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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: [email protected]