Overview of Aftertreatment Products for Diesel Retrofit

Overview of Aftertreatment Products for Diesel Retrofit. Presented by. Susan Cleaver. 2. Agenda. Introduction; Verified Technologies. Closed Crankcase ...
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1.Overview of Aftertreatment Products for Diesel Retrofit Presented by Susan Cleaver

2. Agenda  Introduction  Verified Technologies – Closed Crankcase Ventilation System (CCV) – Diesel Oxidation Catalyst (DOC) – DOC + CCV – Diesel Particulate Filter (DPF) 2

3. Introduction  Cummins Emissions Solutions (CES) is a division of Cummins Inc.  CES leverages Cummins experience in engine design, exhaust and filtration to develop retrofit technologies  Partner with key catalyst suppliers (Johnson Matthey)  Over 1.5 CES aftertreatment products in operation  Provide exhaust aftertreatment for all 2007 and newer Cummins engines  Cummins Southern Plains is the authorized Cummins distributor for Texas and Oklahoma 3

4.Closed Crankcase Ventilation (CCV)

5. Closed Crankcase Ventilation (CCV)  Crankcase emission (blowby) is the result of high pressure gases and oils escaping around the piston rings and venting into the atmosphere  Natural occurrence in diesel engines  Crankcase emissions were not included in EPA engine certification test protocol until 2007 5

6. Closed Crankcase Ventilation (CCV)  Blowby gases are taken directly from the engine to the breather assembly  Heavy oil and aerosol particles are captured, separated and coalesced by the media material  Filters up to 99% of oil drip and 95% of aerosol vapors from blow-by  Eliminates 100% of engine compartment fumes  3-5% PM reduction* *Not EPA/CARB verified as a stand-alone product. 6

7. Closed Crankcase Ventilation (CCV)  Compact design mounts easily in engine compartment  Coalescing filter must be changed once a year, or every 1500 hours (school bus) or 1000 hours (all other applications)  Engine operating temperatures must be at least 150 degrees C during the duty cycle  CV51118 Standard Kit comes with: – Coalescing filter assembly – Crankcase depression regulator valve and bracket – Oil drain-back to engine oil sump  1991 -2003 engines 7

8.Diesel Oxidation Catalyst (DOC)

9. Diesel Oxidation Catalyst  Flow through device designed to replace the existing muffler system  Effective at removing unburned fuel and lube (soluble organic fraction) from exhaust  Emissions reductions: – PM 20-30% – CO & HC >50% – NOx None 9

10. Diesel Oxidation Catalyst Stainless Steel Housing Cordierite Ceramic Flow Distribution Substrate Device 10

11. Diesel Oxidation Catalyst  Compatible with low sulfur (< 500 ppm) and ultra low sulfur (<15 ppm) diesel fuel  Does not require a minimum operating temperature  Maintenance-free design is easy to install and requires no monitoring  1993 and newer engines 11

12.Diesel Oxidation Catalyst + Closed Crankcase Ventilation

13. DOC + CCV  Tailpipe and crankcase emissions combined  DOC + CCV verified emissions reduction*: – PM 30% – CO 50% – HC 74%  Engine operating temperatures must be at least 150 degrees C during the duty cycle *Must be used in conjunction with ULSF to achieve these emissions reductions 13

14.Diesel Particulate Filter (DPF)

15. Diesel Particulate Filter (DPF)  Passive retrofit system that traps and oxidizes soot before turning it to ash  Patented Johnson Matthey design utilizes two chambers Exhaust flows A portion of NO in through a wall-flow the exhaust is filter; soot is oxidized to create trapped and NO2 destroyed by the NO2 product 15

16. Diesel Particulate Filter (DPF)  Provides the best emissions reductions – PM 90% – CO 85% – HC 95%  Designed to replace the existing muffler system  DPF kit comes with: – Complete two-stage catalytic filter – Monitor and sensors – Noise control built in – Exhaust piping and mounting brackets 16

17. Diesel Particulate Filter (DPF)  Monitoring is required for use with a DPF  UCM monitors filter backpressure and temperature and sends a fault code if outside of acceptable operating parameters  Reduces the risk of: – Plugging – Uncontrolled regeneration – Catalyst poisoning / deactivation – Engine progressive damage 17

18. Diesel Particulate Filter (DPF)  Ultra low sulfur fuel is required  Must be data logged prior to installation to insure minimum operating temperatures are met – CRT: 240 degrees C for 40% of operating time – CCRT: 200 degrees C for 40% of operating time  May be used with up to B20 biodiesel  1991 and newer engines in good operating condition  Filter element must be cleaned every 60 – 100k miles or as indicated by the UCM 18

19. Retrofit Product Summary Technology PM CO HC Maintenance ULSD CCV 3-5% n/a n/a Replace CCV No filter DOC 20% 50% 50% No No DOC + CCV 30% 50% 74% Replace CCV Yes filter DPF 90% 85% 95% Clean filter Yes section 19