EMISSIONS SOLUTIONS GUIDE
New technology targets Rail and Marine markets to meet EPA Tier 0, 1 & 2 Standards.
September 30, 2008
New Integrated Catalyst/Exhaust Manifold Helps Rail and
Commercial Marine Industry Meet EPA Tier 0, 1, and 2 Standards
New technology targets locomotive and marine diesel engines.
Tulsa, OK — A new integrated Diesel Oxidation Catalyst (DOC) exhaust manifold kit from MIRATECH Corporation, allows operators of diesel locomotives and marine vessels to meet — and exceed — current and future EPA Tier 0, 1, and 2 standards for exhaust emissions.
Dubbed “V-CAT™,” the new patented (U.S. Patent #7,412,824) catalyst/exhaust manifold system addresses a number of engineering challenges which have hampered previous emission control efforts, according to Jonathan Roberts, MIRATECH’s Sales Manager for Locomotive and Marine Markets.
“Traditionally, engineers have had to deal with three major challenges when designing a DOC for use in EMD locomotives and commercial marine vehicles: limited space behind the turbocharger; exhaust gas temps that are too low for effective DOC performance; and the risk of increasing the low exhaust back pressures EMD engines need to operate efficiently,” he says. “We’ve addressed those in V-CAT by, first, integrating the catalyst directly into the exhaust manifold, thereby keeping open access to all areas — including the EMD overhead area — needed for regular service and maintenance. At the same time, because gases are hotter upstream from the turbocharger, integrating V-CAT into the exhaust manifold effectively addresses the issue of low exhaust gas temps. And finally, our customers said they wanted a system that was simple in design; with V-CAT’s Plug and Play design, it could not be much simpler.”
After the install, Roberts says the manifold is wrapped in a thermal insulation blanket, both to further minimize heat loss in this area and to reduce the amount of heat entering the locomotive car body. To alleviate the risk of an increase in exhaust back pressures, MIRATECH’s V-CAT design provides a large catalyst surface area in a small space. Back pressures are kept at a minimal level while the exhaust flows freely through the system.
In order to substantiate V-CAT’s performance in a controlled environment, the manifold system has been applied to an in-use 2,850 kW diesel freight locomotive owned by Union Pacific Railroad Company. After installation, emissions were tested by Southwest Research Institute (SwRI®) per U.S. Government locomotive test methods (CFR40 Part 92) on 15 ppm sulfur diesel fuel. The V-CAT-equipped locomotive started operating in revenue service in October 2006, with SwRI monitoring real world performance via a wireless system that uploads data to the internet every six-minutes. The DOC system was replaced in April, 2008 with an improved design and is back in revenue service. Current V-CAT designs feature removable, square catalyst elements, each of which utilizes the VORTEX™ substrate and proprietary catalyst coatings.
“The end result of these tests has been a proven, dramatic reduction in a broad range of emissions from a simple system that fits within the existing footprint of the locomotive,” says Roberts. “SwRI’s tests showed particulate matter (PM) reductions of better than 50%; a 60% reduction of hydrocarbons; and as much as a 90% reduction in carbon monoxide — all without any sacrifice in fuel economy or NOx emissions. And, because the V-CAT manifold kit is designed to replace existing manifolds on EMD 710, 645 and 567 roots-blown or turbocharged engines, operators can easily rebuild these units to the new EPA-compliant standards.”
MIRATECH Corporation is a Tulsa, Oklahoma-based leader in providing environmentally-sound emission solutions for users of industrial engines throughout the Western Hemisphere. Current products offered include: NSCR and SCR catalyst systems; silencers; diesel particulate filters (DPF); control systems for fuel burner systems used in DPF regeneration, NOx control, and air/fuel ratio controllers; training programs; and technical field service.
MIRATECH Corporation, 420 S 145th East Ave, Tulsa, OK 74108; Phone Toll Free: 1.800.640.3141, Fax: 918.622.3928,
E-mail: info@MIRATECHcorp.com, Web: www.MIRATECHcorp.com
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