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Diesel Emissions (Tier 4). Scott Weyant. Chris Vernon. John Hale. Chris Knipfer. Agenda. Emissions History Emissions Technology Overview Training and Maintenance. Tier 4 – Where does it come from?. 1996 - 20 15. Non-Road equipment evolves to meet tiered emission standards, with - PowerPoint PPT Presentation
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Summer Meeting – 2012
Diesel Emissions (Tier 4)Scott Weyant
Chris Knipfer John Hale
Chris Vernon
Summer Meeting – 2012 2
Agenda
• Emissions History
• Emissions Technology Overview
• Training and Maintenance
Summer Meeting – 2012
Non-Road equipmentevolves to meet tieredemission standards, withTier 4 being the final stepin this process.
1996-2015
Tier 4 – Where does it come from?
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Tier 4 - What is the focus?
• Nitrogen Oxides (NOx)• Particulate Matter (PM)
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Tier 4 – Is it the same for every piece of equipment?
As engine hp increases,the regulations of each tier become more stringent
(in general)
Tier
Stri
ngen
cy
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Regulatory Challenges:– Near-zero targets
– NOx and PM are inversely related
– Standards vary by power rating and geographic area
Emission Reductions by Tier
Phased in by HP Ranges:• 75 -175 hp: 1/1/12• 175 – 750 hp: 1/1/11• >750 hp: 1/1/11 (Tier 2)
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Summer Meeting – 2012
Tier 4 – Clean Diesel Technologies
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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
– Utilizes diesel fuel across DOC to generate heat• Burner Systems
– Combustion Chamber– Electric Heating Element
NOx Reduction Systems • Cooled EGR• Selective Catalytic Reduction (SCR)• Fuel Systems
Wall-flow Design
After Treatment Technologies
Summer Meeting – 2012
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
– Small compact machines (mini-hex, MTL/CTL)
• Heat rejection during or immediately following regen– Delayed engine shutdown systems
• Regeneration after turbo/injector failure– Oil/fuel soaked DPF + Elevated Exhaust Temps
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DPF – Packaging Constraints
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Application considerations with Active DPF regeneration systems:
DPF - Regeneration Considerations
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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
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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
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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
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Lamp / Switch Strategy
DPF Regen Lamp - Engine emissions system tempshigh or outside normal limits
DPF Lamp - DPF requires regeneration
DPF Regen Disable - Inhibits Active regeneration
DPF Soot Load - DPF soot level indicator (if equipped)
Manual Regen Switch - Force or Disable active regeneration(if equipped)
0%
DPF - Regeneration Symbols
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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
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Tier 4 - Maintenance
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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
– Dispose according to local regulations
• Weight of components during removal/installation– Crane accessible engine compartments
• Installation of non-authorized component(s)
DPF Maintenance
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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
Crankcase Ventilation Filters
Summer Meeting – 2012
Critical - Fuel / Oil Requirements
ULSD required for Tier 4 Interim product • 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
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
Fuel additives:• May not exceed 15 ppm (mg/kg) sulfur, OR• May not exceed 1% by volume of the resulting fuel/additive mixture
EPA (required) Fuel inlet label
EU Fuel inlet label
On/Near Oil Inlet
Summer Meeting – 2012