Alternative Control Techniques Document: Stationary Diesel Engines FINAL REPORT EPA Contract No. EP-D-07-019 Work Assignment No. 2-07 EC/R Project No. MME-207 Prepared For: Energy Strategies Group U.S. Environmental Protection Agency (EPA) Office of Air Quality Planning and Standards Sector Policies and Programs Division Research Triangle Park, NC 27711 Prepared By: Bradley Nelson EC/R Incorporated 501 Eastowne Drive, Suite 250 Chapel Hill, North Carolina 27514 March 5, 2010 This page is intentionally left blank. Table of Contents 1.0 INTRODUCTION AND PURPOSE ..................................................................................... 1 2.0 DESCRIPTION OF STATIONARY DIESEL ENGINES .................................................. 3 2.1 OPERATING DESIGN CONSIDERATIONS ................................................................................ 3 2.2 OPERATING CYCLES ............................................................................................................ 4 2.2.1 Two-Stroke Cycle ........................................................................................................ 5 2.2.2 Four-Stroke Cycle ....................................................................................................... 7 2.3 CHARGING METHODS .......................................................................................................... 7 2.3.1 Natural Aspiration ...................................................................................................... 7 2.3.2 Blower-Scavenging ..................................................................................................... 9 2.3.3 Turbocharging/Supercharging ................................................................................... 9 2.4 ENGINE SIZES..................................................................................................................... 10 2.5 INDUSTRY APPLICATIONS .................................................................................................. 10 2.5.1 Stationary Diesel Engine Population ........................................................................ 11 2.5.2 Stationary Diesel Engine Applications ..................................................................... 13 2.6 REFERENCES FOR CHAPTER 2 ......................................................................................... 14 3.0 CHARACTERIZATION OF DIESEL EXHAUST EMISSIONS ................................... 17 3.1 FORMATION OF DIESEL EXHAUST EMISSIONS .................................................................... 17 3.1.1 Formation of Nitrogen Oxides .................................................................................. 17 3.1.1.1 Formation of Thermal NOX ............................................................................ 18 3.1.1.2 Formation of Fuel NOX ................................................................................... 18 3.1.2 Other Products of Incomplete Combustion............................................................... 19 3.1.2.1 Formation of PM ............................................................................................. 19 3.1.2.2 Formation of THC........................................................................................... 20 3.1.2.3 Formation of CO ............................................................................................. 21 3.2 CRITERIA POLLUTANT EMISSION FACTORS ........................................................................ 22 3.3 REFERENCES FOR CHAPTER 3 ......................................................................................... 28 4.0 DIESEL ENGINE CONTROL TECHNIQUES ................................................................ 31 4.1 DIESEL PARTICULATE FILTER/CATALYZED DIESEL PARTICULATE FILTER ........................ 32 4.1.1 Process Description .................................................................................................. 32 4.1.2 Potential Pollutant Reductions ................................................................................. 34 4.1.3 Potential Problems/Issues with DPF/CDPF ............................................................ 34 4.2 SELECTIVE CATALYTIC REDUCTION .................................................................................. 35 4.2.1 Process Description .................................................................................................. 36 4.2.2 Potential Pollutant Reductions ................................................................................. 38 4.2.3 Potential Problems/Issues with SCR ......................................................................... 38 4.3 DIESEL OXIDATION CATALYST .......................................................................................... 40 4.3.1 DOC Process Description......................................................................................... 40 4.3.2 Potential Pollutant Reductions ................................................................................. 41 4.3.3 Potential Issues/Problems with DOCs ...................................................................... 41 4.4 FLOW-THROUGH FILTER .................................................................................................... 41 4.4.1 FTF Process Description .......................................................................................... 42 i 4.4.2 Potential Pollutant Reductions for FTF ................................................................... 43 4.4.3 Potential Issues/Problems with FTF ......................................................................... 43 4.5 EXHAUST GAS RECIRCULATION ......................................................................................... 43 4.5.1 EGR Process Description ......................................................................................... 44 4.5.2 Potential Pollutant Reductions ................................................................................. 44 4.5.3 Potential Issues/Problems with EGR ........................................................................ 44 4.6 OPEN AND CLOSED CRANKCASE VENTILATION SYSTEM ................................................... 45 4.6.1 Open and Closed Crankcase Ventilation System Process Description .................... 46 4.6.2 Potential Pollutant Reductions ................................................................................. 46 4.6.3 Potential Issues/Problems with OCV/CCV ............................................................... 46 4.7 ULTRA LOW SULFUR DIESEL (ULSD) FUEL ...................................................................... 47 4.7.1 Potential Pollutant Reductions ................................................................................. 47 4.7.2 Potential Issues/Problems with ULSD ...................................................................... 47 4.8 EMERGING CONTROL TECHNOLOGIES ................................................................................ 48 4.8.1 Lean NOX Catalysts .................................................................................................. 48 4.8.2 NOX Adsorbers .......................................................................................................... 48 4.9 SELECTION OF STATIONARY DIESEL CONTROL TECHNIQUES ............................................. 50 4.10 REFERENCES FOR CHAPTER 4 ......................................................................................... 52 5.0 CONTROL COSTS ............................................................................................................. 55 5.1 COST EVALUATION METHODOLOGY .................................................................................. 55 5.2 CONTROL COSTS FOR DIESEL ENGINES .............................................................................. 56 5.2.1 Control Costs for SCR .............................................................................................. 56 5.2.1.1 Capital Costs ........................................................................................................ 56 5.2.1.2 Annual Costs ................................................................................................... 57 5.2.1.3 SCR Cost per Ton of NOX Removed ................................................................... 57 5.2.2 Control Costs for CDPF ........................................................................................... 59 5.2.2.1 Capital Costs ................................................................................................... 59 5.2.2.2 Annual Costs ................................................................................................... 59 5.2.2.3 CDPF Cost per Ton of PM and THC Removed ............................................. 59 5.2.3 Control Costs for DOC ............................................................................................. 60 5.2.3.1 Capital Costs ................................................................................................... 60 5.2.3.2 Annual Costs ................................................................................................... 64 5.2.3.3 DOC Cost per Ton of PM, CO, and THC Removed ...................................... 64 5.2.4 Control Costs for FTF .............................................................................................. 64 5.2.4.1 Capital Costs ................................................................................................... 64 5.2.4.2