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Expediting Clean-Diesel Engine Use with Retrofit Technologies

Learn about retrofit emission control tech for diesel engines, cost estimates, and global retrofit programs to reduce NOx, PM, and toxic emissions.

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Expediting Clean-Diesel Engine Use with Retrofit Technologies

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  1. Expediting the Use of Clean-Diesel Engines with Retrofit Emission Control Technologies Air Quality Conference for Local Elected OfficialsMay 10-11, 2001Sacramento, CA

  2. Presentation Outline • Introduction • Background • Retrofit Control Technologies • Elements of a Retrofit Program • Cost Estimates • Conclusion

  3. Introduction • Diesel Engines Are a Major Source of NOx, PM, and Toxic Emissions • Even with the Prospect of Tighter Emission Standards in the Future, Existing, High-Emitting Diesel Engines Will Be in Use for the Next 10 to 20 Years • Retrofitting Existing Diesel Engines with Exhaust Control Technologies or Converting Diesel Engines to Natural Gas Are Available Strategies to Reduce Emissions and Expedite Clean-Vehicle Deployment • A Successful Retrofit Program Must Be Properly Designed and Implemented

  4. Available Retrofit Technologies • PM, CO, HC and Toxics • Diesel Oxidation Catalysts (DOC) • Diesel Particulate Filters (DPF) • Enhanced Combustion Modifications (e.g., cams, coatings, superchargers) • Crankcase Emission Controls

  5. Available Retrofit Technologies (cont.) • NOx • Selective Catalytic Reduction • Lean NOx Catalyst Technology • Systems Strategies (e.g., engine modifications to reduce NOx plus PM exhaust controls) • EGR

  6. Retrofit Experience • Mining • Materials Handling • Truck and Bus • Marine Vessels and Locomotives • Stationary Diesel Engines

  7. Overview of Retrofit Programs • The Number and Scope of Retrofit Programs Is 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)

  8. Diesel Oxidation Catalysts Carbon SOF NOx CO HC Carbon NOx Water Oxidation Catalysts Oxidize CO, HC, and SOF to Reduce PM, CO, HC, and Toxic Emissions.

  9. Diesel Oxidation Catalysts Are Efficient and Proven • Oxidation Catalyst Control Capabilities • PM -- 20-50% Reduction • CO and HC -- >90% • Toxic HCs -- >70%

  10. DOCs Destroy Large Fractions of Toxic Emissions mg/bhp-hr • Toxic Hydrocarbon Compounds Reduced by 68% • PAH Emissions Reduced by 56% • Greater Reductions Possible with Low Sulfur Fuel Source: MECA 1999

  11. Diesel Particulate Filters Trapped PM Cell Plugs Exhaust (CO2, H2O)Out Exhaust(PM, CO, HC)Enter Ceramic HoneycombWall

  12. Diesel Particulate Filters Are Efficient and Are Developing an Impressive Track Record • Filter Control Capabilities • PM -- 80%->90% Reduction • CO and HC -- >90% • Toxic HCs -- >90% Reduction

  13. ARB/ARCO/CEC Retrofit Demonstration Program undetectable Source: SAE 2000-01-1854

  14. Filters Destroy Large Fractions of Toxic Emissions • PAH Emissions Reduced by 89% PAH, mg/bhp-hr 1.2 0.14 Source: MECA 1999

  15. Recent Data Reports nitro-PAH Are Decreased with Filters Octel, SAE TopTec 9/00

  16. Filters Are Very Effective in Reducing Ultra-Fine Particles • Post filtered gas has the same particulate concentrations as the dilution air • Carbon-Based Ultra-Fine Particles Reduced by in Excess of 99.99 % Peugeot SAE 2000-01-0473

  17. Vehicle Application Engine Displacement (l) and Power (hp) Accumulated Distance (mi) Intercity Train 14 430 372,902 89 99 Airport Bus 10 292 357,531 80 n.a. PM Reduction Efficiency (%) Express Bus 10 368 304,598 94 94 Euro ESC1 US FTP2 Mail truck 7 236 294,469 78 93 City Bus 11 260 142,205 93 98 Refuse Truck 7 235 128,342 93 n.a. Refuse Truck 7 235 65,743 92 n.a. Averages: 194,456 88 96 Diesel Particulate Filter Retrofit Durability

  18. SCR Applications SCR

  19. SCR Has Been Used Successfully on Stationary Sources and Is Now Used for Mobile Sources • SCR Control Capabilities • PM – 30-50% Reduction • CO and HC -- >80% • Toxic HCs – >80% • NOx – 60 - >80%

  20. SCR Test Results in European & US Steady State Test Cycle

  21. Integrated System Using a DOC, DPF, and SCR Engine Urea 4-way conversion SCR Oxidation Cat Catalyst/Filter Removal of HC, CO, PM Removal of NOx Removal of NH3 slip if required

  22. Integrated System – Lean NOx Catalysis + Filter Supplementary HC Injection Dirty ExhaustIn LNC (NOx reduction) GainHeat DPF (CO, HC, andPM oxidation) LoseHeat Clean AirOut Recuperator Integrate heat transfer and chemistry for simultaneous reduction of NOx, CO, HC, & PM

  23. Elements of a Proper Retrofit Control Program • The Condition of the Engine Is an Important Factor in Making a Decision Whether to Retrofit Control Technology • For Filter Retrofit, Vehicle Application, Exhaust Temperature (Duty Cycle), and Fuel Sulfur Level Must Be Properly Matched

  24. Elements of a Proper Retrofit Control Program (cont.) • Retrofit Technology Check List • Size • Properly Sized Control Technologies Ensure Low Back Pressure and Maximum Performance • Vehicle Integration • An Important Aspect of Control Technology Retrofit, but Has Been Successfully Accomplished on Both On- and Off-Road Vehicles (muffler replacement or in-line installation)

  25. Elements of a Proper Retrofit Control Program (cont.) • Retrofit Technology Check List (cont.) • Fuel Quality • For PM Control, <15 ppm Allows for Maximum Emission Control Performance and Best Filter Regeneration Characteristics • Oxidation Catalysts Can Be Formulated to Minimize Sulfation, but at the Expense of Some Reduced Emission Control Performance • Some Technologies Can Be Applied to Certain Applications Using Fuels with Higher Sulfur Levels • Maintenance • Vehicles to Be Retrofitted Should Be Properly and Regularly Maintained • Retrofit Technology Should Be Maintained per Manufacturer’s Recommended Procedures

  26. Filter System Retrofitted to a Bus

  27. Filter System Retrofitted to a Bus Filter System

  28. Filter System Retrofitted to a Refuse Truck Filter System

  29. Direct Fit In-line Converter Catalyst

  30. Integrated Converter Muffler Muffler Replacement

  31. Central Artery/Tunnel Project (Big Dig) Filter System

  32. Current Cost • Filter Technology • Depends on Engine Size – Approximately $3000 - $5500 per Vehicle Depending on Type of Vehicle Integration • 2-4 Hours for Installation • Ash Removal at ~60,000 Miles • Oxidation Catalyst Technology • Approximately $500 - $1800 per Vehicle Depending on Type of Vehicle Integration • 2 Hours for Installation • Maintenance – Periodic Inspection and Cleaning if Necessary

  33. Current Cost (cont.) • SCR • Approximately $15,000 - $50,000 per Vehicle Depending on Type of Vehicle • 2 Days for Installation • Reagent Consumed at 6% of Fuel Consumption (depending on conversion efficiency, engine type, etc.) • Lean-NOx/Filter Technology • $5,000 - $10,000 per Vehicle Depending on Type of Vehicle • Costs for Retrofit Control Technologies Will Decrease as Sales Volumes Increase and Systems Are Fully Optimized

  34. Stationary Engine Urea SCR Cost Effectiveness (2000 hp Diesel Engine) 400 hrs/yr8000 hrs/yr • NOx removed 11.3 TPY 225 TPY • Reagent usage 22.6 TPY 450 TPY • Capital recovery factor .20 .26 • Reagent, $/ton $ 400 $ 200 • Annual cost: Capital 17,800 24,960 Reagent 9,040 90,000 Total $26,840 $115,160 • Cost/ton NOx removed $ 2,375 $ 512

  35. Conclusions • A Variety of Demonstrated Retrofit Technologies Are Available to Significantly Reduce PM, NOx, HC, CO, Toxic, Smoke, and Odor Emissions from Existing HDDEs • A Growing Number of Retrofit Programs Are Being Successfully Implemented • A Properly Designed and Implemented Program Can Achieve Important Diesel Exhaust Emission Reductions and Expedite the Use Of Clean-Diesel Engines • Active Participation by All Interested Parties Will Be A Key Element in a Successful Program

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