June, 2005

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June, 2005

• Retrofit Options for the In-use Non-road Fleet
• Kevin F. Brown

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U.S. Mobile Source PM in 2010Total PM Projection
621,000 tons / yr. Total NOx Projection 7.8
million tons / yr.
HD Gasoline 3
Hwy Diesel 15
Hwy Diesel 9
Other 14 ie. aircraft
Nonroad Diesel 38
Other 4 ie. aircraft
HD Gasoline 1
Nonroad Diesel 60
LD Gasoline 16
LD Gasoline 40
NOx Inventory
PM Inventory
Source US Federal Register, Vol 64, No. 92, May
13, 1999
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Retrofit Technology Options

• PM Control
• Particulate Filters
• Oxidation Catalysts
• Fuel Choice
• Reduce Fuel Sulfur
• ULSD
• Bio-Diesel
• Emulsion, etc.
• Rebuild / Repower

• NOx Control
• Fuel Emulsions
• Lean NOx catalysts
• Selective Catalytic Reduction Systems (SCR)
• Exhaust Gas Recirculation (EGR)
• Rebuild / Repower

Commercial
Earlier commercial stages
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Diesel Oxidation Catalysts
CO HC PAH SO2 NO
CO2 H2O SO2 NO

• DOCs are proven, durable, not complex and are
  easily installed
• reduces TPM by 20 to 50
• does not address NOx

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DOC Design for Nonroad
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Fuel Effect on DOC emissions2001 DT466E
Engine-out
g/hp-hr
Source SAE 2004-01-1085, Environment Canada et.
al.
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1997 Capacity Recycle / Split Rear Loader Series
50 310 hp over garbage truck cycle
City of Houston / Environment Canada Vehicle
Emission Reduction StudyTesting of PuriNOx AZ
Purimuffler (Base fuel S level ca. 350 ppm)
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1992 Gradall Excavator with Cummins B 190
hp over off-road excavation cycle
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Reduction Compared to Baseline Diesel
1993 Ford Tractor / Mower with Ford 5L 76hp over
field mower cycle
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1
2
2
3
3
3
Emission
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Port of Houston Testing
Capacity Yard Tractor with Tier 1 Cummins C
engine Tested in-use- fully loaded
condition Baseline No. 2 off-road diesel
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Diesel Particulate Filters
Trapped PM
PM CO HCs PAHs SO2 NO
CO2 H2O NO SO2
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Diesel Particulate Filters

• Passively regenerating DPFs have been used
• successfully on 1994 and newer 4-stroke HD
  engines
• Require ULSD duty cycle to produce minimum
  exhaust temperatures for a specified portion of
  time

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Passive DPF Technology Carry-over from Hwy to
Non-road? Answer Most
often not

• ULSD lt15 ppm Sulfur Fuel will not be mandated
  outside CA until after 2010
• Exposure to Higher Sulfur fuels prevents the
  direct transfer of current catalyzed passive
  DPFs in hwy to non-road
• Excessive sulfate formation offsets PM reduction
• Fuel Sulfur deteriorates / increases regeneration
  temperature of NO2 generating catalysts
• Most non-road engines emit higher levels of PM
• Non-road duty cycles are typically highly
  variable
• The answer will likely be to re-engineer systems
  and re-verify

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How to properly retrofit a DPF?
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Proper Retrofit Installation
Source SAE 2004-01-0077
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Combifilter Experience

• Operates independently of duty cycle fuel
  sulfur
• Used on lift-trucks in Europe since 1986
• Deployed on construction utility vehicles since
  1995
• Engineered for stationary applications since 1999
• Approved by VERT (Swiss certification)
• Approved Sweden Environmental Zones
• ARB Verified

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Unikat CombifilterStandard On-board regeneration
Outlet section (Optional DOC)
Back pressure alarm system
Control panel
Center section with filter
Inlet section with electrical heater
V-Type Cordierite filter, 8 hours
regeneration K-Type SiC filter, 8 hours
regeneration S-Type SiC filter, 60 minutes
regeneration
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Unikat CombifilterExchange System Off-board
regeneration
Inlet without Heating elements
Quick Release Clamp
V-Type Cordierite filter, 8 hours
regeneration K-Type SiC filter, 8 hours
regeneration S-Type SiC filter, 60 minutes
regeneration
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Combifilter Models
Types VK
Types S

• 8 hour regeneration
• Air supplied from panel
• K model uses SiC filter
• V model uses cordierite

• 60 min. regeneration
• Closed loop element control
• On Off-Board regeneration
• Built-in safety features

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Materials Handling
Examples Lift trucks Yard tractors Container
handlers
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Underground / Service Equipment
Tunneling, Subway, Mining, Airports
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Combifilter Systems for Stationary Power
Generation 500 -2500 KVA - Taiwan 6 - 12
Filters per Bank Combifilter Systems
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Construction
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Combifilter Site Implementation

• Regeneration Stations are installed within a
  shipping container or trailer
• The unit is transported to the site and
  hooked-up activating all equipment
• smaller exchange filters regenerated inside
• On-board systems drive up along side unit and
  use access panel

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DPF Cleaning and Maintenance

• Commercial systems available
• Example Combiclean
• Easy connection power shop compressed air
• Fully automated - safe and environmentally
  friendly DPF cleaning process
• 3 hours cleaning cycle
• 2 set programs for Cordierite and Silicon Carbide
  filter materials
• Closed loop temperature for filter and heater
  element protection as well as safe controlled
  regeneration
• Vacuum collection for safe disposal of ash

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Summary

• DOC, DPF and other retrofit technologies are
  commercial and verified for PM control
• Retrofit technologies for NOx control and
  combined PM/NOx control are emerging
• Look for EPA/CARB verified products and published
  data
• Non-road technologies require additional
  attention be paid to design, function and
  installation issues

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Contacts

• Lubrizol Engine Control Systems
• 165 Pony Drive
• Newmarket, Ontario
• L3Y 7V1
• Tel [phone] or 1-800-661-9963
• E-mail ecs_at_lubrizol.com
• Manufacturers of Emissions Control Association
• Washington, DC
• [phone]
• Website www.meca.org