Stationary Diesel Generator / Catalytic Converter Emission Control Evaluation

Power Systems Division Naval Surface Warfare Center, Crane, IN. Cinergy Ventures, Cincinnati, OH
Presenter: Brian Fillingim, NSWC Crane
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Emission Limitation
Federal Standards for NonRoad Emission Requirements
Tier I Phase - 1996 to 2000 Tier 2 / Tier 3 Phase - 2000 to 2008 Limited Annual Hours to Remain With In Air Polution Standards for Total Emissions

Method of Reduction

Selective Catalytic Reduction (SCR) Process Exhaust Catalyst with Anhydrous Ammonia (NH3) Injection Proof of Concept

SCR Process
SCR Reaction Chemistry 4NO + 4NH3 + O2 = 4N2 + 6H2O 6NO2 + 8NH3 + O2 = 7N2 + 12H2O High Temp and Excess NH3 4NH3 + 5O2 = 4NO + 6H2O 4NH3 + 3O2 = 2N2 + 6H2O
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Test Setup
Caterpillar Model 3306 Diesel Generator Set - 250 Kilowatt (kW) Catalytic Converter in place of Stock Muffler
Catalyst Design and Formulation by Catalytic Solutions Inc., Oxnard, CA Catalyst Housing and Integration by ArvinMeritor Inc, Columbus, IN

Manual Setting for NH3 Injection Flow Rate into Engine Exhaust
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Caterpillar Model 3306

Muffler vs Catalytic Converter

Test Procedure
Daily Six to Nine Hour Runs Four to Six Samples per Test Run of: O2, CO, NO, NO2, SO2 Temperature (Pre Converter, Post Converter, Catalyst and Ambient) Third Party Verification of Emission Measurements by GE Energy Serivces Inc

Results
556 Engine Hours 476 Hours with NH3 Injection Final 350 Hours at 90 percent Load (225 kW) with NH3 Injection Maximum NOx Reduction with 13 to 16 standard liters per minute (slpm) NH3 injection (0.8 NH3/NOx) at 90 percent Load GE Energy Services Inc. measured Comparable Data and No Indications of Secondary Emissions
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Conclusions

NH3 Injection and Catalyst Combination Reduced NOx by Approximately 90 percent Further Evaluation in Colder Ambient Temperatures Indicated Further Development and Evaluation of NH3 Controllers is Indicated

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For More Details Contact:

Raj Malyala - Catalytic Solutions Inc., Oxnard, CA (805) 486-4649 x1727 Rmalyala@catsolns.com Jim Lefeld - Cinergy, Cincinnati, OH 513-287-2435 jlefeld@cinergy.com Brian Fillingim - NSWC Crane, IN 812854-2361 brian.fillingim@navy.mil

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