Diesel Emissions (Tier 4)
Scott Weyant
Chris Vernon
Chris Knipfer
John Hale
Summer Meeting – 2012
Agenda
• Emissions History
• Emissions Technology Overview
• Training and Maintenance
Summer Meeting – 2012
2
Tier 4 – Where does it come from?
1996-2015
Non-Road equipment
evolves to meet tiered
emission standards, with
Tier 4 being the final step
in this process.
Summer Meeting – 2012
Tier 4 - What is the focus?
• Nitrogen Oxides (NOx)
• Particulate Matter (PM)
Summer Meeting – 2012
As engine hp increases,
the regulations of each tier
become more stringent
(in general)
Tier Stringency
Tier 4 – Is it the same for every piece of equipment?
Summer Meeting – 2012
Emission Reductions by Tier
Regulatory
Challenges:
– Near-zero
targets
– NOx and PM
are inversely
related
– Standards vary
by power rating
and geographic
area
Phased in by HP Ranges:
• 75 -175 hp: 1/1/12
• 175 – 750 hp: 1/1/11
• >750 hp: 1/1/11 (Tier 2)
Summer Meeting – 2012
Summer Meeting – 2012
Tier 4 – Clean Diesel
Technologies
Summer Meeting – 2012
After Treatment Technologies
Diesel Oxidation Catalyst (DOC)
•
•
•
Oxidizes pollutants as exhaust flows through component
Facilitates passive regeneration (ongoing removal of soot)
Requires no maintenance
Diesel Particulate Filter (DPF)
•
•
•
Traps particulate matter (soot & ash)
Soot removed through regeneration process
Ash removed during maintenance
Regeneration Systems
•
•
Remove soot from DPF
Dosing Systems
•
Burner Systems
–
–
–
Utilizes diesel fuel across DOC to generate heat
Combustion Chamber
Electric Heating Element
NOx Reduction Systems
•
•
•
Cooled EGR
Selective Catalytic Reduction (SCR)
Fuel Systems
Summer Meeting – 2012
Wall-flow Design
DPF - Regeneration
Diesel Particulate Filter
•
Regeneration requires elevated exhaust temps
–
•
Passive vs. Active Regeneration
Active Regeneration System Complexities
–
Dosing Systems
–
Burner Systems
–
Working vs. Idle Regeneration
Considerations:
•
Non-OEM packaging and systems integration
–
•
Heat rejection during or immediately following regen
–
•
Small compact machines (mini-hex, MTL/CTL)
Delayed engine shutdown systems
Regeneration after turbo/injector failure
–
Oil/fuel soaked DPF + Elevated Exhaust Temps
Summer Meeting – 2012
DPF – Packaging Constraints
Summer Meeting – 2012
DPF - Regeneration Considerations
Application considerations with Active DPF regeneration systems:
Summer Meeting – 2012
Fuel System Technology
Common Rail Fuel Systems
•
Increased injection pressures > 30,000 PSI
•
Re-introduction of hard steel lines on engine
•
Some components not re-usable
Considerations:
•
NO Cracking Fuel Lines during Hard Starting
•
Bleed-Off Time after shutdown
•
More pieces/components to remove for repair
Summer Meeting – 2012
NOx After-Treatment Technology
Selective Catalytic Reduction (SCR)
•
Additional components for injection into exhaust
•
Urea based Diesel Exhaust Fluid (DEF)
•
Typically injected post – DPF
Considerations:
•
On board storage of DEF
–
Tank sizing and location
•
Temperature Management of fluid
•
Bulk availability of DEF
Summer Meeting – 2012
Training
Summer Meeting – 2012
Operator Training
• Operators and Foreman
– No longer ‘just new engines’ in the machines
– Daily Walk-Around Inspections
(http://safety.cat.com/Checklists)
• Simple, easy to understand, non-instructor
oriented
– Symbols / Lights
– Systems Operation
– Reactions
• Minimize Impacts to Productivity and Safety
– Rear Vision Camera Systems
Summer Meeting – 2012
DPF - Regeneration Symbols
Lamp / Switch Strategy
DPF Regen Lamp -
Engine emissions system temps
high or outside normal limits
DPF Lamp -
DPF requires regeneration
DPF Regen Disable -
Inhibits Active regeneration
0%
DPF Soot Load -
DPF soot level indicator
(if equipped)
Manual Regen Switch -
Force or Disable active regeneration
(if equipped)
Summer Meeting – 2012
Dealer/Customer - Technician Training
• New Hardware and Technologies
• New Fault Codes and Troubleshooting
– More complex systems and integration
• Emissions Warranty Repairs
• Machine Application / System Operation
– Light Load, Heavy Transient Work
– Regeneration Settings
• Non-OEM Training
– Application and Installations
– Operator Interface Tie-Ins
Summer Meeting – 2012
Tier 4 - Maintenance
Summer Meeting – 2012
DPF Maintenance
Ash in The Diesel Particulate Filter
•
Oxidized lube oil additives
•
Cleaning Process requires removal
•
•
EPA: 4500 hr minimum cleaning interval
Multiple cleaning methods available
•
Stationary tool
•
Centralized Exchange
•
Mobile tool
Issues:
•
Ash Material Capture and Disposal
–
•
Weight of components during removal/installation
–
•
Dispose according to local regulations
Crane accessible engine compartments
Installation of non-authorized component(s)
Summer Meeting – 2012
Crankcase Ventilation Filters
Crankcase Ventilation Filter
• Removes oil from crankcase fumes
• Drains oil back into crankcase
• Additional service point on engine
Issues:
•
Additional Filter Disposal
•
Oil Temperatures
•
Low pressure system
Summer Meeting – 2012
Critical - Fuel / Oil Requirements
ULSD required for Tier 4 Interim product
•
•
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2010 in U.S.: 15 ppm (mg/kg) sulfur content (currently up to 500 ppm
(mg/kg))
Enables engine and aftertreatment performance/durability
Violates EPA regulations if not used
ULSD generally not available in LRC regions
EPA (required) Fuel
inlet label
ECF-3 API CJ-4 oil required: Oil additives formulated to reduce ash
deposit
•
•
Reduced sulfated ash, phosphorous, and sulfur
To maintain DPF performance and cleaning cycles
Biodiesel up to B20, when blended with ULSD
EU Fuel inlet label
Fuel additives:
•
•
May not exceed 15 ppm (mg/kg) sulfur, OR
May not exceed 1% by volume of the resulting fuel/additive mixture
On/Near Oil Inlet
Summer Meeting – 2012
Summer Meeting – 2012