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

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

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

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

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

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

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)

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.

Diesel Oxidation Catalysts Are Efficient and Proven Oxidation Catalyst Control Capabilities –PM % Reduction –CO and HC -- >90% –Toxic HCs -- >70%

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

Diesel Particulate Filters Trapped PM Cell Plugs Exhaust (PM, CO, HC) Enter Ceramic Honeycomb Wall Exhaust (CO 2, H 2 O) Out

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

ARB/ARCO/CEC Retrofit Demonstration Program Source: SAE undetectable

Filters Destroy Large Fractions of Toxic Emissions PAH Emissions Reduced by 89% PAH, mg/bhp-hr Source: MECA

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

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 % Peugeot SAE

Diesel Particulate Filter Retrofit Durability Vehicle Application Engine Displacement (l) and Power (hp) Accumulated Distance (mi) PM Reduction Efficiency (%) Euro ESC 1 US FTP 2 Intercity Train , Airport Bus ,53180n.a. Express Bus ,59894 Mail truck , City Bus , Refuse Truck ,34293n.a. Refuse Truck723565,74392n.a. Averages:194,

SCR SCR Applications

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%

SCR Test Results in European & US Steady State Test Cycle

Integrated System Using a DOC, DPF, and SCR Engine Catalyst/Filter SCROxidation Cat Removal of HC, CO, PM Removal of NOx Removal of NH 3 slip if required 4-way conversion Urea

Integrated System – Lean NOx Catalysis + Filter Integrate heat transfer and chemistry for simultaneous reduction of NOx, CO, HC, & PM LNC (NOx reduction) DPF (CO, HC, and PM oxidation) Dirty Exhaust In Clean Air Out Gain Heat Lose Heat Recuperator Supplementa ry HC Injection

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

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)

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

Filter System Retrofitted to a Bus

Filter System

Filter System Retrofitted to a Refuse Truck Filter System

Direct Fit In-line Converter Catalyst

Integrated Converter Muffler Muffler Replacement

Central Artery/Tunnel Project (Big Dig) Filter System

Current Cost Filter Technology –Depends on Engine Size – Approximately $ $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

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

Stationary Engine Urea SCR Cost Effectiveness (2000 hp Diesel Engine) 400 hrs/yr 8000 hrs/yr NOx removed 11.3 TPY 225 TPY Reagent usage 22.6 TPY 450 TPY Capital recovery factor 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

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