Atlas Copco Compressors LLC

Introduction – IT4Introduction – IT4

Scott EllingerScott Ellinger

EPA Tier 4 Regulations

Two-Phase Introduction: INTERIM & FINAL

Focused on Reducing PM & NOx emissions

Introduction Timing varies by HP Band

US, Canada, EU & Japan will be Broadly Aligned

2

Construction and Ag - 2012

4

2

2

4

4

3

2

Unregulated

Tier 1 / Stage I

Tier 2 / Stage II

Tier 3 / Stage IIIA

Tier 4 Interim / Stage IIIB

Tier 4 Final / Stage IV3

75 -751 HP Engines

EPA Mobile Tier 4 Nonroad Standards

(1) Compliance with optional ‘Option 1’ 0.30 g/kW-hr PM limit in 2008 allows 1-year delay of T4 until 2013.Option 1 engines in 2008 are T4i engines, not T3 engines.

NOx / NMHC / CO / PM (g/kW-hr)(NOx+NMHC) / CO / PM (g/kW-hr) [Conversion: (g/kW-hr) x 0.7457 = g/bhp-hr]

kW (HP)

0 - 7 (0 - 10)

8 - 18 (11 - 24)

19 - 36 (25 - 48) ( 7.5 ) / 5.5 / 0.30

37 - 55 (49 - 74)

56 - 74 (75 - 99)

75 - 129 (100 - 173) ( 4.0 ) / 5.0 / 0.30

130 - 224 (174 - 301) ( 4.0 ) / 3.5 / 0.20

225 - 449 (302 - 602) ( 4.0 ) / 3.5 / 0.20

450 - 560 (603 - 751) ( 4.0 ) / 3.5 / 0.20

>560 (>751)

a. Applies to non-emergency power gen engines >900kW (>1207hp).b. Applies to non-emergency power gen engines >560kW (>751hp).

2011 2012 2013 2014 2015 2016

0.40 / 0.19 / 5.0 / 0.02

2007 2008 2009 2010

(4.7) / 5.0 / 0.40: 37-74 kW

Opt T4i 0.30 PM: 37-55 kW

2017

( 7.5 ) / 6.6 / 0.40

Tier 4 Final

3.5 / 0.40 / 3.5 / 0.10

0.67 / 0.40 / 3.5 / 0.10 a

3.4 / 0.19 / 5.0 / 0.02

3.5 / 0.19 / 3.5 / 0.04

0.67/ 0.19/ 3.5/ 0.03 b

( 4.7 ) / 5.0 / 0.03Note 1

2.0 / 0.19 / 3.5 / 0.02 0.40 / 0.19 / 3.5 / 0.02

( 6.4 ) / 3.5 / 0.20

T2 Tier 4 InterimTier 3

4

Tier 4 Final brings a 90% reduction in emissions compared to Tier 3

Achieving near zero emissions by 2014

Tier 4 Challenge

Representative of most stringent emission levels: 74-751 hp (56-560 kW)

Tier 1 / Stage 1 (1996)

Tier 2 / Stage II (2001)

Tier 3 / Stage IIIA (2005)

0 0.40.15

6.8

4.8

3.0

Tier 1 / Stage 1 (1996)

Tier 2 / Stage II (2001)

Tier 3 / Stage IIIA (2005)

Tier 4 Interim / Stage IIIB (2011)

Tier 4 Final / Stage IV (2014)

1.5

0.3

0.015 PM g/hp-hr

NO

x g/

hp-h

r

45% lower

90% lower

90% lower

5

Emissions & EPA Compliance

Achieving ‘Near-Zero’ Emissions

Cummins Confidential

Emissions from 25 x Tier 4 Final machines will be equivalent to just 1 x Tier 1 machine

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Terms and Key Words – IT4 Applications

Regeneration: The process of eliminating built up soot from the exhaust system

Two types of Regeneration

Active Regeneration: – Using a hydrocarbon (fuel) to elevate exhaust gas temperatures above

1100 F in order to remove built up soot from the exhaust filter

Passive (Natural) Regeneration:– Using temperature alone to burn soot by elevated exhaust temperature

Can be controlled by temperature management of the exhaust stream– Can be achieved by maintaining exhaust gas temperature

– Can also be achieved by control valves that effect exhaust backpressure

At some point Active Regeneration must be used

Terms and Key Words – DOC and DPF

Diesel Oxidation Catalyst (DOC)

Diesel Particulate Filter (DPF)

Diesel Oxidation Catalyst (DOC)

Open cell substrate flow though device Reduces HC and CO significantly Reduces Pm 10 to 30% Converts NO to NO2 for passive regeneration of the DPF Oxidizes HC (diesel fuel) as part of active regeneration strategy No servicing required Requires use of low sulfur diesel or ULSD Typically element is ~100% of engine displacement in size

Diesel Particulate Filter (DPF) Wall flow, high filtration efficiency

(>95%) Traps ash, soot and any particles Needs periodic regeneration / cleaning Periodic ash cleaning required No muffler required in the vast majority

of applications

Regeneration

Active Regeneration– Particulate matter left in the filter system is burned off extending the

lifetime of the filter.

– Uses a fuel burner in the exhaust stream that intermittently raises the temperature above 600°C (1112°F)

– Converts particulate matter to CO2 & Ash.

Terms and Key Words Soot

– Incomplete combustion of hyrdocarbons in the exhaust stream

– Can be purged from the DPF by re-generation

Ash– Incomplete combustion of some hydrocarbon by-products

– CANNOT be purged from the DPF by re-generation

– EPA Mandated that DPF must withstand 4500 hrs before ash cleaning is needed

HPCR– High pressure common rail fuel system

– System pressures up to 30,000 psi

– Allows mulitple injection events to take place reduce emmisions

VGT– Variable Geometry Turbocharger

– Inlet guide vanes can adjust to provide exact boost pressure to work in conjunction with the EGR

Terms and Key Words ULSD

– Ultra low sulfur fuel (less than 15 ppm)

– Must be used on all IT4 machines

– Normal diesel fuel will kill an EGR and DOC within a few tank fulls

Low ash Engine oil– Must be used on all IT4 machines to reduce the formation of ash

accumulating in the DPF

CANbus – Method of communication between controllers or networks. All of Atlas Copco controllers use SAE J1939 Can communication

Emissions & EPA Compliance - EGR

EGR: Exhaust Gas Recirculation– Exhaust gases are cooled and injected back into the engine cylinders to

reduce NOx.

– Result: Lower peak combustion temperature generates less NOx but more

particulate matter

Heat rejection to radiator increases

• NOx reduction with additional cooled EGR – building on Tier 3 PT+

• VGT turbocharger• Larger EGR cooler and valve

• Hydrocarbon (HC) and some Particulate Matter (PM) control with Diesel Oxidation Catalyst (DOC)

• Majority of PM reduction via Diesel Particle Filter (DPF)

• Active Regeneration System for DPF

Air Inlet

Compressed Air from Turbocharger

Cooled Air from Intercooler

Exhaust Gas

Variable Geometry Turbocharger (VGT)

DPF

HC (fuel) Injection

EGRCooler

EGR Valve

Interim Tier 4 PowerTech Plus Technology

DOC

Regeneration Stratagy

DPF Regeneration

• ECU controls active regeneration

• Diesel fuel added to system for 10 minutes every 5 to10 hrs

• Raises temperature into DPF to ~600°C (~1112°F)

So

ot

Lev

el

Exhaust Filter Cleaning & Maintenance

Designed for extended maintenance free operation but ash accumulation does occur.

Minimum maintenance interval for ash removal, as defined by the EPA, is 4500 hours. – This service interval can be increased depending on duty cycle

DPF must be removed from unit and placed in specialized equipment for cleaning by a John Deere service technician.

DPF Information - Indicators

Exhaust Filter Cleaning & Maintenance

Several ways to extend service intervals

Reduce idle time

Enable auto cleaning

Operate in high load condition when possible

Use only Ultra low sulfur diesel fuel

Use only approved low ash oil

Other IT4 items

Preheat is controlled by John Deere without any control or parts from our side– Engine contains the relay, fuse, and all necessary wiring to the glow pugs

– Preheat timing amount is a function of the fuel temperature

– Timing is calculated by the engines ECU

All exhaust piping is Stainless steel

Exhaust piping wrapped with insulation

Exhaust bellows can be leakage points and should be occasionally inspected for distortion

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Contact Numbers

•Main Number Atlas Copco Technical Support 1-800-732-6762 Option 3

•Clayton Jones - Hurricane Boosters/Compressors - Supervisor1-216-643-6802 direct & 1-317-681-4602 mobile

•Andrew Stevenson – Compressors: Low Pressure1-720-479-2486 direct & 1-404-751-6717 mobile

•Will Hudson – Generators/Compressors 1-800-732-6762 Ext. 12920 & 1-832-454-8123 mobile

•Andrew Calendar – Compressors: High Pressure1-720-479-2487 direct & 1-404-242-6203 mobile

•Jon Monaco - Hydraulic Att./Handheld Tools 1-800-732-6762 Ext. 12929 & 1-216-816-5008 mobile

•Brandon Dyer – Compressors: Low Pressure/Hydraulic Att.1-216-643-6807 direct & 1-216-219-2290 mobile

•Scott Ellinger – Compressors1-720-479-2476 direct & 1-720-375-1795 mobile

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Committed to Sustained

Productivity.