Reducing NOx and PM Emissions in Todays Machines: A Caterpillar Perspective

Michael J. Readey, Ph.D. Product Manager, Emissions Solutions Group Caterpillar Inc.

SCAQMD Off-Road Emission Reduction Technology Conference Diamond Bar, California

May 1, 2007 making sustainable progress possible

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Outline
The Emissions Landscape

Caterpillars Path to Emissions Reduction

The RePower Opportunity Upgrading Older Engines Aftertreatment the final frontier

Summary
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The Emissions Landscape: US EPA Regulations

0.5 0.5

US EPA Non-Road Regulations US EPA Non-Road Regulations (175-750 hp) (175-750 hp)
Unregulated Unregulated Tier 11 Tier

0.4 0.4

Particulates (g/hp-hr) Particulates (g/hp-hr)

0.3 0.3

0.2 0.2 Tier 33 Tier 0.1 0.1 Tier 4B Tier 4B Tier 4A Tier 4A 00 22 44 66 88 Tier 22 Tier

0.0 0.0

NOx (g/hp-hr) NOx (g/hp-hr)

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The Emissions Landscape: Upcoming CA ATCM Rules

US EPA Non-Road Regulations vs. California ATCM Rule US EPA Non-Road Regulations vs. California ATCM Rule 0.5 (175-750 hp) 0.5 (175-750 hp)
0.4 0.4 Unregulated Unregulated 175-299hp 175-299hp 300-599 hp 300-599 hp 600-750hp 600-750hp Tier 11 Tier

Particulates (g/hp-hr) Particulates (g/hp-hr)

0.3 0.3

2009 Fleet Average Rule

0.2 0.2 Tier 33 Tier 0.1 0.1 Tier 4B Tier 4B Tier 4A Tier 4A 00 22 44 66 88 Tier 22 Tier

2020

0.0 0.0

NOx (g/hp-hr) NOx (g/hp-hr)

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Caterpillars Path to Emissions Reduction

Emissions Upgrade Overhauls Engine Repowers Rental Equipment

Emissions Solutions
Retire Replace Aftertreatment Filter/Catalysts Cleaner Fuels

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CATs Engine RePower Program

Tier 1, Tier 2, and Tier 3 Primary NOx solution for Cat Retrofit 100+ machine models; 2000+ repowers

Replace the pre-Tier 1 engines with a lower emissions Replace the pre-Tier 1 engines with a lower emissions engine for the most cost-effective NOx reduction engine for the most cost-effective NOx reduction
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Emissions Retrofit Engine Upgrade Groups

Upgrade to Tier 1 emissions levels during an engine overhaul

Turbochargers Fuel pumps / Governors Cylinder packs

Cost effective solutions Cost effective solutions Same Caterpillar reliability and serviceability Same Caterpillar reliability and serviceability Available for select 3306 off-road applications Available for select 3306 off-road applications Available for 3406 off-road in 2007 Available for 3406 off-road in 2007

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Diesel Emission Reduction: Aftertreatment Solutions

Exhaust Aftertreatment
HC + CO Reduction
Oxidation Catalysts (80-95%)

PM Reduction
Oxidation Catalysts (up to 20-25%) Particulate Filters (> 85%)
Exhaust In (Soot, CO, HC, NOx)

NOx Reduction
Urea-SCR HC-SCR Lean NOx Traps Hybrid Catalysts
Clean Exhaust Out (CO2, H2O)

Flow-thru catalyst system

Soot Collection

Wall-flow catalyst system

Generally a muffler replacement

Ideally a muffler replacement, but often much larger

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Reducing Particulate Emissions in CAT Machines

The Diesel Particulate Filter
High filtration efficiency, but High filtration efficiency, but
Space claim & Weight Space claim & Weight Backpressure (fuel economy) Backpressure (fuel economy) Cost ($$$) Cost ($$$)

Top View

Considerable engineering required Considerable engineering required to ensure an optimum retrofit design. to ensure an optimum retrofit design.

Front

Back
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Successful DPF Installations

966G-II Wheel Loader

CAT Engineered & CAT Dealer Installed

CAT DPFs have survived over 6,000hr in the field. CAT DPFs have survived over 6,000hr in the field.
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Successful DPF Installations

HEX Dual DPF Retrofit HEX Dual DPF Retrofit Installation in Switzerland Installation in Switzerland

Sometimes machine Sometimes machine modification is required. modification is required.

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Passive Systems: The Dilemma of Cold Duty Cycles

> 300C 200-300C 100-200 C < 100 C

Operating Region Below Operating Region Below Threshold for Passive Regen Threshold for Passive Regen

Torque (N-m)

Cracking
Speed (RPM)

Ash Buildup Melting

Excessive soot loading can lead to an Excessive soot loading can lead to an unexpected thermal event. unexpected thermal event. Temps can exceed 1000C, resulting in Temps can exceed 1000C, resulting in localized melting localized melting Severe thermal up-shock induces Severe thermal up-shock induces structural failure. structural failure.

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Active Regeneration Strategies

Direct Oxidation: C We are currently evaluating several + O2 = CO2
active designs to provide the best customer solution.

Active Regeneration Active Regeneration (550-650C) (550-650C)

Auxiliary Auxiliary Combustion Combustion Systems Systems

In-Exhaust In-Exhaust Injection Injection (DOC+CSF) (DOC+CSF)

ElectricallyElectricallyHeated Heated Systems Systems

Goal: Goal: No NO2 generation as in many passive systems No NO2 generation as in many passive systems Regen on demand (operator transparent) Regen on demand (operator transparent) Eliminate unexpected thermal events Eliminate unexpected thermal events Flexible to various application requirements Flexible to various application requirements

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NOx Aftertreatment Technologies

NOx Reduction

NOx Adsorber
NO+O2 NO2 Pt Base metal Catalyst Support NO3CO2, H2O, N2 Pt Base metal Catalyst Support HC, CO, H2 NOx nitrate

Urea SCR

DeNOx Catalyst

Lean Operation (NOx Trapping)

Rich Transient (Reduce Stored NOx)

Sulfur-tolerance? Sulfur-tolerance? Cost? Cost?

Urea Infrastructure? Urea Infrastructure? Regulator Acceptance? Regulator Acceptance? Operator Acceptance? Operator Acceptance?

Efficiency? Efficiency? Sulfur-tolerance? Sulfur-tolerance?

Retrofittable NOx A/T strategy will depend on Retrofittable NOx A/T strategy will depend on technical, commercial and regulatory issues. technical, commercial and regulatory issues.
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Urea-Selective Catalytic Reduction (SCR)

NOx + Oxygen
Exhaust Oxidation Catalyst

NO + NO2

--A Primer -A Primer

Clean Exhaust

NO + NO2 + Ammonia

= N2 + Water Vapor
SCR Catalyst Clean-up Catalyst

NOx or Ammonia Sensor Urea Dosing System

Urea Tank

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Urea-Free Technology Ready for Prime-Time?

Honda Develops NextGeneration Clean Diesel Delphi Develops Diesel Fuel Reformer System Eaton Develops UreaFree System for Trucks

DaimlerChryslers BlueTec System

While questions remain, too early to rule out significant advances in technology While questions remain, too early to rule out significant advances in technology making sustainable progress possible
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Summary and Retrofit Issues

Incentives and legislation driving down emissions in todays fleets. CAT is actively engaged in providing products, but only when they can meet our standards of excellence Engine Repowers and Emission Upgrade kits are an excellent path to reduce NOx emissions and increase machine value While successful, most Passive DPF Systems require considerable engineering effort - and expertise of the DPF technology, engine and machine application Active Systems permit use of DPFs in broader machine applications, but must do so without introducing new, unintended consequences Availability of ULSD expands aftertreatment toolbox for HC, PM and NOx NOx aftertreatment will likely come as on-highway technology evolves

CAT continues to assess latest technological advances to CAT continues to assess latest technological advances to cost-effectively reduce emissions in existing machines. cost-effectively reduce emissions in existing machines.
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Thank you for your attention.

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