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ARB – Exhaust Emissions – Tier 3

ARB – Exhaust Emissions – Tier 3. Small Off-Road Engine Workshop – Expanded file EMA / OPEI Engine Manufacturers Association / Outdoor Power Equipment Institute Clean Air Act Committee. ARB – Exhaust Emissions – Tier 3. Production Catalyst Systems Small Off-Road Engine experience

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ARB – Exhaust Emissions – Tier 3

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  1. ARB – Exhaust Emissions –Tier 3 Small Off-Road Engine Workshop – Expanded file EMA / OPEI Engine Manufacturers Association / Outdoor Power Equipment Institute Clean Air Act Committee Expanded file -- July 2, 2003

  2. ARB – Exhaust Emissions –Tier 3 • Production Catalyst Systems • Small Off-Road Engine experience • ARB Test Program • Southwest Research Institute • High Efficiency Catalysts • Thermal energy management Expanded file -- July 2, 2003

  3. Small Off-Road Engine -Production Catalyst Systems • International Catalyst System – B&S • Quantum & Mod. 9/10 Side valve • 1.3 in3 ceramic -or- wire mesh substrate • 10-15% Engine Displacement • 20-30% HC+NOx Efficiency (0 hrs) • 2-3 g/hp-hr (minimum) • 10-15% CO Efficiency (0 hrs) • Tier I Carburetor calibration (moderate CO levels) • 50 g/hp-hr CO conversion (maximum) • Limited secondary air / controlled heat release • International Market Product Feature Expanded file -- July 2, 2003

  4. Expanded file -- July 2, 2003

  5. Expanded file -- July 2, 2003

  6. Small Off-Road Engine -Production Catalyst Systems • Tecumseh TVM220 • 21.8 in3 Vertical L-Head • Certified EPA Phase II • 4.2 in3 Reducing Catalyst / 19% Engine Displacement • 15% HC+NOx Efficiency at 0 Hours Tecumseh H35 • 9.5 in3 Horizontal L-Head • Certfied EPA Phase I, CARB Tier II • 4.2 in3 Reducing Catalyst / 44% Engine Displacement • 29% HC+NOx Efficiency at 0 Hours Expanded file -- July 2, 2003

  7. Small Off-Road Engine -Production Catalyst Systems • Emission Sentry System - Kohler • Automotive type system • 12.2 in3 substrate / 50% of Engine displacement • LPG application • 3-way catalyst loading • Full Engine control unit • Closed-loop feedback fuel control • O2 sensor • Low CO levels / High NOx reductions • Low volume production • High-end commercial market Expanded file -- July 2, 2003

  8. ARB / SwRI Test Program • Emission Strategies • Enleanment (2 of 5 engines) • Modified to improve catalyst efficiency - SwRI • Increased NOx / Reduced HC • Engine performance/durability concerns • Secondary Air(all 5 engines) • Needed to achieve target HC reductions - SwRI • Increased CO% efficiency / energy release • 40 to 60% CO conversion (4 of 5 engines) • B&S Intek #2 - 29% CO converted @ 0 hrs. Expanded file -- July 2, 2003

  9. ARB / SwRI Test Program • Emission Strategies • Large Metallic Catalyst substrates(4 of 5 engines) • ensured substrate mechanical/emission durability • 75% to more than 185% of engine displacement • Removed all sound reduction and cooling chamber capacity => “Catalyst container” per SwRI – Honda GCV160 retained cooling • B&S Intek #2 - 32% of engine displacement catalyst Expanded file -- July 2, 2003

  10. ARB / SwRI Test Program • Emission Strategies • Remote mounted containers(3 of 5 engines) • Provided “package space” for Secondary Air • Reduced engine/ catalyst temperature interaction • Reduced catalyst system temperatures • pre-catalyst, substrate mid-bed, container surface & exhaust temperatures • Reduced vibration interaction – system durability • Both B&S Inteks close mounted Expanded file -- July 2, 2003

  11. Catalyst Secondary Air –% CO reductions Expanded file -- July 2, 2003

  12. Catalyst Secondary Air –% CO reductions Expanded file -- July 2, 2003

  13. Catalyst Secondary Air –% CO reductions Expanded file -- July 2, 2003

  14. Catalyst Secondary Air –% CO reductions Expanded file -- July 2, 2003

  15. Catalyst Secondary Air –% CO reductions Expanded file -- July 2, 2003

  16. SwRI – Briggs & Stratton Intek #1 • Emission Strategies • Enleanment - A/F Ratio modified • Performance and Durability concerns • Passive Secondary Air Injection • Increased HC and CO efficiency • Increased Thermal energy release • 9.0 in3 Substrate = 75% of displacement • Replaced Stock Muffler with SLT Optional Muffler • Removed sound/cooling chambers • Catalyst “container” only Expanded file -- July 2, 2003

  17. Expanded file -- July 2, 2003

  18. Expanded file -- July 2, 2003

  19. Expanded file -- July 2, 2003

  20. SwRI – B&S Intek Catalyst System Expanded file -- July 2, 2003

  21. SwRI – B&S Intek Catalyst System Expanded file -- July 2, 2003

  22. SwRI – Tecumseh OVRM120 • Emission Strategies • No Enleanment • Engine close to recommended Temperature limits • Passive Secondary Air Injection • Increased HC and CO efficiency • Increased Thermal energy release • 9.0 in3 Substrate = 75% of engine displacement • Replaced Stock Muffler with Briggs & Stratton SLT Optional Intek Muffler • Removed sound/cooling chambers • Catalyst “container” only • Location modified away from engine to allow room for passive air system Expanded file -- July 2, 2003

  23. Expanded file -- July 2, 2003

  24. Expanded file -- July 2, 2003

  25. Expanded file -- July 2, 2003

  26. SwRI – Honda GCV160 • Emission Strategies • No Enleanment • Manufacturer concerns with startability • Passive Secondary Air Injection • Increased HC and CO efficiency • Increased Thermal energy release • 9.0 in3 Substrate = 92% of engine displacement • Increased muffler/container size 2 times • Removed sound reduction capability • Catalyst “container” with mixing/cooling chambers • Location modified away from engine to allow room for passive air system Expanded file -- July 2, 2003

  27. SwRI – Honda GCV160 Expanded file -- July 2, 2003

  28. Expanded file -- July 2, 2003

  29. Expanded file -- July 2, 2003

  30. Expanded file -- July 2, 2003

  31. SwRI – Honda GCV160 Expanded file -- July 2, 2003

  32. SwRI –Honda GCV160 Expanded file -- July 2, 2003

  33. SwRI – Kawasaki FH601V (V-Twin) • Emission Strategies • Enleanment – A/F Ratio modified • Engine sensitive to intake air temp/humidity • Passive Secondary Air Injection • Increased HC and CO efficiency • Increased Thermal energy release • 77 in3 Substrate =190% of engine displacement • Removed sound reduction capability • Catalyst “container” with mixing/cooling chambers • Location modified away from engine to allow room for passive air system Expanded file -- July 2, 2003

  34. SwRI –Kawasaki Catalyst Expanded file -- July 2, 2003

  35. Expanded file -- July 2, 2003

  36. Expanded file -- July 2, 2003

  37. Expanded file -- July 2, 2003

  38. SwRI – Briggs & Stratton Intek #2 • Emission Strategies • No Enleanment • Passive Secondary Air Injection • Increased HC and CO efficiency • Increased Thermal energy release • 3.7 in3 Substrate = 31% of engine displacement • Replaced Stock Muffler with SLT Optional Muffler • Removed sound/cooling chambers • Catalyst “container” only • Baseline vs. Developed • New Baseline vs. Oct ’02 – Increased HC • Potential Fuel/Oil contamination Expanded file -- July 2, 2003

  39. Expanded file -- July 2, 2003

  40. Expanded file -- July 2, 2003

  41. Expanded file -- July 2, 2003

  42. Ignition Time vs. Temp – selected Forest Fuels U.S Dept of Agriculture, Forest Service Expanded file -- July 2, 2003

  43. Catalyst Application - SORE Expanded file -- July 2, 2003

  44. Catalyst Application – Small Off-Road Engines • Safe & Functional Design Criteria • Increased Temperatures • Exhaust gas & surface • “Over-Rich” conditions • Choke, primers, dirty air cleaners • Field Application concerns • Temperatures, Fuel spillage, Debris • V-twin & High Inertia applications • Additional Problems Expanded file -- July 2, 2003

  45. Catalyst Application - Performance • System durability w/application • High % Class 2 sold w/o mufflers • “Best-in-Class” vs. Mass Market • Catalyst durability/reliability • Thermal Failures • Sintering, Melting, Loosening • Poisoning • Metallic Oil additives Expanded file -- July 2, 2003

  46. Catalyst Application – Other Major Issues • Application Concerns • Increased package size, shielding, weight • Increased development / qualification to ensure compliance – Emissions & Safety • Reduced reliability & Increased variability ( 2 systems => engine/catalyst ) • OEM “Add-on” – Certification & audit • Increased costs – component & equipment Expanded file -- July 2, 2003

  47. Catalyst Application – Cost Impact • High conversion efficiency will require new engines (new tooling) • Current average engine-out levels in production must be met by nearly all production units if high-efficiency converters are to perform according to design • Thermal management for safety and engine durability • Other impacts • Equipment manufacturers • California consumers and businesses Expanded file -- July 2, 2003

  48. ARB – Exhaust Emissions – Tier 3 • High HC+NOx conversion efficiency catalysts are not possible without high CO conversion efficiency.  Thermal Management • Engine & Equipment manufacturers cannot meet standards based on high conversion efficiency without major engine and equipment modifications • New tooling for most lawn & garden engines  not an add-on package. Expanded file -- July 2, 2003

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