Retrofit Emission Control Technologies for On- and Off-Road

Retrofit Emission Control Technologies for On- and Off-Road Diesel Engines Manufacturers of Emission Controls Association May 2002

Presentation Outline l Introduction l Overview of Retrofit Control Technologies l Examples of Emissions Control Performance l Retrofit Experience l Conclusion

Introduction l l l 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 (CO 2, H 2 O) Out Exhaust (PM, CO, HC) Enter Ceramic Honeycomb Wall

Diesel Particulate Filters Are Efficient and Are Developing an Impressive Track Record l Filter Control Capabilities – PM -- >85% Reduction – CO and HC -- >90% Reduction – Toxic HCs -- >90% Reduction l 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 SO 2 NOx C 2 H 2 n+2 CO 2 H 2 O SO 2 /SO 3 NOx PAH Soot Metals SO 2+H 2 O Flow through monolith with catalytic coating CO + 1/2 O 2 HC + O 2 PAH + O 2 Aldehydes + O 2 CO 2 + H 2 O SO 2+H 2 O Soot Metals

Diesel Oxidation Catalysts Are Efficient and Have Excellent Operating Experience l Oxidation Catalyst Control Capabilities – PM -- 20 -50% Reduction – CO and HC -- >90% Reduction – Toxic HCs -- >70% Reduction l 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 LDD Vehicles in Europe

Crankcase PM Emissions Can Be Controlled 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 l EGR Control Capabilities – >40% NOx Reduction – Can Be Used in Conjunction with Filter Technology to Provide Substantial PM Reductions As Well l 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 diagno operating se data ED C engine reducing agent ECU DCU (NH 2) 2 CO exhaust gas NOx, O 2 Catalyst (NH 2) 2 CO purified exhaust gas N 2 , H 2 O

SCR Has Been Used Successfully on Stationary Sources and Is Now Used for Mobile Sources l SCR Control Capabilities (w/ Integral Oxidation System) – PM – 20 -50% Reduction – CO and HC -- >90% – Toxic HCs – >70% – NOx – 50 to >80% l SCR Operating Experience – 18 HD Trucks Demonstrated in Europe since 1995 with Mileage Exceeding 200, 000 miles – Over 20 Marine Vessels since mid-1990 s – 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 l 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

Diesel Particulate Filters Are Extremely Effective (NYB Cycle) 93 -98% Reduction 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) 89 -98% Reduction In Excess of a 98% Reduction in Total Carbonyl Emissions

SCR Test Results in European & US Steady State Test Cycle

Retrofit Experience

Retrofit Experience l Mining l Materials Handling l Truck and Bus – Transit bus, school bus, waste haulers, delivery trucks, utility trucks l Marine Vessels and Locomotives l Stationary Diesel Engines – Emergency Standby, Peak Shaving, Base Loaded

Overview of Retrofit Programs l 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. ) l 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 Replacement

Both Oxidation Catalysts and Diesel Particulate Filters Have Been Extensively Retrofitted to This Type of Mining Vehicle

Conclusions l l 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