Jeremy Harris Simultaneous Reduction of PM, NOx, HC & CO From Large Stationary Diesel Engines March 21, 2006.

Jeremy Harris

Simultaneous Reduction of

PM, NOx, HC & CO

From Large Stationary Diesel Engines

March 21, 2006

OUTLINE

• Overview/Introduction

• Particulate, HC and CO Reduction - CRT® Particulate Filter System

• NOx Reduction

• SCR Catalyst System

• Urea Injection System

• Operating Data

• Conclusions

• Acknowledgements

SNOW SUMMIT MOUNTAIN RESORT

Courtesy of Snow Summit Mountain Resort

INTRODUCTION

• Snow Summit Mountain Resort is an isolated site• Two Cummins 2700DQLA generators powered by Cummins

QSK78-G6 diesel engines• South Coast Air Quality Management District (SCAQMD)

requires BACT for these engines• Johnson Matthey elected to use a combination of SCR and

patented CRT® (Continuously Regenerating Technology) particulate filter system

• This combined system is marketed by Johnson Matthey as an SCRT® system

• Systems commissioned late 2003

ENGINE BASELINE & SCAQMD EMISSION LIMITS

Emission Baseline Levels Regulation Levels

% Reduction Required

Nitrogen Oxides (NOx) 8.75 g/bhp-hr 0.60 g/bhp-hr 93.2%

Carbon Monoxide (CO) 0.72 g/bhp-hr 0.60 g/bhp-hr 16.7%

Hydrocarbon (HC) 0.20 g/bhp-hr 0.15 g/bhp-hr 25%

Particulate Matter (PM) 0.30 g/bhp-hr 0.045 g/bhp-hr 85%

The maximum ammonia slip is 10 ppmvd @ 15% O2

SCHEMATIC OF EMISSION CONTROL SYSTEM

CRT® Filter System

OUTLINE

• Overview/Introduction

• Particulate, HC and CO Reduction - CRT®

Particulate Filter System• NOx Reduction

• SCR Catalyst System

• Urea Injection System

• Operating Data

• Conclusions

• Acknowledgements

GENERAL DESCRIPTION OF CRT®

• Johnson Matthey’s CRT® system is a passive regenerating filter technology

• Upstream platinum based oxidation catalyst oxidizes CO and HC, as well as NO to NO2

• Downstream particulate filter (either cordierite or silicon carbide) traps particulate which is oxidized to CO2 by NO2

• CO + ½ O2 CO2

• HC + O2 CO2 + H2O

• NO + ½ O2 NO2

• C + 2NO2 CO2 + 2NO

CRT® BASICS

Particulate Filters Operation Requirements

• Ultra-low Sulfur Diesel <15PPM Sulfur

• NOx to PM Ratio > 15-20

• Low Ash Engine Lubricating Oils

• Minimum Regenerating Temperature > 465 F.

• Data Logger to Monitor Temperature/Backpressure Conditions

CRTdm Diagnostic Module and Remote Display Module

• Extended data logging capability

• Stores up to 24 hours of data

• Continuously logs exhaust temperature & backpressure

• High speed RS-232 communications

• Maintenance alerts

• Programmable alarm settings

ENGINES AND PARTICULATE FILTER UNITS

OUTLINE

• Overview/Introduction

• Particulate, HC and CO Reduction - CRT® Particulate Filter System

• NOx Reduction

• SCR Catalyst System

• Urea Injection System

• Operating Data

• Conclusions

• Acknowledgements

SCR CHEMISTRY

• Urea Decomposition: • (NH2)2CO + H2O 2NH3 + CO2

• Catalytic Reduction of NOx:

• NH3+ NOx + O2 N2+ H2O

SNOW SUMMIT SCR UNIT

OUTLINE

• Overview/Introduction

• Particulate, HC and CO Reduction - CRT® Particulate Filter System

• NOx Reduction• SCR Catalyst System

• Urea Injection System

• Operating Data

• Conclusions

• Acknowledgements

INJECTION SYSTEM PRINCIPLES

• Two fluid injection of air & urea solution ensures excellent

atomization & distribution

• Single control unit module contains all necessary hardware &

electronics for stand alone hands free automatic operation

• Built in redundancy for critical components

INJECTION SYSTEM CONTROL MODULE

INJECTION SYSTEM CONTROL MODULE

INJECTION SYSTEM CONTROL MODULE INTERNALS

INJECTION SYSTEM CONTROL MODULE ELECTRONICS

• PC based ladder logic controllers

• Multiple touch screens are very user friendly and enable all

operational parameters to be readily input by user.

• No need for external laptop for setup etc., all self contained

• Screens give visual reference to all parameters

• Modbus communications for remote monitoring

• CRTdm data logger fitted to monitor back pressure and

temperature

EXAMPLE OF INJECTION SYSTEM TOUCH SCREENS

INJECTION LANCE

• Two fluid pipe in pipe arrangement - urea in center pipe

• Air utilized for cooling and atomization

• Urea and air mix in the injection nozzle

• Small urea droplet size facilitates the SCR reaction

OUTLINE

• Overview/Introduction

• Particulate, HC and CO Reduction - CRT® Particulate Filter System

• NOx Reduction

• SCR Catalyst System

• Urea Injection System

• Operating Data• Conclusions

• Acknowledgements

SOURCE TEST DATA ENGINE #1

Pollutant SCAQMD

Emissions limit @15% O2

Actual Emissions

Target Reduction

Achieved Reduction

PM10 0.045 g/bhp-hr <0.005 g/bhp-hr 85% >90%

NOx 50 ppm 35 ppm 93.2% >94%

CO 89 ppm 24 ppm 17% >90%

VOC 0.15 g/bhp-hr 0.05 g/bhp-hr 25% >75%

NH3 10 ppm 0.01 ppm Surpassed

SOURCE TEST DATA ENGINE #2

Pollutant SCAQMD

Emissions limit @15% O2

Actual Emissions

Target Reduction

Achieved Reduction

PM10 0.045 g/bhp-hr <0.005 g/bhp-hr 85% >90%

NOx 50 ppm 44 ppm 93.2% >94%

CO 89 ppm 4 ppm 17% >90%

VOC 0.15 g/bhp-hr 0.02 g/bhp-hr 25% >75%

NH3 10 ppm 0.00 ppm Surpassed

OUTLINE

• Overview/Introduction

• Particulate, HC and CO Reduction - CRT® Particulate Filter System

• NOx Reduction

• SCR Catalyst System

• Urea Injection System

• Operating Data

• Conclusions• Acknowledgements

CONCLUSIONS

• First site to require multiple CRT® catalyst and filters housed in a single unit

• First site where PM control is used in conjunction with SCR on a stationary diesel engine application

• After almost 2 years of successful operation, the SCRT® System demonstrates that it is readily possible to simultaneously remove HC, CO, NOx and PM with minimal ammonia slip from a large stationary diesel engine exhaust

ACKNOWLEDGEMENTS

The authors would like to thank the following for permission topublish this work:

• Snow Summit Mountain Resort

• Cummins Cal Pacific

• Johnson Matthey, Stationary Source Emission Control

For More Information Contact:Jeremy Harris 610-971-3110 [email protected]