1. Controlling Diesel Particulate Matter Exposures in Underground Mines William H. Pomroy George P. Saseen Mine Safety and Health Administration pomroy.william@dol.gov 218-720-5448 saseen.george@dol.gov 304-547-2072

2. Available Control Strategies  Ventilation  Environmental Cabs  Administrative Controls  Diesel Engines  Fuels  Maintenance  Biodiesel Fuel  DPM Exhaust Filters EmissionReduction ExposureControls

3. Ventilation, Cabs and Administrative Controls DIESEL PARTICULATE MATTER EXPOSURE OF U/G MNM Miners Summary of Control Technologies

4. VENTILATION  Widely used method for DPM control  DPM reduction proportional to air flow Double air flow = 50% DPM reduction Double air flow = 50% DPM reduction  Ventilation can be costly Major upgrades: 16’ dia shaft = $1000/ft Electricity: 250K cfm @ 1” WG = 40 HP 40 HP x 100 hrs/wk @ 10¢/kw-hr = $15K/yr 40 HP x 100 hrs/wk @ 10¢/kw-hr = $15K/yr 2x airflow = 8x HP = 8x electricity cost 2x airflow = 8x HP = 8x electricity cost Q: How much air is enough? A: Depends on DPM control strategy

5. How Much Air Is Enough?  PI = Particulate Index = Airflow quantity required to dilute DPM emissions to 1,000 µg/m 3  2x PI ► 500 DPM µg/m 3 = 400 TC µg/m 3 = 308 EC µg/m 3  PI’s for MSHA Approved engines listed on internet (link to MSHA DPM Single Source Page)  Examples: Cat 3306 PCTA215 HPPI = 31,000 cfm Cat 3306 PCTA215 HPPI = 31,000 cfm Cat 3176 ATAAC270 HPPI = 7500 cfm Cat 3176 ATAAC270 HPPI = 7500 cfm  Boosting air flow a good start, but also need to direct air where needed Eliminate short circuits and recirculation paths Eliminate short circuits and recirculation paths Ensure coverage in all working areas and faces Ensure coverage in all working areas and faces

6. Series Ventilation - Room-and-Pillar Intake Return Face Line

7. Dead Ends - Fan and Vent Bag Airflow

8. Dead Ends - Fan and Vent Bag Airflow

9. Dead Ends - Fan and Vent Bag Airflow Auxiliary Ventilation

10. Dead Ends - Fan and Vent Bag Airflow Auxiliary Ventilation

11. Dead Ends - Free Standing Fan Airflow

12. Dead Ends - Free Standing Fan Airflow Auxiliary Ventilation

13. Dead Ends - Free Standing Fan Airflow Auxiliary Ventilation

15. Natural Ventilation  NVP= 0.03”wg per 100 feet per 10 o F  For 100’ Shaft and 40 o change (15º to 95º) NVP = 0.03 x 100/100 x 40/10 = 0.12” WG NVP = 0.03 x 100/100 x 40/10 = 0.12” WG  0.12” WG ► 20K to 50K cfm (typical)  0.12” WG maximum value - - usually less!  Not sufficient for DPM dilution  Reverses from summer to winter  Very low (sometimes zero) spring and fall

16. Ventilation  Ensure sufficient air volume based on Equipment emissions – PI’s Equipment emissions – PI’s Other DPM controls Other DPM controls  Natural ventilation insufficient - need fans  Distribute air where needed Brattice, long pillars, rock/waste filled CX Brattice, long pillars, rock/waste filled CX Need to advance and maintain ventilation controls Need to advance and maintain ventilation controls May need boosters/auxiliary fans May need boosters/auxiliary fans  May need to consult with mine ventilation specialist

17. Environmental Cabs  Environmental Cabs Can: Reduce DPM exposure and EC levels Reduce DPM exposure and EC levels Reduce noise exposure Reduce noise exposure Reduce silica dust exposure Reduce silica dust exposure  Cabs Should Be: Tight - seal openings, repair broken windows Tight - seal openings, repair broken windows Pressurized with filtered breathing air (follow regular filter change-out schedule - 250 hr) Pressurized with filtered breathing air (follow regular filter change-out schedule - 250 hr) Operated with doors/windows closed (may need air conditioning) Operated with doors/windows closed (may need air conditioning) Maintained in good condition Maintained in good condition

18. Enclosed Cabs

19. Cab Pressurization Monitoring Magnehelic gage with rubber hose extending into cab Magnehelic gage should register + 0.20“ WG or more

20.  Magnehelic gage should register at least 0.20” WG. If not, check: Outside air vs. recirculate control setting. Should be set on outside air. Outside air vs. recirculate control setting. Should be set on outside air. Fan capacity vs. cab volume. Goal should be 1 air change per minute. 100 cubic foot cab requires 100 cfm pressurizer - - 300 cubic foot cab requires 300 cfm pressurizer. Fan capacity vs. cab volume. Goal should be 1 air change per minute. 100 cubic foot cab requires 100 cfm pressurizer - - 300 cubic foot cab requires 300 cfm pressurizer. Openings into cab. Close and seal openings. Openings into cab. Close and seal openings. Air filter. Replace if dirty/clogged. Air filter. Replace if dirty/clogged. Intake duct. Remove obstructions, repair and seal holes/damage Intake duct. Remove obstructions, repair and seal holes/damage Cab Pressurization Monitoring

21. Environmental Cabs Hoses entering cab Gap in window seal Cab air filter and pressurizing fan

22. Administrative Controls  Control DPM exposures through operating procedures, work practices, etc.  Job rotation prohibited as DPM administrative control [§57.5060(e)] Job rotation means assigning a job to more than one worker so that each worker does the assigned job for only part of a shift Job rotation means assigning a job to more than one worker so that each worker does the assigned job for only part of a shift Job rotation spreads exposure to more workers Job rotation spreads exposure to more workers In accordance with good industrial hygiene practice, job rotation not acceptable for control of exposure to carcinogens In accordance with good industrial hygiene practice, job rotation not acceptable for control of exposure to carcinogens

23. Examples of Work Practices  Work Practices Can Affect Emissions And DPM Concentrations Minimize engine idling Minimize engine idling Avoid lugging engines (low RPM - high load) Avoid lugging engines (low RPM - high load) Keep fuel and lube oil clean Keep fuel and lube oil clean Traffic control Traffic control Route traffic away from areas where miners work outside cabs Route traffic away from areas where miners work outside cabs Route haul trucks in return air, especially when ascending ramps loaded Route haul trucks in return air, especially when ascending ramps loaded Limit HP in work area based on available CFM’s Limit HP in work area based on available CFM’s Schedule blasters on non-production shifts Schedule blasters on non-production shifts

24. § 57.5067 (a) Engines  Any Diesel Engine Introduced Underground –(a)(1) Have Affixed A Plate Evidencing Approval Under Subpart E of Part 7, Or Under Part 36 –(a)(2) Meet Or Exceed The Applicable PM Emission Requirements Of The U.S. EPA Listed In Table 57.5067-1

25. MSHA Approval No.s  Permissible Engines: 7E-A001 or 07-EPA030001  Non-permissible Engines 7E-B001 or 07-ENA030001  Internet Listing of MSHA Approved engines  https://lakegovprod1.msha.gov/R eportView.aspx?ReportCategory= EngineAppNumbers https://lakegovprod1.msha.gov/R eportView.aspx?ReportCategory= EngineAppNumbers https://lakegovprod1.msha.gov/R eportView.aspx?ReportCategory= EngineAppNumbers

26. MSHA Approved Diesel Engines Approval Number Engine Manufacturer Model HP @ RPM at 1000ft Elevatio n Particul ate Index, CFM DPM grams/ hr weight ed DPM grams/- hp-hr weighted Exhaust BP Max Limit, in.H2O 07-ENA040001CUMMINS QSB- 155C 155 @ 2500 55008.870.1141 07-ENA040018DEUTZ F6L 914 117 @ 2300 35005.730.0940 07-ENA050001MITSUBISHIS4S-DT 77 @ 2500 45006.910.1832 7E-B001DEUTZ MWM 916 94 @ 2300 1150019.540.4240 7E-B003CATERPILLAR 3306 PCNA 150 @2200 2300039.080.4934 7E-B035DEUTZ F8L 413FW 182 @ 2300 950016.140.1630 7E-B063CATERPILLAR 3306PC TA 215 @ 2200 3100052.680.4527

27. EPA DPM Limits MSHA Table 57.5067-1  Hp < 11 0.75 g/bhp-hr Tier 1 MY2000  11≤ HP<25 0.60 g/bhp-hr Tier 1 MY2000  25≤ HP<50 0.60 g/bhp-hr Tier 1 MY1999  50 ≤ HP < 100 0.30 g/bhp-hr Tier 2 MY2004  100 ≤ HP < 175 0.22 g/bhp-hr Tier 2 MY2003  175 ≤ HP < 750 0.40 g/bhp-hr Tier 1 MY1996  Hp ≥ 750 0.40 g/bhp-hr Tier 1 MY2000

28. Engine Combustion Design  Pre 1993 Direct Injection Engines –0.5 – 1.0 gm/hp-hr.  Indirect Injection (Pre Chamber) Engines –0.3 – 0.5 gm/hp-hr.  Post 1993 Direct Injection Engines –High Pressure Fuel Direct Injection –Turbocharged –Computerized Electronic Fuel Injection –0.05 – 0.2 gm/hp-hr for the higher horsepower engines  2001 - EPA Tier 2 for all horsepowers range from 0.15 g/bhp-hr to 0.60 g/bhp-hr

29. Engine Out Emissions  Total Emissions = Hp specific emissions x Horsepower x Hours of use.

30. Total Engine Out Emissions Emissionsx Horsepower x Hours = DPM  Loader: 0.1 x 275 x 8 = 220 grams  Drill: 0.5 x 150x4 = 300 grams

31. Three Strikes and It’s Out  Strikes: –High horsepower (greater than 150), –High emissions (greater than 0.3 gm/hp-hr), –High use (greater than 6 hours per shift).  Target Equipment: –Production Loaders and Trucks (primary), –Drills and Scalers (secondary) –PC engines (specialty mining equipment).  One bad engine can spoil the entire fleet.

32. Clean Engines vs. Ventilation  Clean engines reduce emissions by 80 to 90%. –Fuel savings pay for engine in 2 to 3 years.  Estimate that 80% of engines are currently Tier 1 or better.  Ventilation remains important, must be able to remove DPM and other exhaust gases

33. EPA Tier 3  50 ≤ HP < 100Tier 3MY2008  100 ≤ HP < 175Tier 3MY2007  175 ≤ HP < 750Tier 3MY2006  NOX reductions only, no change in DPM

34. EPA Tier 4  Hp < 25Tier 4MY2008  25≤HP<75Tier 4MY2008 & 2013  75≤HP<175Tier 4MY2012 - 2014  175≤HP<750Tier 4MY2011 - 2014  Hp ≥ 750Tier 4MY2011 - 2015  Substantial DPM reductions above 25 hp  Substantial NOX reductions above 75 hp

35. Diesel Fuel  MSHA §57.5065 requires diesel fuel with a sulfur content of less than 0.05 percent (500 ppm)  EPA requirement for on-highway diesel fuel to be at 0.0015 percent (15 ppm) sulfur by mid – 2006  EPA requirement for non-road diesel fuel to be at 0.0015 percent (15 ppm) sulfur by 2010

36. Fuel Additives and Fuel Catalyst  Combustion Enhancers –Cetane booster  Lubricity Increasers  Fuel Catalyst Devices: –Rentar –ECONET - Magnet technology

37. Alternative Fuel Testing  D1 / Jet A / Kerosene – 10 to 20 % reduction  Bio-Diesel Blends – 15 to 50+ % reduction  Water Emulsions – 50 – 75 % reductions  Synthetic Fuels – Synpar 200 and S2 – 30% reductions

38. Synthetic Fuels  MSHA Laboratory Tested 2 Types  SYNPAR 200 – Solvent Based  S-2 – Derived from Methane  Approximate 31% reduction in EC  Associated 4 – 6% loss in horsepower at sea level (1000 feet)  Similar Results at High Altitude, 7500 feet (simulated)

39. PuriNOx ™ PuriNOx ™  A diesel emissions control technology –A means of reducing NOx and PM from diesel engine exhaust  An emulsified diesel fuel (EDF) –Contains up to 20% emulsified water –Stable emulsion –Skim milk in appearance and consistency –When dyed for off-road, looks like “Pepto Bismal”

40. Engine Maintenance  Cleaning: Engine, Radiators, Air/Oil Coolers  Intake Systems: Air Filters, Turbo Boost Pressures, Leaks  Exhaust Systems: Backpressure, Leaks  Cooling Systems  Fuel Systems: Proper Settings, Altitude  Electronic Controlled Systems  Emission Tests

41. Exhaust Leaks  No holes upstream  No loose joints  No evidence of leaks, ie: black streaks on pipes or near exhaust outlets  Check flanges on Catalytic Converters and DPM Filters  Make sure Disposable Filters are Properly Sealed when installed

42. Check backpressure gauge  Backpressure is an indication that the filter is loading up with dpm  Each engine has maximum allowable backpressure specification. Engine specification is listed by engine manufacturer and filter manufacturer  Backpressure is a good indicator for changing or cleaning the filter.  If backpressure exceeds limit, then engine and filter can be damaged.

43.  Procedure to determine exhaust backpressure –A Magnehelic gauge is normally used to measure the backpressure. –Install backpressure gauge prior to the filter or other control device. –Run engine at high idle and loaded engine condition –Verify that backpressure is below allowable limit

44. Engine Ceramic Filter Total Backpressure BP1 BP measured at BP1 can increase to the maximum allowable backpressure before the filter needs cleaned Deutz BF4M2011 - 30 inches H 2 O Detroit Diesel OM904LA - 44 inches H 2 O Catalytic Converter

45. Gaseous Emission Check Gaseous Emission Check Torque stall the machine to achieve maximum load on the engine Torque stall the machine to achieve maximum load on the engine Use a gas analyzer that has a sample probe that can be placed directly in the exhaust gas stream, normally before any control devices Use a gas analyzer that has a sample probe that can be placed directly in the exhaust gas stream, normally before any control devices The concentration or changes in concentration of CO above baseline will indicate a change in engine performance. The concentration or changes in concentration of CO above baseline will indicate a change in engine performance. Some mines are using a doubling of the baseline as an action level. Some mines are using a doubling of the baseline as an action level.

47. Biodiesel DIESEL PARTICULATE MATTER EXPOSURE OF U/G MNM Miners Summary of Control Technologies

48. Biodiesel - What is it?  EPA registered diesel fuel  Designated alternative fuel per DOT, DOE  100% biodiesel, neat biodiesel, B100  Biodiesel blend - biodiesel mixed with petrodiesel, called Bxx where xx is the volume % of biodiesel in the blend B20 – 20% biodiesel, B2 – 2% biodiesel B20 – 20% biodiesel, B2 – 2% biodiesel  Biodiesel is “drop-in” replacement for standard diesel. Any diesel engine will run on biodiesel.

49. Biodiesel – Where does it come from? (Catalyst) (Catalyst) 100 pounds + 10 pounds 10 pounds + 100 pounds Triglyceride Alcohol Glycerine Mono-Alkyl Esters Triglyceride Alcohol Glycerine Mono-Alkyl EstersIngredients: Triglycerides………..Soy oil, corn oil, canola oil, beef tallow pork lard, used cooking oil Triglycerides………..Soy oil, corn oil, canola oil, beef tallow pork lard, used cooking oil Alcohol………………Methanol, ethanol Alcohol………………Methanol, ethanol Catalyst: ………………Sodium hydroxide, potassium hydroxide Product: Mono-Alkyl Esters….Biodiesel Mono-Alkyl Esters….Biodiesel  Raw Vegetable Oil is NOT Biodiesel ! ! !  Biodiesel must meet ASTM D 6751-06

50. Biodiesel Properties  High Cetane number  Ultra Low Sulfur (averages ~ 2 ppm)  High Lubricity, even in blends as low as B1 and B2. Can blend with ULS diesel  Reduces emissions of carbon monoxide, carbon dioxide, oxides of sulfur, polycyclic aromatic hydrocarbons, and total hydrocarbons  High flash point  Solvent and cleaning properties

51. Biodiesel and DPM Emissions  NIOSH PRL isolated zone study, Stillwater mine at Nye, MT  Simulated load-haul-dump mining cycle Cat Elphinstone R1300, 3.7 yd 3 Cat Elphinstone R1300, 3.7 yd 3 Cat 3306 DITA de-rated to 165 hp w/OCC Cat 3306 DITA de-rated to 165 hp w/OCC Constant ventilation, intake in fresh air Constant ventilation, intake in fresh air #2 diesel compared to B20 and B50 soy biodiesel fuel #2 diesel compared to B20 and B50 soy biodiesel fuel  B20 produced 26% EC reduction  B50 produced 48% EC reduction

52. Biodiesel and DPM Emissions  MSHA Tech Support compliance assistance at Carmeuse Lime and Stone – area samples EC reductions (compared to D2)  Maysville Mine B20 (recycled vegetable oil)35% B20 (recycled vegetable oil)35% B50 (recycled vegetable oil)71% B50 (recycled vegetable oil)71% B50 (virgin soy oil)49% B50 (virgin soy oil)49%  Black River Mine B35 (recycled vegetable oil)33% B35 (recycled vegetable oil)33% B35 (virgin soy oil)16% B35 (virgin soy oil)16%

53. Biodiesel and DPM Emissions Elemental Carbon, EC, µg/m 3 500400300200100 0 Year 2002 2003 2004 2005 2006 Standard D2 100% Biodiesel Detroit Salt Company, MSHA compliance samples, EC

54. Biodiesel and DPM Emissions Elemental Carbon, EC, µg/m 3 500400300200100 0 Year 2003 2004 2005 2006 Standard D2 100% Biodiesel Durham Mine, MSHA compliance samples, EC

55. Biodiesel and DPM Emissions Elemental Carbon, EC, µg/m 3 500400300200100 0 Year 2002 2003 2004 2005 2006 2002 2003 2004 2005 2006 Standard D2 99% Biodiesel Standard D2 99% Biodiesel Ft. Dodge Mine, MSHA compliance samples, EC

56. Biodiesel and DPM Emissions Elemental Carbon, EC, µg/m 3 500400300200100 0 Year 2003 2004 2005 2006 Standard D2 100% Biodiesel Standard D2 100% Biodiesel Weeping Water Mine, MSHA compliance samples, EC

57. Biodiesel and DPM Emissions Elemental Carbon, EC, µg/m 3 500400300200100 0 Year 2002 2003 2004 2005 2006 2002 2003 2004 2005 2006 Standard D2 100% Biodiesel Hutchinson Salt Co., MSHA compliance samples, EC

58.  Diesel Emissions Evaluation Program (DEEP) study at INCO Creighton Mine, Sudbury, ON  Univ. of MN, MI Tech Univ., INCO, NIOSH, CANMET, ORTECH  Isolated zone, simulated L-H-D cycle  Wagner ST-8, Deutz F12L413W, 275 hp, OCC  Week 1: #2 diesel Week 2: B50 soy biodiesel  EC reduced by 28.6% with B50  No statistically significant changes in NO or NO 2 levels Biodiesel and DPM Emissions

59.  Former US Bureau of Mines research  Laboratory testing Deutz/MWM 6.3 liter NA, EPA 8-mode testing Deutz/MWM 6.3 liter NA, EPA 8-mode testing DPM reduced 50% with B100 vs. #2 diesel DPM reduced 50% with B100 vs. #2 diesel  Field testing, Homestake mine, Lead, SD Wagner 3.5 yd 3 LHD, Cat 3306 PCNA, 134 hp, OCC, 6 week test Wagner 3.5 yd 3 LHD, Cat 3306 PCNA, 134 hp, OCC, 6 week test DPM reduced 72-80% with B100 vs. #2 diesel DPM reduced 72-80% with B100 vs. #2 diesel Higher DPM reduction vs. lab testing attributed to heavier duty cycles in mine Higher DPM reduction vs. lab testing attributed to heavier duty cycles in mine Miners commented on lower smoke levels Miners commented on lower smoke levels Biodiesel and DPM Emissions

60. Biodiesel DPM & Gaseous Emissions  U.S. Environmental Protection Agency (EPA) per Clean Air Act Section 211(b) B100 B20 B100 B20 Diesel Particulate Matter- 47% - 12% Carbon Monoxide- 48% - 12% NOX (NO + NO 2 )+ 10% + 2% Total Hydrocarbons- 67% - 20% PAH- 80% - 13% Sulfates - 100% - 20%

61. Biodiesel and Gaseous Emissions NIOSH PRL isolated zone study, Stillwater mine at Nye, MT B20 w/OCC vs. #2 diesel w/OCC CO no change (both were zero) CO 2 no change NO- 5.8% NO 2 - 5.5% B50 w/OCC vs. #2 diesel w/OCC CO no change (both were zero) CO 2 no change NO+ 4.4% NO 2 + 5.5%

62. Biodiesel Costs  Historically, B100 costs about $1.00 per gallon more than standard #2 diesel  Blender’s federal excise tax credit amounts to 1¢ per gallon per % biodiesel (virgin feedstock), thus: B99.9 (virgin feedstock) receives federal excise tax credit of about $1.00 per gallon B99.9 (virgin feedstock) receives federal excise tax credit of about $1.00 per gallon B50 (virgin feedstock) receives federal excise tax credit of 50¢ per gallon B50 (virgin feedstock) receives federal excise tax credit of 50¢ per gallon  When diesel prices spiked in late summer 2005 and spring 2006, B100 was cheaper than #2 diesel in some areas, after tax credit applied

63. Biodiesel Costs Diesel prices, selected US cities, 06-09-2006 (fuel prices do not include taxes, tax credits or subsidies) Source: Alternative Fuels Index, EMI Source: Alternative Fuels Index, EMI B100#2 diesel ∆ w/o credit ∆ w/credit B100#2 diesel ∆ w/o credit ∆ w/credit Albany, NY $3.17 $2.24 + $0.93- $0.07 Billings, MT $3.41 $2.44 + $0.97- $0.03 Charleston, WV $3.41 $2.30 + $1.11+ $0.11 Chicago, IL $3.31 $2.27 + $1.04+ $0.04 Indianapolis, IN $3.34 $2.26 + $1.08+ $0.08 Louisville, KY $3.37 $2.29 + $1.08+ $0.08 Pittsburgh, PA $3.40 $2.23 + $1.17+ $0.17 Seattle, WA $3.37 $2.32 + $1.05+ $0.05 US Average $3.37 $2.29 + $1.08+ $0.08

64. Biodiesel Availability  Available in all states except Alaska  8 BQ-9000 accredited producers  Over 1400 commercial distributors  Over 750 retail filling stations  National Biodiesel Board on-line guide to buying biodiesel: http://www.nbb.org/buyingbiodiesel/guide/default.shtm  Purchasers should specify fuel meeting ASTM D6751-06 requirements

65. Current Biodiesel Plants Current Biodiesel Plants 2004 Production: 25,000,000 Gallons 2005 Production: 75,000,000 Gallons Current Production Capacity: 395,000,000 Gallons

66. Future Biodiesel Plants 58 Plants under construction/expansions: 714M gal 58 Plants under construction/expansions: 714M gal 36 Plants in pre-construction phase:755M gal 36 Plants in pre-construction phase:755M gal Construction - 50 Expansion - 8 Pre-construction - 36

67. Biodiesel Commercial Distributors

68. Biodiesel Retail Filling Stations

69. Biodiesel Use Issues (>B20)  Cold weather Below cloud point, need heated storage tanks, indoor storage, fuel line heaters, etc. Below cloud point, need heated storage tanks, indoor storage, fuel line heaters, etc.  Solvent/cleaning properties Biodiesel can soften and degrade certain elastomers. Need to replace natural rubber, butyl rubber, nitrile, etc. with Teflon ® or Viton ® Biodiesel can soften and degrade certain elastomers. Need to replace natural rubber, butyl rubber, nitrile, etc. with Teflon ® or Viton ® Biodiesel dissolves and removes sediments from fuel tanks and lines Biodiesel dissolves and removes sediments from fuel tanks and lines Need to clean out tanks and lines and/or be prepared to replace filters frequently until systems fully cleaned Need to clean out tanks and lines and/or be prepared to replace filters frequently until systems fully cleaned

70. Biodiesel Use Issues (>B20)  Long term storage stability Recommend use within 6 months of manufacture Recommend use within 6 months of manufacture If stored longer than 6 months, should test for acid number If stored longer than 6 months, should test for acid number  Engine oil change intervals Due to higher viscosity, more biodiesel may pass over piston rings and into oil pan Due to higher viscosity, more biodiesel may pass over piston rings and into oil pan Biodiesel may polymerize and cause engine sludge problems Biodiesel may polymerize and cause engine sludge problems May need to change oil more often May need to change oil more often

71. Biodiesel Use Issues (>B20)  Energy content Biodiesel has 8-10% lower energy content than #2 diesel resulting in lower peak power output delivered by engine Biodiesel has 8-10% lower energy content than #2 diesel resulting in lower peak power output delivered by engine Generally not noticeable with B2 to B20 Generally not noticeable with B2 to B20 May be evident with high biodiesel blends when engine operates under heavy load May be evident with high biodiesel blends when engine operates under heavy load Effect usually not significant due to mixed duty cycle (idle, low, medium, high loads) Effect usually not significant due to mixed duty cycle (idle, low, medium, high loads) Better cleaning, lubricity may compensate Better cleaning, lubricity may compensate Fuel usage usually higher than #2 diesel Fuel usage usually higher than #2 diesel

72. Biodiesel Use Issues (>B20)  Engine warranties Engines are warranted against defects in materials and workmanship. Engine warranties do not cover fuel, either biodiesel or standard petroleum diesel. Engines are warranted against defects in materials and workmanship. Engine warranties do not cover fuel, either biodiesel or standard petroleum diesel. Many manufacturers have issued “position statements” on the use of biodiesel fuel Many manufacturers have issued “position statements” on the use of biodiesel fuel Example from Cummins on-line “fact sheet”: Example from Cummins on-line “fact sheet”: “Cummins neither approves or disapproves of the use of biodiesel fuel. …The use of biodiesel fuel does not affect Cummins Material and Workmanship warranty. Failures caused by the use of biodiesel fuels or other fuel additives are NOT defects of workmanship and/or materials as supplied by Cummins Inc. and CANNOT be compensated under the Cummins’ warranty.”

73.  Biodiesel can produce significant DPM reductions in engines that would not be good candidates for DPM filters due to very high rates of DPM generation. Some MSHA Approved engines and older “grandfathered” engines still in use at mines may produce 0.5-1.0 g/bhp-hr of DPM Some MSHA Approved engines and older “grandfathered” engines still in use at mines may produce 0.5-1.0 g/bhp-hr of DPM  Some evidence suggests that DPM passive filters regenerate at a lower temperature (≈ 20-30º C) when engines are run on biodiesel compared to standard petroleum diesel. More research data needed to verify. Biodiesel and DPM Filters

74. Biodiesel Resources  National Biodiesel Board is the national trade association representing the biodiesel industry and the coordinating body for research and development in the United States. Their internet web address is: www.biodiesel.org  “Biodiesel Handling and Use Guidelines” US Dept. of Energy, publication # DOE-GO- 102006-2288, 2 nd edition, March 2006  DieselNet, an on-line information service for clean diesel engines and diesel emissions: www.dieselnet.com www.dieselnet.com

75. Diesel Particulate Filters (DPF)  Filters filter.  80 to 99% efficient.  Operational issues.  Control Technologies: http://www.msha.gov/01-995/Coal/DPM- FilterEfflist.pdf http://www.msha.gov/01-995/Coal/DPM- FilterEfflist.pdfhttp://www.msha.gov/01-995/Coal/DPM- FilterEfflist.pdfhttp://www.msha.gov/01-995/Coal/DPM- FilterEfflist.pdf

76. Haul Truck with Muffler

77. Haul Truck with Ceramic DPF

78. Ceramic Wall Flow DPM Filter

83. Dirty Exhaust In

84. Ceramic Wall Flow DPM Filter DPM Trapped On Substrate Through Ceramic Gases Pass

85. Ceramic Wall Flow DPM Filter Gases Out

86. Effectiveness of DPM Filters

87. DPM Builds Up On In-Take Side Substrate

88. DPM Builds Up On In-Take Side Substrate

89. DPM Builds Up On In-Take Side Substrate

90. DPM Builds Up On In-Take Side Substrate

91. DPM Builds Up On In-Take Side Substrate

92. Back Pressure, Heavy Duty Cycle Causes Engine To Work Harder, Increasing Exhaust Temperature Substrate

93. Hotter Exhaust Ignites DPM DPM “Burns Off” Of Substrate CO 2 Passes Through Substrate Substrate CO 2

94. Hotter Exhaust Ignites DPM DPM “Burns Off” Of Substrate CO 2 Passes Through Substrate Substrate CO 2

95. Substrate CO 2 Hotter Exhaust Ignites DPM DPM “Burns Off” Of Substrate CO 2 Passes Through Substrate

96. Substrate CO 2 Hotter Exhaust Ignites DPM DPM “Burns Off” Of Substrate CO 2 Passes Through Substrate

97. Substrate CO 2 Hotter Exhaust Ignites DPM DPM “Burns Off” Of Substrate CO 2 Passes Through Substrate

98. DPM Layer Removed Process Referred to as “Regeneration” Substrate

99.  Regeneration of Ceramic Filters –Passive - Ceramic Filters are regenerated on board the machine. Exhaust gas temperature is used to generate the heat needed to burn off the dpm –Active - Ceramic Filters are regenerated either on board or off board the machine. An external heat source is needed to burn off the dpm –May be combination of both passive and active –If the correct regeneration method is not used, the filter will clog with dpm

100. Choosing a Ceramic DPF  NIOSH and MSHA developed a DPF Selection Guide –http://www.msha.gov/nioshmnmfilt erselectionguide/dpmfilterguide.htm http://www.msha.gov/nioshmnmfilt erselectionguide/dpmfilterguide.htmhttp://www.msha.gov/nioshmnmfilt erselectionguide/dpmfilterguide.htm  Provides information for choosing the correct DPF, Do’s and Don'ts  Exhaust Temperature Profiles/Traces  How to apply the information

101. Guidelines for Passive Regeneration DPF  Based on temperature profile of engine exhaust, if: –T30% >550 o C, Uncatalyzed “bare” trap, –T30% >420 o C, Base-metal catalyzed trap, –T30% >365 o C, Heavily Pt-catalyzed trap, –T30% >330 o C, Lightly Pt-catalyzed trap plus fuel borne catalyst.

102. Bolter, Caterpillar 3306 DITA 39% @ 370 o C

103. 972 Loader, Caterpillar 3306 B 34% @ 470 o C

104. Cannon Drill, Caterpillar 3306 PC 51% @ 390 o C

105. Cannon Drill, Caterpillar 3304 PC 30% @ 480 o C

106. Cannon Drill, Caterpillar 3306 DITA 51% @ 350 o C

107.  Filter Section Guide Matches Exhaust Temperature Data to Available DPF Technology  Example

108. Active Systems Off – Board Regeneration  Keep DPM filter small enough for one person to handle  Keep DPM filter small enough for one person to handle  Locate for easy access  Gas-tight, quick connects  Develop exchange logistics: When, Where, How to Transport

109. Active Systems On Board Regeneration  Located anywhere in exhaust, not depend on temperature  Requires off-duty time or between shifts  Controller subject to shock and vibration

110. High Temperature “Synthetic” Filter Media  80-99% Efficient  Operating Time Will Vary Between Replacement  Temperature Limit – 650 F  May require a heat exchanger prior to media  Filter Location  Disposable

111. Diesel Particulate Reactor TM  Substrate is a catalytic emissions reduction system  Woven stainless steel alloy fabric cartridge that is brazed to solidify the unit.  Designed to bridge gap between DOC and ceramic/synthetic based media

112. Rypos  Sintered metal fibers can be designed to achieve any filter efficiency by changing fiber sizes, porosity, and thickness of filter medium.  Active Regeneration DPF where the Filter element is the Heating element  Automatic regeneration cycles  Pressure and temperature sensing can be used to initiate regeneration cycles

114. Terex TR-70 Haul Truck 700 hp engine

115. Fleetguard Longview Lean NOX Catalyst Filter  Ceramic – Silicon Carbide Catalyzed Filter Media  Injects fuel prior to the filter to reduce NOX emissions using a NOX reducing catalyst  Passive Regeneration - Requires exhaust gas temperature of 500 o F (260 o C) at least 25% of the operating time. Must temperature profile machine

117. DPM Exposure Estimator  Conduct simulation to assist in developing control strategy.  Need to measure exposures.  Need to assess engines and use.  Need to determine air flows.

118. Area Sampling Locations Mine IntakeMine Exhaust Section Exhaust Blaster Loader Outside Loader

119. DPM Estimator  Equipment  Engine  Horsepower  Emissions  Hours of Use

120. Disclaimer The Department of Labor has developed this presentation to assist the mining industry in complying with the DPM final rule. This is a process that is continually under development. While we try to keep the information timely and accurate, we make no guarantees. We will make an effort to correct errors brought to our attention.