankcase Control
–Clean Diesel Technology, DOC & Fuel Borne Catalyst
•Several Verifications in Process
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Diesel Retrofit Technologies:
An Overview
• Existing emission controls systems can greatly
reduce diesel particulate matter (PM) emissions
– Diesel oxidation catalysts and diesel particulate filters
• Existing and developing emission control systems
can greatly reduce NOx and PM emissions
– Lean NOx catalysts, EGR, SCR and combined
systems
• Technologies to control crankcase emissions
• Advanced fuels
– Low sulfur
Diesel Retrofit Technologies: An
Overview
• Integrated emission control systems will
allow diesel engines to meet future
emission challenges
• Integration will involve the entire vehicle
including:
– The engine
– The emission control system
– The fuel
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Diesel Oxidation Catalysts
Carbon
SOF
Carbon
NOx
NOx
CO
Water
HC
Oxidation catalysts oxidize carbon monoxide (CO),
hydrocarbons (HCs) and the soluble organic fraction
(SOF) to reduce particulate matter (PM), CO, HCs, and
toxic emissions
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Diesel Oxidation Catalysts Are
Efficient
and a Proven Technology
• Hundreds of thousands have been retrofitted
since the 1960s on highway, mining,
materials handling and construction vehicles
• Durabilities in excess of 10,000 hours of
operation
• Diesel oxidation catalyst control capabilities
– PM 20 to 30% reduction
– CO > 40%
– HCs > 50%
Diesel Particulate Filter
Technology
Trapped Soot
Cell Plugs
Exhaust (CO2, H2O)
Out
Exhaust In
(Soot, CO, HC)
Enter
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Diesel Particulate Filters Are
Efficient and Are Developing
an Impressive Track Record
• Filter control capabilities
– PM 80% to 90% reduction
– CO > 75%
– HCs > 85%
PM Emissions
with Trap
• Typical test filter –
current standards
• Test filter – 2007
standards
• Unused test filter
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Diesel Particulate Filter Retrofit
Experience
• Retrofitting existing diesel engines with diesel
particulate filters is an available strategy to
reduce emissions including PM, CO, and HCs
• A growing number of programs and applications
have been successfully completed on highway,
non-road and stationary engines
• More than 25,000 filter systems have been
installed on highway vehicles
• Retrofit technology development continues to
expand the range of applications available
Filter Regeneration Strategy:
Some Considerations
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•
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•
•
Application and duty cycle
Engine out emissions
Vehicle/engine condition
Fuel sulfur level
Maintenance and operational procedures
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Filter Regeneration Strategies
Used to Date In Retrofit
Applications
•
•
•
•
•
•
Engine reliant
Catalyst-assisted
Electric heater-assisted
Fuel burner-assisted
Off-board regeneration
Intake/exhaust throttling
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Overview of Filter Retrofit
Programs
• The number and scope of retrofit programs
are rapidly growing
– North America (California, New York, New
England, Mexico, and elsewhere)
– Europe (Austria, Finland, France, Germany,
Sweden, Switzerland, and United Kingdom)
– Asia (Hong Kong, Korea, Japan, and Taiwan)
– Latin America (El Salvador and Nicaragua)
• Over 50,000 filters retrofitted worldwide on
highway and non-road vehicles
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Other Control Technologies
• Emulsified Fuel- up to 50% PM, 10 to 15%
NOx
• Biodiesel (B-20 up to 7% PM, 4% NOx)
• DOC w/ fuel borne catalyst (41-50% PM)
• DOC w/ crankcase filtration (25+% PM)
• Lean-NOx catalysts
• Exhaust gas recirculation (EGR)
• Selective catalytic reduction (SCR)
Lean NOx Catalysts
• Used on passenger cars in Europe and
on some heavy-duty engines as original
equipment
• Have been retrofitted on a limited scale
• Can achieve modest NOx reductions, 515%
• Hydrocarbon injection can increase
control capabilities
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Exhaust Gas Recirculation (EGR)
• A portion of the engine’s exhaust is
recirculated to the turbocharger inlet or intake
manifold
• Cooled, recirculated gases lower combustion
temperatures and reduce NOx formation
• Particulate filters are an important part of
EGR systems, preventing PM from being
recirculated to the engine
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Exhaust Gas Recirculation (cont.)
• EGR systems have been installed on
some newer engines
• Technology demonstration programs of
retrofits have been conducted in
Houston and Los Angeles; more
programs are planned for other cities
• EGR can achieve NOx reductions of
>40%
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Selective Catalytic Reduction
(SCR)
• Used extensively on stationary sources
• Has been applied to marine vessels and
locomotives and in truck and passenger car
demonstration programs
• Involves use of a catalyst, a reagent (usually
a solution of urea, sometimes ammonia)
and dosing equipment to inject the reagent
into the exhaust stream
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Selective Catalytic Reduction
(cont.)
• SCR control capabilities
– PM – 30 to 50% reduction
– CO and HC – >80%
– NOx – 60 to 80%
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Key Considerations for Retrofit
Programs
• How long the vehicle is going to remain in
service
• The condition of the engine is an important
factor in making a decision whether to install
retrofit control technology
• Retrofit at the time of engine rebuild can be
advantageous
• For filter retrofit, one must consider: vehicle
application, exhaust temperature (duty cycle),
engine-out PM emissions, fuel sulfur level, and
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the regeneration strategy to be followed
Key Considerations for Retrofit
Programs
• Retrofit Technology Check List
– Model Year
• Generally, only 1994 and newer should get PM
filters
• Some newer engines came with DOCs from the
factory
– Size
• Properly sized control systems ensure low back pressure and
maximum performance
– Vehicle Integration
• Space, accessibility and exhaust temperature are important
vehicle integration issues
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• Devices are often installed in-line or as a muffler replacement
Key Considerations for Retrofit
Programs
• Retrofit Technology Check List (cont.)
– Fuel Type
• For PM control, <15 ppm sulfur fuel allows for
maximum emission control performance (even for
DOCs) and best filter regeneration characteristics
– Maintenance
• Vehicles to be retrofitted should be properly and
regularly maintained—key factor for success
• Retrofit technologies should be maintained per
their manufacturer’s recommended procedures
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Frequently Asked Questions
Concerning Retrofit Programs
• Costs
– Costs depend on many factors including:
•
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Number of vehicles retrofitted (sales volume)
Retrofit technology used (oxidation catalyst, filter, etc.)
Engine size (displacement)
Engine out emissions
Fuel quality
Exhaust temperature and duty cycle (These factors will
affect which retrofit technology will be appropriate.)
– Costs are expected to decrease as the market
expands
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Frequently Asked Questions
Concerning Retrofit Programs
(cont.)
Technology
Diesel Oxidation Catalysts (DOC)
Cost per Device/System ($)
425 to 1,150
Diesel Particulate Filters (DPF)
Combined Lean NOx Catalyst/DPF
Systems
3,000 to 5,500
5,000 to 10,000
EGR Systems
13,000 to 15,000
SCR Systems
10,500 to 50,000
Notes: DPF costs are higher for active systems and systems that include backpressure
monitoring.
Year 2000 data.
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•
Frequently Asked Questions
Concerning Retrofit Programs
(cont.)
Drivability
– Properly selected retrofit technologies do not
impair driving performance
• Maintenance
– Oxidation and lean NOx catalysts are virtually
maintenance free
– Filters require very little maintenance (ash
removal)
– SCR maintenance, as per manufacturer’s
specifications
• Effects on Engine Life
– Properly maintained engines and retrofit control
systems do not shorten engine life
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Frequently Asked Questions
Concerning Retrofit Programs
(cont.)
• Fuel Penalties
– Most oxidation and lean NOx catalysts
have no effect on fuel consumption
– Most filters have no effect on fuel
consumption
– Urea consumption in SCR systems results
in an equivalent fuel penalty of 3-5%
• Warranties
– Manufacturers provide various warranties
as part of a purchase agreement
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Conclusions
• A wide variety of retrofit options are available
for diesel engines to reduce HC, CO, PM and
toxic emissions
• NOx retrofit controls are emerging
• A growing number of retrofit programs are
being successfully implemented
• Technology development continues to expand
the range of applications available for retrofit
• A successful retrofit program must be
properly designed and implemented
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Some Diesel Retrofit Web Sites
• EPA’s Voluntary Diesel Retrofit Program:
– http://www.epa.gov/otaq/retrofit
• The Manufacturers of Emission Controls
Association:
– http://www.meca.org
– Click on “Publications” to access MECA fact
sheets and technical documents on diesel retrofit
• The Diesel Technology Forum:
– http://www.dieseltechnologyforum.com/
• The California Air Resources Board’s Diesel
Risk Reduction Program:
– http://www.arb.ca.gov/diesel/dieselrrp.htm
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