Environmental Technology Verification
Test Report of Mobile Source Emissions Control Devices
Donaldson Company, Inc.
Series 6100 Diesel Oxidation Catalyst Muffler
Prepared by Southwest Research Institute Research Triangle Institute
Under a Cooperative Agreement with U.S. Environmental Protection Agency
THE ENVIRONMENTAL TECHNOLOGY VERIFICATION
PROGRAM
U.S. Environmental Protection Agency
ETV Joint Verification Statement
TECHNOLOGY TYPE: APPLICATION: MOBILE DIESEL ENGINE AIR POLLUTION CONTROL CONTROL OF EMISSIONS FROM MOBILE DIESEL ENGINES IN HIGHWAY USE BY DIESEL OXIDATION CATALYSTS DONALDSON COMPANY, INC. SERIES 6100 DIESEL OXIDATION CATALYST MUFFLER DONALDSON CO., INC. 1400 WEST 94TH STREET MINNEAPOLIS, MN 55431-2370 PHONE: (952) 887-3730 FAX: (952) 887-3937 http://www.donaldson.com imes@mail.donaldson.com
TECHNOLOGY NAME:
COMPANY: ADDRESS:
WEB SITE: E-MAIL:
The U.S. Environmental Protection Agency (EPA) has created the Environmental Technology Verification (ETV) Program to facilitate the deployment of innovative or improved environmental technologies through performance verification and dissemination of information. The goal of the ETV Program is to further environmental protection by accelerating the acceptance and use of improved and cost-effective technologies. ETV seeks to achieve this goal by providing high-quality, peer reviewed data on technology performance to those involved in the design, distribution, financing, permitting, purchase, and use of environmental technologies. ETV works in partnership with recognized standards and testing organizations; stakeholder groups, which consist of buyers, vendor organizations, permitters, and other interested parties; and with the full participation of individual technology developers. The program evaluates the performance of innovative technologies by developing test plans that are responsive to the needs of stakeholders, conducting field or laboratory tests (as appropriate), collecting and analyzing data, and preparing peer-reviewed reports. All evaluations are conducted in accordance with rigorous quality assurance protocols to ensure that data of known and adequate quality are generated and that the results are defensible. The Air Pollution Control Technology Verification Center (APCTVC), one of six centers under the ETV Program, is operated by Research Triangle Institute (RTI), in cooperation with EPA’s National Risk Management Research Laboratory. The APCTVC has evaluated the performance of an emissions control system consisting of an exhaust oxidation catalyst for mobile diesel engines, the Donaldson Company, Inc. Diesel Oxidation Catalyst Muffler, Series 6100 Catalyst Formulation. i
ETV TEST DESCRIPTION All tests were performed in accordance with the general test plan Test/QA Plan for the Verification Testing of Diesel Exhaust Catalysts, PM Filters, and Engine Modification Technologies for Highway and Nonroad Use Diesel Engines and the Test-Specific Addendum to ETV Mobile Source Test/QA Plan for the Donaldson Company, Inc. diesel oxidation catalyst muffler and Spiracle™. These documents are written in accordance with the applicable generic verification protocol and include requirements for quality management, quality assurance, procedures for product selection, auditing of the test laboratories, and test reporting format. The mobile diesel engine air pollution control technology was tested at Southwest Research Institute. The performance verified was the percentage emission reduction achieved by the technology for particulate matter (PM), nitrogen oxides (NOx), hydrocarbons (HC), and carbon monoxide (CO) relative to the performance of the same baseline engine without the technology in place. Operating conditions were documented and ancillary performance measurements were also made. A summary description of the ETV test is provided in Table 1. Table 1. Summary Description of the ETV Test
Test Type Engine Family Engine Make–model year Service Class Engine Rated Power Engine Displacement Technology Technology description Highway Transient Federal Test Procedure (FTP), heavy-duty cycle WDDXH12.7EGD Detroit Diesel Corporation Series 60–1998 Heavy Duty Diesel 299 kW (400 bhp) @ 1,800 rpm 12.7 L Donaldson Company, Inc. Diesel Oxidation Catalyst Muffler, Series 6100 Catalyst A ceramic oxidation catalyst matrix wash-coated with catalyst, packaged in a muffler-sized can for retrofit installation by a moderately skilled mechanic. No engine modifications required. One cold-start and three hot-start tests according to FTP test EPA standard low-sulfur and ultralow-sulfur No. 2 diesel fuels per 40 CFR Part 86.1313 PM, NOx, HC, and CO NO, CO2, and exhaust back-pressure, exhaust temperature, fuel consumption, and exhaust PM soluble organic fraction (SOF)
Test cycle or mode description Test fuel description Critical measurements Ancillary measurements
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VERIFIED TECHNOLOGY DESCRIPTION This verification statement is applicable to the Donaldson Company, Inc. Diesel Oxidation Catalyst Muffler (Series 6100 Catalyst Formulation). According to the vendor, the Donaldson Company, Inc. Diesel Oxidation Catalyst Muffler with Series 6100 Catalyst Formulation is packaged and marketed for use on diesel engines from 150 to 600 bhp. The unit whose performance was verified had part number 5190B2396. It is applicable to engines fueled by ultralow-sulfur (15ppm or less) diesel fuel. This verification statement describes the performance of the tested technology on the diesel engine and fuels identified in Table 1. The performance was measured for a degreened device. A degreened device has been operated a brief period before testing (25 to 125 hours) to achieve a stable emissions reduction. VERIFICATION OF PERFORMANCE The Donaldson Company, Inc. Diesel Oxidation Catalyst Muffler (Series 6100) achieved the reduction in tailpipe emissions shown in Table 2 at the stated conditions. Table 2. Verified Emissions Reductions for System Consisting of a Donaldson Company, Inc. Diesel Oxidation Catalyst Muffler with Series 6100 Catalyst Formulation
Fuel Device type Degreened LSD Degreened ULSD
a
Mean Emissions Reduction (%) PM 28 NOx
a
95% Confidence Limits on the Emissions Reduction (%) PM 25-30 19-25 NOx
a
Baseline
Controlled ULSD
HC 49 66
CO 38 41
HC 19-79 52-79
CO 32-44 37-46
22 ULSD
1.0
0.3-1.7
The emissions reduction could not be distinguished from zero with 95% confidence.
For the purposes of determining the status of the technology in regard to EPA’s voluntary diesel retrofit program, the prospective user is encouraged to contact EPA’s Office of Transportation and Air Quality (OTAQ) or visit the retrofit program web site at http://www.epa.gov/otaq/retrofit/. The APCTVC QA Officer has reviewed the test results and quality control data and has concluded that the data quality objectives given in the generic verification protocol and test/QA plan have been attained. EPA and APCTVC quality assurance staff have conducted technical assessments at the test laboratory and of the data handling. These confirm that the ETV tests were conducted in accordance with the EPA-approved test/QA plan. This verification statement verifies the emissions characteristics of the Donaldson Company, Inc. Diesel Oxidation Catalyst Muffler (Series 6100) with diesel fuels for the stated application. Extrapolation outside that range should be done with caution and an understanding of the scientific principles that control the performance of the technologies. This verification focused on emissions. Potential technology users may obtain other types of performance information from the manufacturer.
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In accordance with the generic verification protocol, this verification statement is valid, commencing on the date below, indefinitely for application of Donaldson Company, Inc. DCM Oxidation Catalyst Muffler (Series 6100) with diesel fuels within the range of applicability of the statement.
Original signed by H.W. McKinnon 9/15/03 Hugh W. McKinnon, MD Date Director National Risk Management Research Laboratory Office of Research and Development United States Environmental Protection Agency Original signed by J.R. Farmer Jack R. Farmer Program Director 9/30/03 Date
Air Pollution Control Technology Verification Center
NOTICE: ETV verifications are based on an evaluation of technology performance under specific, predetermined criteria and the appropriate quality assurance procedures. EPA and RTI make no expressed or implied warranties as to the performance of the technology and do not certify that a technology will always operate as verified. The end user is solely responsible for complying with any and all applicable federal, state, and local requirements. Mention of commercial product names does not imply endorsement.
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Environmental Technology Verification
Report
Mobile Source Retrofit Air Pollution Control
Devices
Donaldson Company, Inc.
Series 6100 Diesel Oxidation Catalyst Muffler
Prepared by
Research Triangle Institute
Southwest Research Institute
EPA Cooperative Agreement No. CR829434-01-1
EPA Project Manager:
Theodore G. Brna
Air Pollution and Control Division
National Risk Management Research Laboratory
Office of Research and Development
Research Triangle Park, NC 27711
September 2003
Notice This document was prepared by Research Triangle Institute (RTI) and its subcontractor Southwest Research Institute, with partial funding from Cooperative Agreement No. CR829434-01-1 with the U.S. Environmental Protection Agency (EPA). The document has been submitted to RTI/EPA’s peer and administrative reviews and has been approved for publication. Mention of corporation names, trade names, or commercial products does not constitute endorsement or recommendation for use of specific products.
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Foreword The Environmental Technology Verification (ETV) Program, established by the U.S. Environmental Protection Agency (EPA), is designed to accelerate the development and commercialization of new or improved technologies through third-party verification and reporting of performance. The goal of the ETV Program is to verify the performance of commercially ready environmental technologies through the evaluation of objective and quality-assured data so that potential purchasers and permitters are provided with an independent and credible assessment of the technology that they are buying or permitting. The Air Pollution Control Technology Verification Center is part of the EPA’s ETV program and is operated as a partnership between Research Triangle Institute (RTI) and EPA. The Center verifies the performance of commercially ready air pollution control technologies. Verification tests use approved protocols and verified performance is reported in verification statements signed by EPA. RTI contracts with Southwest Research Institute to perform verification tests on engine emission control technologies. Retrofit air pollution control devices used to control emissions from mobile diesel engines are among the technologies evaluated by the APCTVC. The APCTVC developed (and EPA approved) the Generic Verification Protocol for Diesel Exhaust Catalysts, Particulate Filters, and Engine Modification Control Technologies for Highway and Nonroad Use Diesel Engines to provide guidance on the verification testing of specific products that are designed to control emissions from diesel engines. The following report reviews the performance of the Donaldson Company, Inc. Diesel Oxidation Catalyst Muffler (Series 6100 catalyst formulation). ETV testing of this technology was conducted during November 2002 at Southwest Research Institute. All testing was performed in accordance with an approved test/QA plan that implements the requirements of the generic verification protocol at the test laboratory. This report is one of a set of three reports that separately report the performance data from three control device configurations included in the test series.
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Availability of Report Copies of this verification report are available from • Research Triangle Institute Engineering and Technology Division P.O. Box 12194
Research Triangle Park, NC 27709-2194
• U.S. Environmental Protection Agency Air Pollution Prevention and Control Division (E305-01) 109 T. W. Alexander Drive Research Triangle Park, NC 27711 Web sites: http://www.epa.gov/etv/verifications/verification-index.html (electronic copy) http://www.epa.gov/ncepihom/
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Contents ETV Joint Verification Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Availability of Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
Acronyms/Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
Section 1.0 Section 2.0 Section 3.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description of Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Test Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Engine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Engine Fuel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Summary of Emissions Measurement Procedures . . . . . . . . . . . . . . . 4
3.4 Deviations from the Test/QA Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Documented Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Section 4.0 Summary and Discussion of Emission Results . . . . . . . . . . . . . . . . . . . . 9
4.1 Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Section 5.0 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ix
Figures
Baseline engine: a 1998 Detroit Diesel Corporation heavy-duty diesel engine,
mounted in Southwest Research Institute’s engine test cell #4 . . . . . . . . . . . . . . . . . . . . . 4
2. Constant volume sampler setup for emissions measurement . . . . . . . . . . . . . . . . . . . . . . . 6
1.
Tables 1. 2. 3. 4. 5a. 5b. 5c. 5d. 6. 7. Engine Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Selected Fuel Properties and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brake Specific Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Baseline Emissions Data (English units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Baseline Emissions Data (metric units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Controlled Emissions Data (English units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Controlled Emissions Data (metric units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Summary of Verification Test Emission Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Summary of Verification Test Emission Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
x
Acronyms/Abbreviations °F °C APCTVC degrees Fahrenheit degrees Celsius Air Pollution Control Technology Verification Center brake horsepower brake horsepower hour brake specific fuel consumption Code of Federal Regulations centimeter(s) carbon monoxide carbon dioxide Detroit Diesel Corporation diesel oxidation catalyst Environmental Protection Agency environmental technology verification Federal Test Procedure foot (feet) gram(s) hydrocarbon(s) heavy duty heated flame ionization detector inch(es) inches of water inches of mercury kilowatt(s) kilopascal(s) liter(s) liters per minute pound(s) pound foot (feet) low-sulfur diesel meter(s) minute(s) millimeter(s) newton(s) newton-meter nitrogen oxide xi NO2 NOx NDIR OTAQ Pa PM ppm QA QC rpm RTI SOF SOP SwRI TPM ULSD nitrogen dioxide nitrogen oxide nondispersive infrared Office of Transportation and Air Quality pascal(s) particulate matter parts per million by volume quality assurance quality control revolutions per minute Research Triangle Institute soluble organic fraction standard operating procedure Southwest Research Institute total particulate matter ultralow-sulfur diesel
bhp bhp-hr BSFC CFR cm CO CO2 DDC DOC EPA ETV FTP ft g HC HD HFID in. in. H2O in. Hg kW kPa L Lpm lb lb-ft LSD m min. mm N N-m NO
Acknowledgments The authors acknowledge the support of all of those who helped plan and conduct the verification activities. In particular, we would like to thank Theodore Brna, EPA’s Project Manager, and Paul Groff, EPA’s Quality Assurance Manager, both of EPA’s National Risk Management Research Laboratory in Research Triangle Park, NC. We would also like to acknowledge the assistance and participation of all the Donaldson Company, Inc. personnel who supported the test effort. For more information on the Donaldson Company, Inc. Diesel Oxidation Catalyst Muffler with Series 6100 Catalyst Formulations, contact: Julian Imes Donaldson Company, Inc. 1400 West 94th Street Minneapolis, MN 55431-2370 Telephone: (952) 887-3730 Fax: (952) 887-3937 Email: imes@mail.donaldson.com Web site: http://www.donaldson.com OR Fred Schmidt Donaldson Company, Inc. 1400 West 94th Street Minneapolis, MN 55431-2370 Telephone: (952) 887-3835 Fax: (952) 887-3008 Email: fschmidt@mail.donaldson.com Web site: http://www.donaldson.com
For more information on verification testing of mobile sources air pollution control devices, contact: Jenni Elion Research Triangle Institute P.O. Box 12194 Research Triangle Park, NC 27709-2194 Telephone: (919) 541-6826 Email: jme@rti.org Web site: http://etv.rti.org/apct/index.html
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Section 1.0
Introduction
This report reviews the performance of the Donaldson Company, Inc. Diesel Oxidation Catalyst Muffler (Series 6100 Catalyst Formulation). Environmental Technology Verification (ETV) testing of this technology was conducted during a series of tests in November 2002 by Southwest Research Institute (SwRI) under contract with the Air Pollution Control Technology Verification Center (APCTVC). This report addresses one of the three baseline-control device configurations covered by this test series. The objective of the APCTVC and the ETV Program is to verify, with high data quality, the performance of air pollution control technologies. Control of air emissions from diesel engines is within the scope of the APCTVC. An APCTVC program area was designed by Research Triangle Institute (RTI) and a technical panel of experts to evaluate the performance of diesel exhaust catalysts, particulate filters, and engine modification control technologies for mobile diesel engines. Based on the activities of this technical panel, the Generic Verification Protocol for Diesel Exhaust Catalysts, Particulate Filters, and Engine Modification Control Technologies for Highway and Nonroad Use Diesel Engines (RTI, 2002)1 was developed. The specific test/quality assurance plan addendum for the ETV test of the technology submitted by Donaldson Company, Inc. was developed and approved on October 3, 2002.2 The goal of the test was to measure the emissions control performance of the technology systems and their emissions reductions relative to an uncontrolled engine. A description of the Donaldson Company, Inc. Diesel Oxidation Catalyst Muffler (Series 6100 Catalyst Formulation) is presented in Section 2. Section 3 documents the procedures and methods used for the test and the conditions over which the test was conducted. The results of the test are summarized and discussed in Section 4, and references are presented in Section 5. This report contains only summary information and data as well as the verification statement. Complete documentation of the test results is provided in a separate test report3 and audit of data quality report.4 These reports include the raw test data from product testing and supplemental testing, equipment calibration results, and quality assurance (QA) and quality control (QC) activities and results. Complete documentation of QA/QC activities and results, raw test data, and equipment calibration results are retained in Southwest Research Institute’s files for seven years.
1
Section 2.0
Description of Products
The APCTVC conducted verification testing for the Donaldson technology system described below (descriptions were provided by Donaldson Company). The system consisted of a Donaldson Company, Inc. Diesel Oxidation Catalyst (DOC) Muffler with Series 6100 catalyst formulation for use with ultralow-sulfur diesel (ULSD) fuel (15 ppm maximum sulfur content). The technology was provided directly to the APCTVC’s test organization, Southwest Research Institute, as a degreened Donaldson Company, Inc. DOC Series 6100 catalyst formulation (part number 5190B2396). The catalyst was degreened on an engine operated for 25 hours. For the first eight hours, the engine was operated in a repeated cycle with 15 minutes at idle followed by 15 minutes at peak torque speed and loaded to produce 400 °C exhaust gas temperature at the DOC inlet. For the remaining time, the engine was run at the steady state condition of peak torque speed and loaded to produce 400 °C exhaust gas temperature at the DOC inlet. All testing was conducted on a Detroit Diesel Series 60 engine fueled by conventional No. 2 diesel fuel.
2
Section 3.0
Test Documentation
The ETV testing took place at Southwest Research Institute under contract to the APCTVC. Testing was performed in accordance with: • Generic Verification Protocol for Diesel Exhaust Catalysts, Particulate Filters, and Engine Modification Control Technologies for Highway and Nonroad Use Diesel Engines,1 • Test/QA Plan for the Verification Testing of Diesel Exhaust Catalysts, Particulate Filters, and Engine Modification Control Technologies for Highway and Nonroad Use Diesel Engines,5 and • Test-Specific Addendum to ETV Mobile-Source Test/QA Plan for Donaldson Company, Inc. DOC Converter Muffler.2 The applicant had reviewed the generic verification protocol and had an opportunity to review the test/QA plan prior to testing. 3.1 Engine Description
The ETV testing was performed on a 1998 Detroit Diesel Corporation Series 60 heavy-duty diesel engine. The engine was an in-line six-cylinder with a 12.7 liter (L) displacement and rated for 400 bhp at 1,800 rpm. It was turbocharged and used a laboratory water-to-air heat exchanger for a charge air aftercooler. The engine was owned by SwRI and has been used on various research programs. Table 1 provides the engine identification details. The baseline engine is shown in Figure 1. Table 1. Engine Identification Information
Engine serial number Date of manufacture Make Model year Model Engine displacement and configuration Service class EPA engine family identification Rated power Rated torque Certified emission control system Aspiration Fuel system Electronic control module 06R0422316 April 1998 Detroit Diesel Corporation (DDC) 1998 Series 60, 6067TK60 12.7 L, Inline 6 On-highway, heavy-duty (HD) diesel engine WDDXH12.7EGD 400 bhp at 1,800 rpm 1,550 lb-ft at 1,200 rpm Electronic control Turbocharged, air-to-air intercooled Direct injection, electronically controlled unit injectors DDEC-III
3
Figure 1.
Baseline engine: a 1998 Detroit Diesel Corporation heavy-duty diesel engine, mounted in Southwest Research Institute’s engine test cell #4.
3.2
Engine Fuel Description
Two different diesel fuels were used during this verification test; a conventional, on-road No. 2 LSD fuel and a No. 2 ULSD fuel. The sulfur levels for these fuel batches were 346 ppm and 8 ppm, respectively. The fuels meet current EPA diesel fuel specifications given in 40 CFR § 86.1313-98, Table N98-26 for LSD fuel and 40 CFR § 86.1313-2007, Table N07-27 for ULSD fuel. Table 2 summarizes selected fuel properties from the suppliers’ analyses. 3.3 Summary of Emissions Measurement Procedures
The ETV tests consisted of baseline uncontrolled tests and tests with the control system installed. The baseline engine was tested on conventional LSD and ULSD fuels. The standard heavy duty (HD) Transient Federal Test Procedure8 (FTP) for exhaust emissions testing was performed. The Donaldson DOC Series 6100 catalyst formulation was then installed. The installed parts were conditioned using three FTP cycles before they were set up for the cold-start test. The engine test cycle for the DOC muffler verification testing was the heavy-duty FTP cycle. The DOC muffler was tested on only ULSD fuel. These tests were official tests with one cold and three hot-start transient cycles conducted in accordance with the test/QA plan.5 Individual exhaust gas and PM samples were taken for each cycle, and a soluble organic fraction (SOF) analysis was performed on the baseline engine exhaust PM samples. 4
Table 2.
Selected Fuel Properties and Specifications
Code of Federal Regulations Specificationa Item ASTM D613 D976 D86 D86 D86 D86 D86 D287 D2622 Type-2D 40–50 40–50 340–400 (101–204) 400–460 (204–238) 470–540 (243–282) 560–630 (293–332) 610–690 (321–366) 32–37 – (300–500) (7-15)c 27 d 130 (54) 2.0–3.2 –
b
Test Fuel “LSD” EM-4712-F 46.0 47.3 365 (185) 427 (219) 510 (266) 587 (308) 633 (334) 35.17 0.8490 346 “ULSD” EM-4579-F 47.4 47.5 364 (184) 401 (205) 488 (253) 588 (309) 665 (352) 36.95 0.840 8.47
Cetane number Cetane index Distillation range: Initial boiling point, °F (°C) 10% Point, °F (°C) 50% Point, °F (°C) 90% Point, °F (°C) End point, °F (°C) Gravity (American Petroleum Institute) Specific gravity Total sulfur, ppm Hydrocarbon composition: Aromatics (min.), % Paraffins, naphthenes, and Olefins, % Flash point (min.), °F (°C) Viscosity, centistokes @ 40 °C Fuel supplier
a
D1319 D1319 D93 D445 –
29.2 70.8 164 (73) 2.6
27.5 72.5 155 (68) 2.2
Chevron Phillips Chemical Co.
b c d
Diesel fuel specification as in CFR 40 86.1313-98(b)(2) for the year 1998 and beyond and CFR 40 86.1313 2007(b)(2) for the year 2007 and beyond, for heavy-duty diesel engines. 1998 sulfur range specification.
2007 sulfur range specification.
Remainder of the hydrocarbons.
Emissions Test Procedures Exhaust emissions were measured using HD Transient FTP8 and the experimental setup shown in Figure 2. Dilute exhaust emissions measured during tests over the transient FTP operating conditions included total hydrocarbons (HC), carbon monoxide (CO), carbon dioxide (CO2), nitrogen oxides (NOX), nitric oxide (NO), and exhaust PM. The CO and CO2 levels were determined using nondispersive infrared (NDIR) instruments. Total HC were measured using continuous sampling techniques that employed a heated flame ionization detector (HFID). The NOX and NO were measured continuously using two separate chemiluminescent analyzers fed simultaneously from a common path. The nitrogen dioxide (NO2) was reported as the difference between NOX and NO.
5
Pump CO, CO2, HC, and NOx Background Bag
HC Analyzer
HFID
NOx Analyzer
Mixing Orifice Dilution Air Heated Line Heated Line Pump
10 Diameters
Pump Filter Pack Exhaust Line Secondary Dilution Particulate Sample Pump Gas Meter
Dilution Air
Primary Filter Back-Up Filter
Heat Exchanger
CO, CO2 Sample Bag
ENGINE
Positive Displacement Pump (PDP)
Gas Meter
Figure 2. Constant volume sampler setup for emissions measurement.
The exhaust PM level for each test was determined using dilute sampling techniques that collected PM on a pair of 90-mm diameter Pallflex T60A20 filter medium, which were used in series. The particulate filter pair was weighed together both before and after each test to establish exhaust PM emissions for the test. The SOF was determined for engine baseline tests using the same pair of 90-mm filters that were used to determine exhaust PM mass emissions. The extraction process for the SOF used a micro-Soxhlet apparatus with toluene-ethanol solvent, as specified by the California Air Resources Board test method.9 3.4 Deviations from the Test/QA Plan
Only one baseline test was originally planned using LSD fuel; however, due to a lower than expected baseline emissions level, the vendor requested a second baseline test (one cold start and three hot starts). The cold start for this second baseline test failed the y intercept requirement of the speed regression line, described in Figure N90-11 of 40 CFR, Part 86, Subpart No. 86.1341-90,10 by 3 rpm. While, the cold start failed statistics by a minor amount, 6
SwRI voided this test and repeated the second baseline. Both the first baseline test and the repeated second baseline test were judged as valid data and were averaged. 3.5 Documented Test Conditions
Engine Performance Table 3 summarizes observed power and torque for all baseline and control configurations. The engine performance was similar for all configurations. The coefficient of variation was less than one percent for both rated power at a rated speed of 1,800 rpm and for peak torque at 1,200 rpm. The torque map performances for all DOC muffler configuration tests were similar, with a coefficient of variation of less than two percent. Table 3. Engine Performance Data
Fuel LSD Test Date 10/30/2002 10/31/2002 11/1/2002 11/9/2002 Average: Standard deviation: Coefficient of variation, %: ULSD 11/5/2002 11/6/2002 11/7/2002 Average: Standard deviation: Coefficient of variation, %:
a b
Test Number 4712-BO-P1 4712-B22-SC-P1 4712-M11-SC-P1 4712-BO-P2
Test Type Baseline Controlled Controlled Baseline
Rated Powera bhp (kW) 405 (302) 404 (301) 403 (301) 402 (300) 404 (301) 1.3 0.3
Peak Torqueb lb-ft (N-m) 1182 (1602) 1181 (1600) 1177 (1575) 1175 (1592) 1179 (1597) 3.3 0.3 1162 (1551) 1160 (1549) 1162 (1551) 1161 (1550) 1.2 0.1
4579-BO-P1 4579-B22-SC-P1 4579-B23-O-P1
Baseline Controlled Controlled
398 (297) 396 (296) 399 (298) 398 (297) 1.5 0.4
Engine power at rated speed of 1,800 rpm. Engine peak torque at rated speed of 1,200 rpm.
7
Engine Exhaust Back-Pressure The engine exhaust back-pressure was set to 2.8 in. Hg (9.5 kPa) in accordance with the engine manufacturer’s specifications for the baseline tests. The DOC muffler configuration tested displayed a similar back-pressure of 2.8 in. Hg (9.5 kPa) at rated engine power. Engine Exhaust Temperature Temperature measurements were made in the exhaust system at the inlet and outlet of the DOC. The temperature probes were located five in. upstream of the DOC inlet and ten in. downstream of the DOC outlet. Typical temperatures averaged over the transient test cycle were 470 to 480 °F (240 to 250 °C) at the DOC inlet and 510 to 530 °F (270 to 280 °C) at the DOC outlet. Fuel Consumption Table 4 presents the brake specific fuel consumption (BSFC) for all baseline and control configurations. Table 4. Brake Specific Fuel Consumption
Test Number 4712-BO-C1 4712-BO-H1 4712-BO-H2 4712-BO-H3 4712-BO-C3 4712-BO- H7 4712-BO-H8 4712-BO-H9 4579-BO-C1 4579-BO-H1 4579-BO-H2 4579-BO-H3 4579-B23-O-C1 4579-B23-O-H1 4579-B23-O-H2 4579-B23-O-H3 Test Type Cold-start Hot-start Hot-start Hot-start Cold-start Hot-start Hot-start Hot-start Cold-start Hot-start Hot-start Hot-start Cold-start Hot-start Hot-start Hot-start BSFC, BSFC, Test Date lb/bhp-hr kg/kW-hr First engine baseline with LSD fuel 10/31/02 0.428 0.259 10/31/02 0.414 0.250 10/31/02 0.411 0.249 10/31/02 0.410 0.248 Second engine baseline with LSD fuel 11/12/02 0.426 0.258 11/12/02 0.415 0.251 11/12/02 0.415 0.251 11/12/02 0.412 0.249 Engine baseline with ULSD fuel 11/06/02 0.434 0.263 11/06/02 0.416 0.252 11/06/02 0.408 0.247 11/06/02 0.418 0.253 Degreened DOC Series 6100 and ULSD fuel 11/08/02 0.432 0.261 11/08/02 0.414 0.252 11/08/02 0.412 0.251 11/08/02 0.414 0.250 Weighted BSFC, lb/bhp-hr Weighted BSFC, kg/kW-hr
0.416 0.413 0.413
0.252 0.250 0.250
0.417 0.417 0.414
0.252 0.252 0.250
0.419 0.412 0.420
0.253 0.249 0.254
0.417 0.415 0.417
0.252 0.251 0.252
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Section 4.0
Summary and Discussion of Emission Results
The baseline and controlled emissions data are summarized in Tables 5a through 5d. The emissions were measured at each test point for HC, CO, NOx, and PM. Tables 5a through 5d also provide data on the SOF of the exhaust PM during baseline tests, speciation of the NOx emissions, CO2 emissions, and work. For each pollutant and each cold- or hot-start test, the mass emissions per work (bhp-hr) was calculated. The transient composite-weighted emissions were then calculated following the fractional calculation for highway engines to provide composite emissions rates for each pollutant, hot-start test combination as follows. (ECOMP)m = 1/7 � ECOLD + 6/7 � (EHOT)m where: m = 1, 2, or 3 hot-start tests ECOMP = composite emissions rate, g/bhp-hr ECOLD = cold-start emissions rate, g/bhp-hr EHOT = hot-start emissions rate, g/bhp-hr These composite emissions rates were then used to calculate the mean and standard deviations for the baseline and controlled emissions rates. These data were in turn used to calculate mean emissions reductions and 95 percent confidence limits. These calculations are based on the generic verification protocol1 and test/QA plan.5 However, this calculation procedure differed slightly from the equation in the CFR8 in the order of the calculation. The CFR specifies that the mass emissions in grams and the work in bhp-hr are first weighted for the cold- and hot-start tests before the mass emissions are divided by the work. Table 6 summarizes the composite weighted emission values and Table 7 the verified emissions reductions and their 95 percent confidence limits. As shown in Table 7, the mean emissions reductions for PM emissions ranged from 22 to 28 percent depending on the fuel used. The mean emissions reductions for NOx showed little or no significant change. For HC, it ranged from 49 to 66 percent, and for CO, it ranged from 38 to 41 percent. (1)
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5a. Baseline Emissions Test Data (English units)
Test Number Test Type Test Date g/bhp-hr Exhaust PM SOF NOX NO NO2
a
NO2/ NOX, %
g/bhp-hr HC CO CO2
Work, bhp-hr
First engine baseline with LSD fuel and open crankcase configuration 4712-BO-C1 4712-BO-H1 4712-BO-H2 4712-BO-H3 Cold-start Hot-start Hot-start Hot-start 10/31/02 10/31/02 10/31/02 10/31/02 0.132 0.070 0.072 0.073 0.081 0.029 0.031 0.015 3.96 3.91 3.93 3.90 3.50 3.41 3.41 3.36 0.46 0.51 0.52 0.54 11.7 13.0 13.3 13.8 0.443 0.096 0.106 0.105 1.87 1.05 1.02 1.05 612 594 589 587 29.52 29.58 29.62 29.53
Second engine baseline with LSD fuel and open crankcase configuration 4712-BO-C3 Cold-start Hot-start Hot-start Hot-start 11/12/02 11/12/02 11/12/02 11/12/02 0.093 0.077 0.076 0.08 0.04 0.025 0.024 0.026 4.08 4.04 4.01 4.01 3.60 3.52 3.49 3.48 0.48 0.52 0.51 0.53 11.7 12.8 12.8 13.2 0.238 0.181 0.201 0.281 1.55 1.03 0.98 0.97 610 594 595 591 29.61 29.61 29.60 29.72
10
a
4712-BO-H7 4712-BO-H8 4712-BO-H9
Engine baseline with ULSD fuel and with open crankcase configuration 4579-BO-C1 4579-BO-H1 4579-BO-H2 4579-BO-H3 Cold-start Hot-start Hot-start Hot-start 11/06/02 11/06/02 11/06/02 11/06/02 0.122 0.066 0.067 0.065 0.089 0.020 0.019 0.017 4.00 3.97 3.99 3.98 3.49 3.41 3.46 3.44 0.51 0.56 0.53 0.53 12.8 14.1 13.3 13.3 0.753 0.197 0.194 0.209 2.14 1.03 1.03 1.00 618 596 585 599 29.40 29.32 29.30 29.32
NO2 calculated as NOx - NO.
5b. Baseline Emissions Test Data (metric units)
Test Number 4712-BO-C1 4712-BO-H1 4712-BO-H2 4712-BO-H3 4712-BO-C3 4712-BO-H7 4712-BO-H8 4712-BO-H9 4579-BO-C1 4579-BO-H1 4579-BO-H2 4579-BO-H3
a
Test Type Cold-start Hot-start Hot-start Hot-start Cold-start Hot-start Hot-start Hot-start Cold-start Hot-start Hot-start Hot-start
Test Date 10/31/02 10/31/02 10/31/02 10/31/02 11/12/02 11/12/02 11/12/02 11/12/02 11/06/02 11/06/02 11/06/02 11/06/02
g/kWh Exhaust PM 0.176 0.093 0.096 0.097 0.124 0.103 0.101 0.107 0.163 0.088 0.089 0.087 SOF 0.108 0.039 0.041 0.020 0.053 0.033 0.032 0.035 0.119 0.027 0.025 0.023 NOX 5.28 5.21 5.24 5.20 5.44 5.39 5.35 5.35 5.33 5.29 5.32 5.31 NO 4.67 4.55 4.55 4.48 4.80 4.69 4.65 4.64 4.65 4.55 4.61 4.59 NO2
a
NO2/ NOX, % 11.7 13.0 13.3 13.8 11.7 12.8 12.8 13.2 12.8 14.1 13.3 13.3
g/kWh HC 0.591 0.128 0.141 0.140 0.317 0.241 0.268 0.375 1.004 0.263 0.259 0.279 CO 2.49 1.40 1.36 1.40 2.07 1.37 1.31 1.29 2.85 1.37 1.37 1.33 CO2 815 792 785 783 813 792 793 788 824 795 780 799
Work, kWh 22.14 22.19 22.22 22.15 22.21 22.21 22.20 22.29 22.05 21.99 21.98 21.99
First engine baseline with LSD fuel and open crankcase configuration 0.61 0.68 0.69 0.72 0.64 0.69 0.68 0.71 0.68 0.75 0.71 0.71
Second engine baseline with LSD fuel and open crankcase configuration
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Engine baseline with ULSD fuel and open crankcase configuration
NO2 calculated as NOx - NO.
5c. Controlled Emissions Test Data (English units)
Test Number Test Type Test Date g/bhp-hr Exhaust PM SOF
b b b b
NOX
NO
NO2a
NO2/ NOX, %
g/bhp-hr HC CO CO2
Work, bhp-hr
Degreened DOC (B2396) and ULSD fuel
4579-B23-O-C1 Cold-start Hot-start Hot-start Hot-start 11/08/02 11/08/02 11/0802 11/08/02 0.074 0.056 0.056 0.054 4.06 3.92 3.91 3.94 3.75 3.52 3.53 3.54 0.31 0.40 0.38 0.40 7.6 10.1 9.7 10.2 0.332 0.011 0.101 0.057 1.45 0.59 0.51 0.60 617 599 596 593 29.33 29.25 29.31 29.38
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a b
4579-B23-O-H1 4579-B23-O-H2 4579-B23-O-H3
NO2 calculated as difference of NOx - NO. Measurement not conducted.
5d. Controlled Emissions Test Data (metric units)
Test Number Test Type Test Date g/kWh Exhaust PM SOF
b b b b
NOX 5.41 5.23 5.21 5.25
NO
NO2
a
NO2/ NOX, % 10.1 13.9 12.9 13.6
g/kWh HC CO CO2 823 799 795 791
Work, kWh
Degreened DOC (B2396) and ULSD fuel
4579-B23-O-C1 4579-B23-O-H1 Cold-start Hot-start Hot-start Hot-start 11/08/02 11/08/02 11/08/02 11/89/02 0.099 0.075 0.075 0.072 5.00 4.69 4.71 4.72 0.41 0.53 0.51 0.53 0.443 0.015 0.135 0.076 1.93 0.79 0.68 0.80 22.00 21.94 21.98 22.04
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a b
4579-B23-O-H2 4579-B23-O-H3
NO2 calculated as difference of NOx - NO. Measurement not conducted.
Table 6. Summary of Verification Test Emission Levels
Fuel Composite Weighted Emission Value, g/bhp-hr (g/kWh)
Device type
Controlled
Baseline
Baseline PM 0.081 (0.108) 0.074 (0.099) NOx 4.0 (5.3) 4.0 (5.3) HC 0.19 (0.25) 0.28 (0.37) CO 1.1 (1.5) 1.2 (1.6) CO2 594 (792) 597 (796) PM 0.058 (0.077) 0.058 (0.077) NOx 3.9 (5.2) 3.9 (5.2)
Controlled HC 0.10 (0.13) 0.10 (0.13) CO 0.69 (0.92) 0.69 (0.92) CO2 599 (799) 599 (799)
Degreened Degreened
LSD ULSD
ULSD ULSD
Table 7 Summary of Verification Test Emission Reductions
Fuel Device type Degreened LSD Degreened ULSD
a
Mean Emissions Reduction (%) PM 28 NOx
a
95% Confidence Limits on the Emissions Reduction (%) PM 25-30 19-25 NOx
a
Baseline
Controlled ULSD
HC 49 66
CO 38 41
HC 19-79 52-79
CO 32-44 37-46
22 ULSD
1.0
0.3-1.7
The emissions reduction could not be distinguished from zero with 95% confidence.
4.1
Quality Assurance
The environmental technology verification of the DOC muffler for heavy-duty diesel engines was performed in accordance with the test/QA plan.5 An audit of data quality included the review of equipment, personnel qualifications, procedures, record keeping, data validation, analysis, and reporting. Preliminary, in-process, and final inspections, and a review of 10 percent of the data showed that the requirements stipulated in the test/QA plan5 were achieved. The APCTVC’s quality manager reviewed the test results and the quality control data and concluded that the data quality objectives given in the generic verification protocol have been attained. EPA and RTI quality assurance staff conducted audits of SwRI’s technical and quality systems in April 2002 and found no deficiencies that would adversely impact the quality of results. The equipment was appropriate for the verification testing, and it was operating satisfactorily. SwRI’s technical staff are well qualified to perform the testing and conduct themselves in a professional manner.
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Section 5.0
References
1. Research Triangle Institute. Generic Verification Protocol for Diesel Exhaust Catalysts, Particulate Filters, and Engine Modification Control Technologies for Highway and Nonroad Use Diesel Engines. Research Triangle Park, NC, January 2002. Research Triangle Institute. Test-Specific Addendum to ETV Mobile Source Test/QA Plan for Donaldson Company, Inc. DOC Converter Muffler. Research Triangle Park, NC, October 2002. Southwest Research Institute. Environmental Technology Verification of Several Diesel Oxidation Catalyst Mufflers and a Spiracle Blow-By Emission Control Device for HeavyDuty Diesel Engines. San Antonio, TX, December 2002. Southwest Research Institute. Audit of Data Quality for Environmental Technology Verification of Several Diesel Oxidation Catalyst Mufflers and a Spiracle™ Blow-By Emission Control Device for Heavy-Duty Diesel Engines. San Antonio, TX, January 2003. Research Triangle Institute. Test/QA Plan for the Verification Testing of Diesel Exhaust Catalysts, Particulate Filters, and Engine Modification Control Technologies for Highway and Nonroad Use Diesel Engines. Research Triangle Park, NC, April 2002. Fuel specifications, 40 CFR § 86.1313-98, Table N98-2 (updated July 2001). Fuel specifications, 40 CFR § 86.1313-2007, Table N07-2 (updated January 2001). 40 CFR § 86, Subpart N, as of July 1, 1999, http://www.epa.gov/epahome/cfr40.htm California Air Resources Board. Test Method for Soluble Organic Fraction (SOF) Extraction, El Monte, CA, April, 1989.
2.
3.
4.
5.
6. 7. 8. 9.
10. 40 CFR, § 86.1341-90, Figure N90-11 (as amended September 5, 1997), http://www.access.gpo.gov/nara/cfr/cfrhtml_00/Title_40/40cfr86a_00.html
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