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FERRARA 14.November 2006

Best Available Technology to Eliminate Ultrafine Particle

Emissions of Combustion EnginesExperience with 12’000 Retrofits

Construction Machines,Locomotives and Busesin Switzerland

A.Mayer / TTM

TTM.A.Mayerfor Emission Reduction of IC-Engines

TTM is responsible in Switzerland for - VERT Verification or Particle Filter Systems- Quality Control of Filter Retrofits

- Research and Development in International Projects - Implementation of Emission Reduction Measures (Germany, Austria, Poland, Italy, California, Canada, Ecuador, Chile, Korea, Japan ..),

- Organization of Seminars and Conferences

All Combustion Engines are High Emitters ofSolid Particles

Size range20-300 nm“

(Quelle: M.Kasper/ ME )

Soot Particles deposited on a 5 Micron Filter Fiber

• Measurementof total Particle MassPM onlyas required byEU-regulation

- size ?- number ?- substance ?

Measurementof Number, Size and Masssimple,sensitive accurate and very repeatable

acc. to EU-PMP

Diesel Sootinvisibleno tasteno smellinert

dangerous

Source: METZ, BMW

Aerosol Number-Size distributionsin Urban (Zürich) and Rural Areas

10 100 1000 1000010-2

10-1

100

101

102

103

104

105

106

Urban Area: (Downtown Zürich)

Day (SMPS) Night (SMPS) Day (OPC) Night (OPC)

dN/d

(logD

) (c

m-3)

Dp (nm)10 100 1000 10000

Rural Region:(Zürcher Oberland)

Day (SMPS) Night (SMPS) Day (OPC) Night (OPC)

Bukowiecki et al., Atmospheric Environment, 2002

6 November 2001

Depositionof particles in the airwaysdepends mainlyon particle sizenot on mass

(Source: Hinds, 1982Aerosoltechnology )

Mortalitydue to Ultrafines

6-Cities-StudyUSA 1978-9315‘000 casesCorrelation onlywith ultrafineParticles

(Quelle: DockeryNEJM 1993 )

EURO 4 and 5 compared to EURO 3

[g/kWh] CO HC NOx PM EC PZ NO2

EURO 3 w/o DPFLimits

< 2.12.1

< 0.70.7

< 5.05.0

< 0.10.1

? ? ?

EURO 4 - PM-KatLimits

0.1 1.5

0.010.5

3.023.5

0.0140.02

? ? ?

EURO 5 – SCRLimits

0.271.5

0.010.5

1.562.0

0.0130.02

? ? ?

Problem 1: Mixed Substances in PM (EC+OC+SOx+H2O+..?)and NOx (NO+NO2)

Problem 2: Strong Artefacts with NO2 and PM-Measurement

Let‘s have a close look to new Diesel Engines

EURO 4: EGR with PM-Kat(MAN, SCANIA)

PM-Kat® (MAN)

- Aerodynamisches Abscheidesystem- Abscheidegrad 30 - 50% - Keine VERT-Zertifizierung

Particle-Emission with PM-Kat at idle

EURO 5: Selective Catalytic Reduction SCR(IVECO, MB)

Oxi- /Sperrkat

SCR-Katalysator

Reduktionsmittel

Regelung

EURO 5 with SCR compared to EURO 3 with/without Filter at 50 % Load

Technology is availableWall flow ceramic substrate - 10 micron pore sizeCORNING 1982

First DPF- Application by Daimler-Benz in a passenger car 1985 in California

Cordierite and Silicon-Carbide typical ceramic materials for extruded filters

.. but also sintered metal substrates, ceramic and metal fibers and paper materials from organic fibers

BAT is required by LawExhaust Gas downstream Filter is cleaner than Ambient Air !

1.00E+03

1.00E+04

1.00E+05

1.00E+06

1.00E+07

10 100 1000mobility diameter [nm]

num

ber c

once

ntra

tion

dN/d

logD

p[cm

-3] without trap

clean room ambient air1downstream of the trap

Soot-Reaction with O2 und NO2

0

5E-12

1E-11

1.5E-11

2E-11

2.5E-11

0 100 200 300 400 500 600 700Temperatur (°C)

CO

2-In

tens

ität

NO2 O2O2(kat. Reaktion)

0

5E-12

1E-11

1.5E-11

2E-11

2.5E-11

00

5E-12

1E-11

1.5E-11

2E-11

2.5E-11

0 100 200 300 400 500 600 700Temperatur (°C)

CO

2-In

tens

ität

NO2 O2O2(kat. Reaktion)

CRT : Continuous Regeneration by NO2

CRT-Filter-System with DOC

Full Flow Diesel Burner

PFS for large engines in locomotives and ships

Restsauerstoff im Abgas: > 8%

Heizleistungen: 30 – 400 kWDruckluft > 5 bar: 20 Nm3/h

Dieselkraftstoff: 3 – 40 l/h

Stromversorgung: 24 VDC

FS26 spezial

Standard Filtermodul

Disposable Filters

Swiss Particle Filter Regulations

• 1990 (EJPD): Retrofit permitted under conditions:- no additional Noise Emission- no Formation of secondary toxic Air Contaminants

• 1993: VERT-project started• 1994: Diesel-Emissions classified carcinogenic--• 1998: Limit for stationary engines < 5 mg/m3 EC BACT• 1998: VERT PFS specification and verification protocol• 2000: VERT-PFS regulation in tunneling• 2002: VERT-PFS regulation for construction • 2003: only VERT approved PFS for onroad vehicles

Pioneers Retrofit Offroad - at the Working Placenot OE-Cars, Trucks and Buses

Improvement of Air Quality in Swiss Tunneling by Filter Introduction

PFS on large and very small Construction Machines

Installation on an Excavator by OEM

Retrofit-Installation on an Excavator12000 Construction Machines; > 10‘000 operation hours

Truck-Installationin place of Muffler

ca 300 trucks

Many Installations in City Buses

DPF on Locomotives and Ships > 300 locomotives 300-3000 kW ,

Locomotives > 15‘000 op.hrs. 1 ship > 30‘000 op. hrs.

19

Peugeot with FAP – 1.5 Mio ; total 3 MioLDV successfully in operation !

Filter-Failure:due to high temperature because of uncontrolled regeneration

Quelle: Johnson Matthey

Typical Failure with segmented SiCwithout Filtration Degradation (Quelle IBIDEN)

Quality Control Tools

• VERT-Type Approval Test:4-Stage Test incl. 2000 hrs endurance .

• Engine Maintenance and Periodic Emission Controlat least once per Year .

VERT-Specifications

New 2000 Bh• Filtration Efficiency

Number based > 95% > 95%Size Range 20 – 300 nm

• Filtration Efficiency > 90% > 90%„EC-Mass“ based

• Opacity at free accelleration < 0.12 m-1 < 0.12 m-1

• No increase of limited Emissions CO, HC, NOx und PM

• No relevant Increase of Secondary Emissions• Loss of approval : K > 0.24 m-1

VERT- Testfor

Type Approval

What is measured during VERT-Tests

• Particle Properties:size, number, surface, EC/OC, PM-Mass

• limited gases: NOx, HC, CO and O2 • NO2 hot• PAH, Nitro-PAH, VOC, Aldehydes• Dioxines, Furanes• Filter: backpressure, temperature up/down• engine parameters: fuel consumption etc.• noise

Measurements during steady state and transient conditions

Quality of „VERT“- approved Filter SystemsStand 8/2003

Aktive Regeneration Passive Regeneration Filtrations-Effizienz

DEUTZ Vollstrombrenner > 98%, alte Daten

ECS-UNIKAT Elektr. Beheizung Kat. Beschichtung 99.99

HJS CRT, Treibstoffadditive 99.40

JOHNSON MATTHEY Elektr. Beheizung CRT, Treibstoffadditive 99.50

HUSS Elektr. Beheizung, Stillstandsbrenner

99.99

DCL Elektr. Beheizung, Ansaugdrosselung

Treibstoffadditive, kat. Beschichtung

99.99

ARVINMERITOR Vollstrombrenner 99.84

ENGELHARD Kat. Beschichtung 99.60

HUG Vollstrombrenner Kat. Beschichtung 98.60

INTECO Treibstoffadditive 99.24EHC Wechselfilter 96.70

TSH Elektr. Beheizung Kat. Beschichtung 98.90

AKPF-Q-Labelfor PFS with outstanding Filtration Quality

1

1112

0203 04 05

06

07

Controls

• Yearly Failure Statistics by Retrofitters- Reporting to the EPA: installations, faillures

techn.modification if failures exceed 3 %• Emission Test every 2 Years - documented

- Opacity measurement - Check of all emission-relating elements

• Controls by local Authorities - Fines up to 10 % of vehicle value

Split Responsibility

• Authority- Filtration & Emissions-Approval:VFT1, VSET - Reliablility-Approval: 2000 hrs. VFT2/3

• Retrofitter - Installation, Safety, Functionality, OBD - 2 Years Warranty

• User - Maintenance

Reliability of PFS in Switzerland

• 1990: 230 Filters installed in Buses Failure rate probably 10 % pa

• 2000: 2400 PFS in Operation, > 6% Failures per yearFailure rate > 6 %Measures: 2000 h endurance, electronic OBC

• 2006: > 12’000 PFS in OperationFailures 2-3 % per year

> 1’000‘000 km with Trucks and Buses> 10‘000 op.hrs with Construction Machines> 30‘000 op-hrs on a Ferry Boat

Failure Target: < 1% pa

Cost is still high but coming downand Benefit / Cost - Ratio is > 5

11 October 2004

Worldwide Retrofit Projects

• Schweden: Environmental Zones ab 1996: heute 8000 Filter• Schweiz: Baurichtlinie 2000: heute > 12’000 Baumaschinen• Kalifornien: 1’200’000 Diesel mit Filter “risk reduction 2000”• Tokyo: > 500’000 und andere japanische Städte folgen• Seoul: > 200’000 ab 2008• New York: Baumaschinen und Kommunalfahrzeuge 2006• Holland und Dänemark: LEZ in allen grösseren Städten 2007• Berlin und München: LEZ ab 2007 mit Filterpflicht 2007• London: 8’000 Busse, BM ab 2008, LEZ ab 2007 • EU - Direktive für Filternachrüstung in Vorbereitung - 2008• Santiago/Chile rüstet 2000 Busse nach – andere Grossstädte in

Lateinamerika folgen• Schweiz plant Filter für LKW, PKW und Traktoren

Summary and Conclusions

• PFS reduce particle emission by > 99%• Careful homologation and selection is needed• Filter onboard control is needed• PFS have long life – no filtration-deterioration • PFS are available for all applications • PFS-cost is acceptable • Ratio of Health Benefit to Cost is > 5

Further Information

• ETH-Konferenz “combustion generated nanoparticles” CD mit Proceedings www.nanoparticles.ethz.ch

• Minimierung der PartikelemissionenExpert-Verlag 2004; ISBN 3-8169-2430-1

• BUWAL-Homepage: www.umwelt-schweiz.ch/buwal• AKPF-Homepage: www.akpf.org• DieselNet: www.dieselnet.com• Nanopartikelmesstechnik: www.matter-engineering.com• Partikelfilteranwendung: ttm.a.mayer@bluewin.ch