Cleantech Forum 2006, Lahti

1
Cleantech Forum 2006, Lahti

• Technology for Cleaning Air in Asian Metropolitan
  Areas

Cleantech Forum 5.-6. June. 2006 Arno
Amberla Technology Director Finnkatalyt Ltd.
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OVERVIEW

• Air quality in Asian Metropolitans
• Emission facts
• Situation in each region
• Retrofit referencies in Asia region
• Hong Kong
• Korea
• Japan
• Technologies
• Choice of retrofit technology
• Technological comparison
• Conclusions

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EMISSIONS FACTS

• Beijing gt400.000 premature deaths caused by air
  pollution
• In Beijing PM air quality limit exceeded from
  January to mid-April 2006 already 56 times 50
  or days. Limit is 100µg/m3, in EU limit is 50
  µg/m3
• Increase of air pollution by 50 within last 10
  years
• Seoul Diesel emission cause 3 times more
  premature deaths than traffic accidents
• Hong Kong retrofits since 1995, but air quality
  has not been improved significantly, due to
  emission transportation from mainland China
• 350.000 premature deaths annually in EU (1300 in
  Finland), worldwide gt2 million premature deaths
  caused by air pollution
• Number of on-road and off-road engines is nearly
  the same, but in 2008 70 of PM emissions are
  from off-road engines

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SITUATION IN EACH REGION 1/2

• Japan
• Strict regulations and extensive retrofit
  programs
• Clean, low sulfur fuels
• Retrofit regulations applies to more than 450.000
  vehicles
• Korea
• Ministry of Environment is committed to reduce
  on-road emissions 2004-2014
• 270 MUSD / year in Seoul area (2006), other
  cities will follow within few year
• Target is Tokyo / Paris level (PM10 40µg/m3)
• Hong Kong
• Retrofits to various on-road vehicles, low sulfur
  fuels.
• 20MUSD / Year, increases
• China
• Beijing Olympic games 2008 as driving force
• Regulations in Beijing stricted than elsewhere,
  low quality fuels
• Financing is problem

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SITUATION IN EACH REGION 2/2

• Thailand
• Demo financed by World Bank and US EPA (not too
  succesful), only EPA verified products.
• Regulations for 2-wheelers
• India
• Converting diesel engines to gas engines
• Regulations for 2 wheelers.
• Plans for retrofit demo
• Finance problem
• Vietnam
• Gasoline retrofit plans, but no action
• Highest priority on fuel improvement
• Philippines
• Some plans, but no money / driving force or low
  sulfur fuel

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RETROFIT PROJECTS IN HONG KONG

• 1. trucks over 4 tons pre-Euro (31.000 old
  trucks) 2002-2004
• 8000 FINNKAT muffler integrated purifiers
  installed within 18 months
• PM reduction -35, metal substrates
• In-use tested vehicles 85 (by March 2006) , 100
  passed the test.
• Lower noise level compared to original silencer
• 41 complaints (0,5), mostly related to
  installation issues, Total number of complaints
  1200 5

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RETROFIT PROJECTS IN HONG KONG

• 2. Government owned Euro 1 2 vehicles (800) ,
  2003
• PM reduction -25 , metal substrates
• Limited number of special purpose vehicles (300)
• Lower noise level compared to original silencer,
  muffler integrated

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RETROFIT PROJECTS IN HONG KONG

• 3. Long-idling vehicles, 2005 (2600 vehicles)
• Sole supplier. Technical solution only possible
  with tailormade products, targeted for these
  vehicles.
• Long-idling vehicles emitting white smoke
  (unburned hydrocarbon)

• Special purpose vehicles, like concrete mixers
  and cranes requiring long idling duties.
• Metal substrates, two substrates, selective gas
  flow, stabilizing catalyst space velocity over
  whole operating range of vehicle.

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RETROFIT PROJECTS IN KOREA
RETROFIT PROJECTS KOREA

• 1. Kia Bongo Frontier, Pregio, 2004-
• PM reduction -30 or greater.
• Delivered more than 8000 units by May 2006.
• Muffler integrated, metal substrates
• 2. Verification in progress for heavy duty
  vehicles, PM -50

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RETROFIT PROJECTS JAPAN

• Japan LDV
• PM reduction gt 70 (Tokyo Retrofit Program, Tier
  2, category 3)
• Certificate received 2006
• Muffler integrated, metal substrate partial-DPF

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FACTS THAT INFLUENCE THE CHOICE OF RETROFIT
TECHNOLOGY

• Aftertreatment does not replace engine overhaul.
• Maintenance free aftertreatment does not mean
  that vehicle will be maintenance-free.
• Target emission reductions
• Vehicle value vs. Aftertreatment price /
  operating cost
• Fuel quality
• lt15ppm S, 2000ppm S gt3000 ppm
• Service culture
• when something fails and machine does not run any
  more
• Scheduled maintenance
• Maintenance requirements
• Low maintenance culture gt only DOC Diesel
  Oxidation Catalyst possible
• Aftertreatment sensitivity to maintenance
• Application
• Engine baseline emissions
• Duty cycle
• Existing engines / new engines

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AVAILABLE SOLUTIONS FOR DIFFERENT EMISSION
REQUIREMENTS

• DOC Diesel Oxidation Catalyst
• Basic retrofit product.
• PM reduction 20-40
• Maintenance free
• Suitable on most markets and applications
• DOC (add-on) original muffler or muffler
  integrated DOC
• pDPF Partial Diesel Particulate Filter
• Technically mix between DOC and DPF
• PM reduction 40-70
• Maintenance free
• Sulfur tolerant, misfueling ok long term use
  not
• Medium space requirement
• partial-DPF original muffler or muffler
  integrated pDPF

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AVAILABLE SOLUTIONS FOR DIFFERENT EMISSION
REQUIREMENTS

• DPF Diesel Particulate Filter
• Typically wall-flow filter, gt80 PM filtration
  rate
• Maintenance requirements
• Ash removal from filter, possibly regeneration
• Low baseline emissions
• Limits for lubrication oil consumption
• Fuel
• Low sulfur
• Possible fuel penalty
• Misfueling
• Monitoring of DPF
• Low back pressure -gt cracked element
• High back pressure -gt blocked element
• Regeneretion
• Passive or active
• Passive -gt temperature limits

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INSTALLATION ALTERNATIVES

• Lower noise level compared to old muffler
• Warranty covers also silencer
• Cost issue

Muffler integrated DOC/ pDPF

• Traditional installation method

Add-on DOC / pDPF
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pDPF TECHNOLOGY

• Different materials for open filters
• Structured metal foils
• Knitted wire filters
• Metal fleece
• Sintered metal fibres
• PM reductions 40-70 (total PM)
• pDPF is not real filter with over 95 PM
  filtration under all running conditions
• PM reduction is depending on duty cycle and
  engine out emissions.
• Cost increase from 50 to over 60 PM removal
  might be significant.

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PARTICULATE SIZE DISTRIBUTION

• Most harmful ultra fine particulates can also be
  reduced efficiently
• Particulate size distribution over Braunschweig
  cycle. Blue line with OEM option DOC and pink
  link with Finnkat pDPF.
• Test vehicle Volvo B10 city bus, Euro 2 with OEM
  DOC as option
• PM number decrease on lowest ELPI stages 30-45
• PM reduction percentage was not sensitive to test
  cycle.
• Source Retrofit exhaust clean-up systems.
  Performance and costs, Helsinki Metropolitan
  Area Council (YTV), 2006 (in Finnish).

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CONCLUSIONS

• Three steps for cleaner air
• Fuel improvement
• More stringent regulations and enforcement
• Fleet retrofitting
• All these actions and others are needed to
  improve air quality significantly in Asian
  Metropolies
• Retrofitting is efficient method to reduce
  particulate emissions
• Retrofitting is needed as useful lifetime of
  diesel engine is over 15 years (up to 40 years!)
• When choosing the aftertreatment technology, all
  factors to be regarded as part of a whole

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• THANK YOU FOR YOUR ATTENTION!