Diesel Emissions (Tier 4)

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


Non-Road equipmentevolves to meet tieredemission standards, withTier 4 being the final stepin this process.

1996-2015

Tier 4 – Where does it come from?


Tier 4 - What is the focus?

• Nitrogen Oxides (NOx)• Particulate Matter (PM)


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

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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)


Tier 4 – Clean Diesel 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

– 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


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


DPF – Packaging Constraints


Application considerations with Active DPF regeneration systems:

DPF - Regeneration Considerations


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


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


Training


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

http://safety.cat.com/Checklists


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


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


Tier 4 - 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

– Dispose according to local regulations

• Weight of components during removal/installation– Crane accessible engine compartments

• Installation of non-authorized component(s)

DPF Maintenance


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


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

Diesel Emissions (Tier 4)

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