Emissions and Your Business

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Emissions and Your Business

• NSSGA PMD February 2006

Mike Hinrichsen Quarry Aggregates Corporate
Accounts Caterpillar Inc.
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Purpose Today

• Emissions Regulations Effect All of Us
• Significant Impact on Manufacturers
• Understand Impact Today and Future

• Emissions Regulations
• Off-Road Engines New Products
• Retrofit/Repower
• Fuels, Fluids and Filters

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Voice of the Customer My Work is Changing
Customer Driven

• Shortage of Qualified Labor
• Operating Costs Escalating
• Safety Continues to be a Important Issue
• Environmental Regulatory Pressures Increase
• Need to Maximize Productivity Do More with Less

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Emissions Regulations preparing to meet the
challenge
Particulates (Smoke )
98 reduction
97 reduction
Nitric Oxides (NOx)
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The Facts about Diesel Engines

• Diesels are the worlds most efficient internal
  combustion engines
• Todays well-maintained diesels should not emit
  excessive visible smoke
• The presence of smoke emissions equates to

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What Are Diesel Engine Emissions?

• Diesel engines produce four regulated emissions

• The emphasis is historically on NOx and PM
• NOx and PM act as tradeoffs
• During combustion, the sulfur in fuel converts to
  S02

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EPA 2007 On-Highway vs. Off-RoadEmissions
Regulations

• On-highway regulations
• stricter than off-road
• introduced earlier than off-road
• referred to as EPA 07 or EPA 10
• Off-road regulations
• referred to as Tiers
• off-road engines use fewer ACERT building blocks

NOx (g/bhp-hr)
Particulates (g/bhp-hr)
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Changing Emissions RegulationsUS Canada
Off-Road
Ultra Low Sulfur Diesel
Tier 1
Tier 2
Tier 3
Tier 4
Consent Decree companies Caterpillar,
Cummins, Detroit Diesel, Volvo

• Regulations/deadlines apply to manufacturers
  not to buyers.

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Technologies for Tier 3/Stage IIIA
1-Includes Mack 2-SCR for Euro 10/06 3-w/Isuzu
engines 4-Small engine JVs Komatsu brand/JV
w/CNH 5-Supplies Terex Liebherr (large
engines) 6-Alliance with Volvo (small engines)
Different Solutions Acert EGR
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Exhaust Gas Recirculation - Cooled EGR Process
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Caterpillar ACERTTM Technology
In Cylinder Solutions
Improves Combustion
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ACERTTM Technology Definition
Precise control of the combustion cycle, achieved
using a systems approach to fuel delivery, air
management and electronics.
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Building Blocks Systems Integration
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NOx Reduction
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Reliability Operating Cost

• Is the design, hardware and electronics proven on
  job sites like yours?
• Considerations
• of new content
• Field testing - of hours
• of technologies
• Heat rejection
• Soot loading

• Does this solutions provide similar maintenance
  schedule and fluid specs?
• Considerations
• No change in oil change intervals
• No change in oil specifications
• No change in oil reservoir capacity
• Similar fuel economy

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Retrofit / Repower
Replace the existing engine with a lower
emissions engine for significant NOx and PM
reductions.
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Emissions Retrofit Solutions Group
The adaptation of emissions reduction
technologies to existing products to reduce
emissions output.
2750 Retrofits 6,482 Tons of NOx Reduced 1,082
Tons of Particulate Matter Reduced
Repower
Aftertreatment
Upgrade Groups
Catalyzed Converter/Mufflers
Diesel Particulate Filters

• Options for 38 models (3306)

• Options for 114 models

• Options for 211 models

• Off-Road and On-Highway Applications

Data from 2002 through 2004
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Repower Considerations

• Installation
• Engine and support systems must fit
• Performance
• Specifications must match to maintain the drive
  train reliability and overall performance
• Operation
• No modification can adversely affect the basic
  machine operation

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Other Emissions Retrofit Options

• Aftertreatment
• Catalyzed Converter/Mufflers
• Reduce emissions in Cat machines
• Diesel Particulate Filters
• Remove high levels of PM from exhaust flow
• Emissions Upgrade Groups
• Upgrade to Tier 1 emissions levels during an
  overhaul
• Limited product line

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Diesel Fuel Regulatory Changes
Fuel Sulfur Content Regulations (effective
September 1 of each year)
Varies depending on refiner, some states more
strict.
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• Fuel Sulfur Lower levels for reduced emissions
  are coming
• Process of removing sulfur can impact lubricity.
  Fuel suppliers treat fuel with additives to
  provide adequate lubrication.
• Fuel suppliers responsible for the additives and
  ensuring fuel meets required specifications

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Bio-Fuels (Bio Diesel)

• Background
• Made from variety of sources soybean and canola
  oil are most common
• Characteristics
• Provides less energy per gallon than distillate
  diesel fuel
• Low ambient temperature problems for storage and
  operation
• Requires heated storage
• Plugs filters
• Poor oxidation stability ? long-term storage
  problems
• Excellent medium for microbial contamination and
  growth
• Corrosive to fuel system
• Blocks fuel filter
• Water naturally more likely to exist in biodiesel
• Facilitates microbial contamination, corrosion,
  etc.

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History Of Oil Grades
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How Much Dirt Damages Injectors ?

• Abrasives cause accelerated wear in Injectors
• To maintain performance, injectors must have
  VERY clean, highly filtered fuel
• HOW CLEAN?Can only be reduced by removing
  contaminants from the fuel

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Improved Filtration on ACERT Engines

• Driving Forces
• Migration to higher-pressure fuel system
• Additional and more efficient filtration
• Improved injector life
• New Products
• Advanced High Efficiency primary fuel filter /
  water separators (10 microns)
• Advanced High Efficiency secondary fuel filters
  (2 microns)
• Advanced Efficiency lube filters (22 microns)

Same change interval!
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Summary

• Dramatically More Stringent Regulations
• Manufacturers Investing Billions
• Emissions / Regulations Will Grow
• Will Existing Machine Population Be Effected?
• Repower May Need to Be Considered
• Deep Machine Systems Integration Required
• Low Sulfur Fuels, Filters and Contamination
  Control
• More Emphasis on Maintenance
• Increasing Enforcement Efforts Could Be Expected
• Who Is Considering These Issues In Your Business?