1. Understanding Diesel Retrofit Technologies
Lanny Cole
Cummins Atlantic LLC
Filtration and Emission Sales Manager
North Carolina, South Carolina, and Virginia
ext 202

2. Diesel Emission Retrofit Projects
Why Retrofit ?

3. Environmental Effects
Why Reduce Emissions?
Economic Effects
Environmental Effects
Health Effects
EPA estimates that for every $1 spent on retrofit, there is a $13 return on healthcare cost

4. Evolution of On-Highway Standards - EPA
Euro
EPA 1994
5.0
EPA 1998
4.0
EPA 2004
NOx [g/HP-hr]
2.5
1.2
EPA 2007*
* Aftertreatment Required
0.2
EPA 2010*
0.01
0.015
0.075
0.10
0.11
PARTICULATE [g/HP-hr]

5. Key Regulated By-products
Nitrogen Oxides – air quality / smog (Ground Level Ozone)
PM - health effects
56% emitted of PM attributable to diesel engine
Black smoke
HC / CO / Toxic Hydrocarbons – smell
Retrofitting Existing Diesel Engines with Emission Control Technologies is the primary way to reduce emissions

6. Diesel Emission Basics

7. Ways to Reduce Emissions?
Engine design changes
Combustion
Air handling
Exhaust gas recirculation (EGR)
Closed Crankcase Ventilation (CCV)
Fuels
Ultra Low Sulfur Diesel
Additives?
Water emulsions?
Biodiesel?
Exhaust after-treatment
Diesel Oxidation Catalysts – >25% PM, > 70%HC and >40% CO reduction
Passive (catalyzed) Filters - >85% PM reductions, HC & >70%CO reduction,
Active (electric, non-catalyzed) Filters - 85% PM reduction
NOx Reducing Catalysts - 85% PM reduction, 25% NOx reduction, HC & CO reduction
Selective Catalytic Reduction (SCR) 60-90% NOx reduction, HC & CO reduction
CCV
Combustion advances
EGR
DPF

8. Verification EPA CARB What does verified technology mean?
Process that EPA and CARB use to certify a technology does what the manufacturer claims.
Identifies application guidelines for each device
Identifies qualified engines and markets for that devices application
Why is using verified technology important?
Verification is required for most publicly funded projects
Enables a standardized understanding and classification of technologies
EPA
EPA lists verified technologies alphabetically by Manufacturer
CARB
CARB lists verified technologies by classification
Level 1 = >25%
Level 2 = >50%
Level 3 = >85%

9. EPA/CARB Verified Product Summary
DOC
Passive DPF
Active DPF
SCR
Design
Passive Diesel
Oxygen Catalyst
Passive DOC
with Wall Flow
PM filter
active DPF w/ NO2 decomp cat using fuel as NO2 reductant
CRT with urea based SCR system and NH3 slip catalyst
Market
Any
Pre EGR and EGR engines
EGR engines
Pre EGR and EGR engines
Emission
Reduction
PM > 25%,
HC > 70%,
CO > 40%
PM = >85%,
HC =90%,
CO = 70%
PM = 85%,
HC = 90%,
PM >85%, HC >90%, CO >70%, NOx>65%
Maximum HP
Ratings
600HP
600 HP
Temperature
Requirements
None
40%
Monitor Required No
Yes
Maintenance
60-100K level 1 cleaning

10. Diesel Oxidation Catalyst (DOC)

11. Diesel Oxidation Catalyst
The DOC may either replace or be added to the existing vehicle muffler.
Easily installs
Needs no maintenance
Requires no monitoring
Can be used with low-sulfur (500 ppm) or ultra-low sulfur diesel fuels (15 ppm)
Oxidation Catalyst Control Capabilities
PM >25% Reduction
CO >50%
HCs and Toxic HCs -- >70%

12. Closed Crankcase Ventilation (CCV)

13. Crankcase Ventilation Filter
Closes the current open crankcase system by filtering blow-by gases thus removing oil residues and routing the residues and gases back into the engine.
Simple, high efficiency, serviceable
Interval – every 3rd to 4th oil change
Additional 10% to 15% reduction in emissions.
Replaceable filter element

14. Diesel Oxidation Catalyst + Closed Crankcase Ventilation
Combines the benefits of both for additional emissions reductions.
Applies to many applications
The CCV Kit eliminates 100% of engine compartment blow-by.
Verified as a combination package by the EPA/CARB

15. Diesel Particulate Filter (DPF)

16. Diesel Particulate Filter
The CRT filter is capable of converting >
90% of Particulate matter
>90% Hydrocarbons
>70% Carbon Monoxide.
Requires Ultra Low Sulfur Fuel
Can use B20 bio-diesel fuel
Maintenance:
Periodic filter cleaning required
Vehicle requires datalogging for approval to retrofit
Retrofit DPFs are generally be installed as a passive system but active systems are available

17. Diesel Particulate Filter
Oxidation catalyst with
Precious Metal Coating
Existing exhaust temperatures are used for Passive Regeneration
Oxidize injected fuel is used to produce heat for Active Regeneration
PM = 90% reduction
HC = >90% reduction
CO = >70% reduction

18. Particulate Filters are required on engines
Heavy Duty Solution
2007
Particulate Filters are required on engines
built after Jan1, 2007

19. 2010 Heavy Duty Solution 15L Selective Catalytic Reduction Particulate
For 2010, Cummins will be building on the technology that we currently have in the market place. Building on our successes with Exhaust Gas Recirculation (EGR) introduced in 2002 and the Cummins Particulate Filter technology introduced in 2007, Cummins will meet the 2010 emissions standards with the addition of Nitrogen Oxide (NOx) aftertreatment using SCR.
Please note….this slide is not to scale.
Particulate
Filter
Cooled EGR
Same as today

20. Some models already have
What Technology Where?
DOC
DPF
Active DPF
Urban Bus
Post ’93 already have DOC
Available
School / Shuttle Bus
Available,
Some models already have
Refuse
Emergency
Not recommended
Construction
Must have LSD
Must have ULSD
Watch space

21. Planning a Diesel Emission Retrofit Project
Start with the Money

22. Retrofit Funding Sources
US EPA
Grants
Santee Cooper consent decree
Retrofitted 105 school buses, 60 in upstate region
Smartway Program
Rebates to individuals who retrofit
State DAQ
Spartanburg County EPF project
County and City Clean Air Stakeholders
State DOT
Private Corporations
Duke Power
Cleaning up power plants and support equipment

23. Starting A Retrofit Project

24. Compile A Fleet List Fleet list is the road map of the project
Why does an accurate up to date fleet list matter?
Not every engine can be retrofitted
There is no “one size fits all” retrofit device
Fleet list is the road map of the project
Allows vehicles to be sorted into emission reduction “buckets”
Retrofit
Repower
Replace
Rebuild
Refuel

25. Fleet List Equipment Make:___________________
Equipment Model:___________________
Engine Manufacturer:_________________
Engine Model:_______________________
Engine Year:________________________
Engine Horse Power:_________________
EPA Engine Family #:_________________
Quantity of Like Units:_________________
Muffler Part # or Dimensions:___________

26. Vehicle Retrofit Priority
Reduction Goals
Remaining Service Life
Retrofit Device Maintenance
Annual costs and fleet impact
The Right Technology In The Right Place

27. Product Decision Tree What is the projects goal?
PM Reduction
NOx Reduction
Verification Required ?
(CARB / EPA)
Manufacturers warranty consideration
Fuel Type?
ULSD (15 ppm)
Off-road fuel
BioDiesel
Engine Age
EPA Certification Year/Emission Tier Level?
Duty cycle/temperature of application?
Datalogging needed

28. Timing What is the projects timeline? Installation: Funding Source
Required Installation due date
Installation:
When are the vehicles available?
When will the retrofit devices be available?
Will installation be done by the retrofit vendor?
Transportation to and from
Down time
How long to install the device

29. Reminders 1.Funding: - You cannot receive funding if you do not apply.
- If you do not succeed on your first attempt try again.
- Build and Maintain working relationships with air quality stakeholders.
2. Compiling Fleet Information:
- Maintain a fleet list of potential retrofit equipment.
3. What technology to use:
-The right technology on the right application
4. Vehicle Priority:
-Remaining years of service
-Quantity of vehicles
5.. Cost Considerations:
-Amount and type of reduction you are trying to achieve.
-Maintenance vs. no maintenance technology
6.Timing:
-Funding dealines
-Installation constraints

30. Business Case
Funding
Retrofit Success
Technology

31. Thank you