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DIESEL RETROFITS FOR HEAVY-DIESEL RETROFITS FOR HEAVY-DUTY VEHICLESDUTY VEHICLES
ROUNDTABLE ON CLEAN FUELS ROUNDTABLE ON CLEAN FUELS AND VEHICLES in TURKEYAND VEHICLES in TURKEY
May 4, 2006May 4, 2006Katherine Buckley, US EPAKatherine Buckley, US EPA
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Why Diesel Retrofit?Why Diesel Retrofit?
New emission standards generally only affect New emission standards generally only affect new vehicles or new engines.new vehicles or new engines.Air quality benefits must wait for fleet Air quality benefits must wait for fleet turnover.turnover.Diesels can last 20-30+ years or more.Diesels can last 20-30+ years or more.Cost effective technologies are available Cost effective technologies are available today for existing diesels.today for existing diesels.Desire to demonstrate benefits of ultra low Desire to demonstrate benefits of ultra low sulfur fuel with advanced technologies.sulfur fuel with advanced technologies.
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EPA Funded Diesel Retrofit ProjectsEPA Funded Diesel Retrofit Projects
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Typical Retrofit Demo Schedule Typical Retrofit Demo Schedule Establish stakeholder/technical groupsEstablish stakeholder/technical groupsDatalogging of exhaust temperaturesDatalogging of exhaust temperaturesSelection and purchase of retrofit devicesSelection and purchase of retrofit devicesBaseline emission testingBaseline emission testingInstall Install verifiedverified retrofit devices retrofit devices1 month break-in “degreening”1 month break-in “degreening”Emission testingEmission testingPublic Rollout “White Cloth Test”Public Rollout “White Cloth Test”1 year of operation1 year of operation– Monitor performance and maintenanceMonitor performance and maintenance– Monitor fuelingMonitor fueling
Final emission testingFinal emission testingOutreach to publicOutreach to public
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Mexico City Diesel Retrofit Pilot Mexico City Diesel Retrofit Pilot Project Project
Retrofitted 20 transit buses Retrofitted 20 transit buses
Used Ultra-Low Sulfur Diesel Used Ultra-Low Sulfur Diesel Fuel (1 PPM) Fuel (1 PPM)
Trucked in from USTrucked in from US
Emission testing using Emission testing using portable RAVEMportable RAVEM
Measured PM and Measured PM and gaseous emissionsgaseous emissions
Partnered with Mexico City, Partnered with Mexico City, Ministry of Environment, RTP Ministry of Environment, RTP Bus Company, Center for Bus Company, Center for Sustainable Transport, Sustainable Transport, WRI/EmbarqWRI/Embarq
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Technologies UsedTechnologies UsedDiesel Particulate Filters Diesel Particulate Filters (DPFs) = Highly Effective(DPFs) = Highly Effective– Filter control capabilitiesFilter control capabilities
PM 80% to 90+% reductionPM 80% to 90+% reductionCO > 75%CO > 75%HCs > 85%HCs > 85%
– Require Ultra Low Sulfur Diesel Require Ultra Low Sulfur Diesel FuelFuel
Optimally <15 ppmOptimally <15 ppm– Use on Euro II or newer enginesUse on Euro II or newer engines
Diesel Oxidation Catalysts Diesel Oxidation Catalysts (DOCs) = Efficient and Proven(DOCs) = Efficient and Proven– Hundreds of thousands have been Hundreds of thousands have been
retrofitted since the 1960s on retrofitted since the 1960s on highway, mining, materials highway, mining, materials handling and construction vehicleshandling and construction vehicles
– Durabilities in excess of 10,000 Durabilities in excess of 10,000 hours of operationhours of operation
– Diesel oxidation catalyst control Diesel oxidation catalyst control capabilitiescapabilities
PM 20 to 30% reductionPM 20 to 30% reductionCO > 40%CO > 40%HCs > 50%HCs > 50%
Exhaust InExhaust In(Soot, CO, HC)(Soot, CO, HC)EnterEnter
Trapped SootTrapped Soot
Exhaust (COExhaust (CO22, H, H22O)O)
OutOut
Cell PlugsCell Plugs
Diesel Particulate Filter
Diesel Oxidation Catalyst
CarbonCarbon
NOxNOx
WaterWater
CarbonCarbon
SOFSOF
NOxNOx
COCO
HCHC
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Mexico City Pilot Retrofit HighlightsMexico City Pilot Retrofit Highlights
Use of Verified Use of Verified TechnologiesTechnologies– Devices proven to reduce Devices proven to reduce
emissions for specific emissions for specific applicationsapplications
Comprehensive testing Comprehensive testing and Review of Resultsand Review of ResultsQuantitative determination Quantitative determination of percent emissions of percent emissions reductionreduction
– Verified by:Verified by:USA EPA (USA EPA (& listed at & listed at EPA.gov.OTAQ/retrofit)EPA.gov.OTAQ/retrofit)California Air Resources California Air Resources Board (CARB)Board (CARB)
Use of Ultra Low Sulfur Use of Ultra Low Sulfur FuelFuel
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Measured ResultsMeasured Results
Emissions Emissions ReductionsReductions
1991 1991 Buses Buses (DOC)(DOC)
2001 2001 Buses Buses (DPF)(DPF)
Particulate Particulate MatterMatter
29-44% 29-44% 90-92%90-92%
•Typical test filter – Typical test filter – current standardscurrent standards
•Test filter – 2007 Test filter – 2007 standardsstandards
•Unused test filterUnused test filter
PM Emissions with DPFPM Emissions with DPF
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Additional Ongoing US EPA International Additional Ongoing US EPA International Retrofit ProjectsRetrofit Projects
Bangkok, ThailandBangkok, ThailandDOCs and DPFs on transit buses, and DOCs and DPFs on transit buses, and vans vans
50 ppm S diesel fuel to be used with 50 ppm S diesel fuel to be used with DPFs onlyDPFs only
DOCs have been installed, working wellDOCs have been installed, working well
DPFs not yet installedDPFs not yet installed
Emission testing in laboratory on chassis Emission testing in laboratory on chassis dynamometerdynamometer
Santiago, ChileSantiago, ChileAlready have 50 ppm S diesel fuelAlready have 50 ppm S diesel fuel
Trucks only; DPFs onlyTrucks only; DPFs only
Looking to incorporate retrofit into Looking to incorporate retrofit into future regulatory programsfuture regulatory programs
Emission testing in laboratory – Emission testing in laboratory – chassis dynamometerchassis dynamometer
Beijing, ChinaBeijing, China25 Euro 1 and Euro 2 buses 25 Euro 1 and Euro 2 buses
DOCs, DPFs and PFFs DOCs, DPFs and PFFs
ULSD fuel for buses with DPFsULSD fuel for buses with DPFs
Engine dyno testing at beginning and end of Engine dyno testing at beginning and end of projectproject
PM testing with portable sampling systemPM testing with portable sampling system
Dekati DMM 230 for PM onlyDekati DMM 230 for PM only
Pune, IndiaPune, India
20 buses; DOCs, DPFs, PFFs20 buses; DOCs, DPFs, PFFs
Just launched in April 2006Just launched in April 2006
PMT buses to participatePMT buses to participate
Guidance from Advisory Group and Guidance from Advisory Group and Technical PanelTechnical Panel
““In-Kind” support from Indian partnersIn-Kind” support from Indian partners
Currently determining fuel sourceCurrently determining fuel source
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Partial Flow FiltersPartial Flow Filters
An intermediate step between DOCs and DPFsAn intermediate step between DOCs and DPFs– New technologyNew technology
Using some in Beijing for first timeUsing some in Beijing for first timeRely on turbulent flow and impaction to reduce PMRely on turbulent flow and impaction to reduce PMPartial Filter Control CapabilitiesPartial Filter Control Capabilities– PM PM >>50%50%– HC and CO HC and CO >> 50% 50%
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Frequently Asked Questions Frequently Asked Questions Concerning Retrofit ProgramsConcerning Retrofit ProgramsDrivabilityDrivability• Properly selected retrofit Properly selected retrofit
technologies do not impair technologies do not impair driving performancedriving performance
MaintenanceMaintenance• Oxidation catalysts and Oxidation catalysts and
partial flow filters are partial flow filters are virtually maintenance freevirtually maintenance free
• DPFS require very little DPFS require very little maintenance (infrequent ash maintenance (infrequent ash removal)removal)
Effects on Engine LifeEffects on Engine Life• Properly maintained engines Properly maintained engines
and retrofit control systems and retrofit control systems do not shorten engine lifedo not shorten engine life
Fuel PenaltiesFuel Penalties– Most oxidation catalysts Most oxidation catalysts
have no effect on fuel have no effect on fuel consumptionconsumption
– Most filters have no effect Most filters have no effect on fuel consumption on fuel consumption
WarrantiesWarranties– Manufacturers provide Manufacturers provide
various warranties as part various warranties as part of a purchase agreementof a purchase agreement
Cost ConsiderationsCost Considerations– DOC ($425-1500)DOC ($425-1500)– DPF ($3000-5500)DPF ($3000-5500)
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Lessons LearnedLessons Learned
Insist on verified productsInsist on verified productsGo through open bidding Go through open bidding process to get productsprocess to get productsEnsure buses have been Ensure buses have been and are well maintainedand are well maintainedSet buses to spec before Set buses to spec before testingtestingProtect fuel supplyProtect fuel supplyLocking fuel caps on Locking fuel caps on buses with DPFsbuses with DPFsAnalyze fuel periodically Analyze fuel periodically for Sulfurfor Sulfur
Involve all relevant Involve all relevant stakeholdersstakeholders– Stakeholder Group and Stakeholder Group and
Technical PanelTechnical Panel
Treat drivers and Treat drivers and mechanics as partnersmechanics as partnersBuild public supportBuild public supportHave engine Have engine manufacturer supportmanufacturer supportTry to do muffler Try to do muffler replacements if possiblereplacements if possibleStrategize how to use the Strategize how to use the emission resultsemission results
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Lessons Learned (Cont)Lessons Learned (Cont)
Have a key person in the Have a key person in the city with the retrofit city with the retrofit project to handle day-to-project to handle day-to-day thingsday thingsFormulate good test planFormulate good test planRequire technical support Require technical support from vendorfrom vendorHold a “White Cloth” test Hold a “White Cloth” test to demonstrate DPFs to to demonstrate DPFs to publicpublicThink about particle Think about particle sizes….sizes….
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ContactsContactsKatherine BuckleyKatherine BuckleyUS EPA / Office of International AffairsUS EPA / Office of International AffairsTel: +1-202-564-6426Tel: +1-202-564-6426Fax: +1-202-565-2412Fax: +1-202-565-2412Email: Email: buckley.katherine@epa.govbuckley.katherine@epa.gov
US EPA Diesel Retrofit Information: US EPA Diesel Retrofit Information: www.epa.gov/cleandieselwww.epa.gov/cleandiesel
US EPA Verified Technologies Information:US EPA Verified Technologies Information:www.epa.gov/otaq/retrofit/retroverifiedlist.htmwww.epa.gov/otaq/retrofit/retroverifiedlist.htm