Retrofit Presentation

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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
Clean Air Act requires EPA to take steps to
remedy regional haze in 156 pristine Class I
areas
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2007 Highway HDE Program
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Nationwide Heavy-Duty PM Emissions
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Nationwide Heavy-Duty NOx Emissions
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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
  pollution-reducing 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 engines
  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

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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 NOx CO HC
Carbon NOx Water
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 Efficientand 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 gt 40
• HCs gt 50

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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 gt 75
• HCs gt 85

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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

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Filter Regeneration Strategy Some Considerations

• 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)

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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, 5-15
• Hydrocarbon injection can increase control
  capabilities

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Exhaust Gas Recirculation (EGR)

• A portion of the engines 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 gt40

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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 gt80
• 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
  the regeneration strategy to be followed

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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
• Devices are often installed in-line or as a
  muffler replacement

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Key Considerations for Retrofit Programs

• Retrofit Technology Check List (cont.)
• Fuel Type
• For PM control, lt15 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 maintainedkey factor for success
• Retrofit technologies should be maintained per
  their manufacturers recommended procedures

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Frequently Asked Questions Concerning Retrofit
Programs

• Costs
• Costs depend on many factors including
• 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.)
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 manufacturers
  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

• EPAs 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 Boards Diesel Risk
  Reduction Program
• http//www.arb.ca.gov/diesel/dieselrrp.htm