Transcript Activation Energy Profile with and without a Catalyst

Retrofit Emission Control Technologies
for On- and Off-Road Diesel Engines
Manufacturers of Emission Controls Association
May 2002
Presentation Outline
 Introduction
 Overview of Retrofit Control Technologies
 Examples of Emissions Control Performance
 Retrofit Experience
 Conclusion
Introduction
 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 Technologies
Diesel Particulate Filters
Trapped PM
Cell Plugs
Exhaust (CO2, H2O)
Out
Exhaust
(PM, CO, HC)
Enter
Ceramic Honeycomb
Wall
Diesel Particulate Filters Are Efficient and
Are 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 Catalyst
CO
Aldehydes
HC
PAH
SO2
NOx
C2H2n+2
CO2
H 2O
SO2 /SO3
NOx
PAH
Soot
Metals
SO2+H2O
Flow through monolith
with catalytic coating
CO + 1/2 O2
HC + O2
PAH + O2
Aldehydes + O2
CO2
CO2 + H2O
CO2 + H2O
CO2 + H2O
SO2+H2O
Soot
Metals
Diesel Oxidation Catalysts Are Efficient and
Have 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 Controlled
blow-by filter &
pressure regulator
air filter
breather
port
engine
turbo
aftercooler
check valve
drain to oil sump
Returns Crankcase PM
Emissions to the Oil Sump
Eliminates a Significant
Source of PM
EGR System
Courtesy of Southwest Research Institute
Retrofit 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
Dosing Unit
diagnos
operating
e
data
reducing
agent
ECU
DCU
EDC
engine
(NH2) 2CO
(NH2) 2CO
exhaust
gas
purified
exhaust gas
NOx,
O2
N2 ,
H2 O
Catalyst
SCR Has Been Used Successfully on Stationary
Sources 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
Emissions 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 Performance
13.14
Diesel Particulate Filters Are Extremely
Effective (NYB Cycle)
14
10
9.1
12
93-98% Reduction
6.5
8
6
4
0.37
0.23
0.6
2
0
THC*10 (g/mile)
CO
OE w/ LSD
(g/mile)
PM *10 (g/mile)
DPF w/ ULSD
In Excess of a
93% Reduction in
PM, CO, and HC
Emissions
Diesel Particulate Filters Are Extremely Effective in
Controlling Toxic Hydrocarbon Emissions (NYB Cycle)
350
300
89-98% Reduction
250
200
Engine-Out
Filter
150
100
50
To
ta
l
Ac
et
on
e
Ac
et
al
de
hy
de
Fo
rm
al
de
hy
de
0
In Excess of a 98%
Reduction in Total
Carbonyl Emissions
SCR Test Results in European & US Steady State Test
Cycle
2500
NOx before catalyst:
NOx after catalyst:
NOx [g/h]
2000
6.79 g/bhphr NOx conversion: 80%
1.34 g/bhphr
1500
1000
500
0
1
2
3
4
5
6
7 8
mode
9
10 11 12 13
Retrofit Experience
Retrofit 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 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.)
 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 Truck
Filter System
Filter System Retrofitted to a Refuse Truck
Filter System
Integrated Converter Muffler
Muffler
Replacement
Both Oxidation Catalysts and Diesel Particulate Filters Have Been
Extensively Retrofitted to This Type of Mining Vehicle
Conclusions
 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