IC 9462 INFORMATION CIRCULAR/2002

Review of Technology Available to the Underground Mining Industry for Control of Diesel Emissions

Department of Health and Human Services Centers for Disease Control and Prevention National Institute for Occupational Safety and Health

Information Circular 9462

Review of Technology Available to the Underground Mining Industry for Control of Diesel Emissions By George H. Schnakenberg, Jr., Ph.D., and Aleksandar D. Bugarski, Ph.D

U.S. DEPARTMENT OF HEALTH AND HUMAN SERVICES Public Health Service Centers for Disease Control and Prevention National Institute for Occupational Safety and Health Pittsburgh Research Laboratory Pittsburgh, PA August 2002

ORDERING INFORMATION Copies of National Institute for Occupational Safety and Health (NIOSH) documents and information about occupational safety and health are available from NIOSH–Publications Dissemination 4676 Columbia Parkway Cincinnati, OH 45226-1998 FAX: 513-533-8573 Telephone: 1-800-35-NIOSH (1-800-356-4674) E-mail: [email protected] Web site: www.cdc.gov/niosh

This document is the public domain and may be freely copied or reprinted. Disclaimer: Mention of any company or product does not constitute endorsement by NIOSH.

DHHS (NIOSH) Publication No. 2002-154

i

CONTENTS Page Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Executive summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.1 Health concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.2 Diesel exhaust composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.3 Occupational exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.4 Selected regulatory limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.5 Diesel particle concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.6 Document purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.7 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2 Control technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.2 Engine design and selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.2.1 Lower DPM emission engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.2.2 Engine derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.3 Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2.3.1 Commercial fuel and the effects of sulfur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.3.2 Alternative fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.3.3 Fuel additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.4 Aftertreatment technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.4.1 Diesel oxidation catalytic converters (DOCCs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.4.2 Diesel particulate filters (DPFs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2.4.3 DOCC and DPF combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 2.4.4 Disposable diesel exhaust filter (DDEF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3 Conclusions and recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Appendix A.—Low-PI MSHA-approved engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ILLUSTRATIONS 1. 2. 3. 4. 5. 6.

Monolithic catalyst substrates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Catalyst washcoat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example of a ceramic monolith filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas flow in a monolith, wall-flow filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knitted microfiber filter (deep-bed filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example of a particulate filter system using fiber media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 24 26 26 27 27

TABLES 1. 2. 3. 4. 5. 6. A-1.

Typical occupational DPM exposure levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Exposure limits for DPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Isuzu-Deutz engine comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Derated Isuzu engine comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Minimum temperature for continuous regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Performance of the available control technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 List of MSHA-approved engines (as of December 2001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

ii

ABBREVIATIONS USED IN THIS REPORT ACGIH CARB CDPF CFR CONCAWE CRT DDEF DECSE DEEP DETR DOC DOCC DPF DPM DST EC EGR ELPI EMA EPA FBC F-T FTP HC ISO LS MECA MOUDI MSHA NIOSH OC OEM OICA PAH PAS PDEAS PI PM PRL RCD SAE SMMT

American Conference of Governmental Industrial Hygienists California Air Resources Board catalyzed diesel particulate filter Code of Federal Regulations Oil Companies’ European Organisation for Environment, Health and Safety Continuously Regenerating Trap disposable diesel exhaust filter Diesel Emission Control–Sulfur Effects Program Diesel Emissions Evaluation Program Department of the Environment, Transport and the Regions (U.K.) diesel oxidation catalyst diesel oxidation catalytic converter diesel particulate filter diesel particulate matter Dry System Technology elemental carbon exhaust gas recirculation electrical low-pressure impactor Engine Manufacturers’ Association Environmental Protection Agency fuel-borne catalyst Fisher-Tropsch Federal test procedure hydrocarbon(s) International Organization for Standardization low-sulfur Manufacturers of Emission Controls Association Micro-orifice uniform-deposit impactor Mine Safety and Health Administration National Institute for Occupational Safety and Health organic carbon original equipment manufacturer Organisation Internationale des Constructeurs d’Automobiles polynuclear aromatic hydrocarbons photoelectric aerosol sensor personal diesel exhaust aerosol sampler (MSHA) particulate index particulate matter Pittsburgh Research Laboratory (of NIOSH) respirable combustible dust Society of Automotive Engineers Society of Motor Manufacturers and Traders Ltd. (U.K.)

iii

SMPS SOF SOL SSPD TC TLV® TPM ULSF VERT

scanning mobility particle sizer soluble organic fraction (of DPM) solid fraction (of DPM) Sasol slurry phase distillate total carbon threshold limit value (ACGIH) total particulate matter ultralow sulfur fuel (