74-2? AWK Preliminary Report - UOP Catalyst and Dana EGR Applied to Medium Duty Vehicles March 1974 Test and Evaluation Branch Emission Control Technology Division Environmental Protection Agency ------- Background Medium duty vehicles (6,000 to 10,000 pound? GVW) have been shown to have many operational similarities to light duty vehicles. Additionally, state authorities have expressed interest in retrofit control for this vehicle class. Some preliminary investigation into the feasibility of retro- fitting this class of vehicles is described in ECTD report 74-10i September 1973. Based on these early encouraging results, a durability program was undertaken using the Dana Retronox EGR system and UOP oxidizing catalysts. The objective of this program was to accumulate 25/000 miles) with testing done at EPA every 4,000.miles. Dana and UO? did provide vehicles, retrofit hardware, and a test track for mileage accumulation. Device Description The Dana Retronox EGR system and UOP oxidizing catalysts were installed on a 1973 Ford F-250 pick-up truck with a 360 CID engine and automatic transmission, and, a \§T$ Chevrolet C-50 stake truck with a 350 CID engine and auto- matic transmission. A detailed operational description of both the Dana Retronox system and the UOP catalysts can be found in report 74-10. Test Program Tests were performed on the trucks in three configurations: stock or baseline only, and the EGR system plus catalyst configurations. Tests were conducted according to the 1975 FTP as described in the November 15, 1972, Federal Register. 4,000 miles were accumulated on the vehicles at the pana track. The vehicles were again tested after this mileage accumulation using the 1975 FTP. Results A summary of results from this testing is given in Table I. At low mileage, the reductions in the emissions levels were consistant with those reported in 74-10. However, ^fter 4,000 miles, the emission levels had risen to levels similar to those reported with the EGR system only at zero device miles. Analysis by UOP indicated that the catalysts had been poisoned by lead from the fuel. Analysis of the fuel showed that the "no-lead" fuel was near the upper limit in the EPA specifications for lead content (.05 gm/gal). UOP ------- reported that though their catalyst had high mechanical strength and durability, it was sensitive to even this amount of lead. UOP has supplied a less sensitive catalyst for future tests of their system. Conclusions Low mileage emissions were similar to those previously reported for an EGR/catalyst retrofit. The catalysts substantially failed at low mileage. ------- TABLE I Summary of Test Results Using Dana EGR Systems and UOP Catalysts Chevrolet C-50 Stake Body Truck Date 9-20 9-25 AVG. 9-27 9-28 AVG. HC (gm/mi) 7.14 5.25 6.20 3.77 3.48 3.62 CO (gm/mi) 115.95 77.43 96.69 65.92 72.70 69.31 NOx (gm/mi) 7.87 7.82 7.85 5.00 5.40 5.20 MPG 6.4 6.7 6.5 6.3 6.5 6.4 Remarks Baseline Baseline Baseline Dana EGR Dana EGR Dana EGR % Reduction from Baseline for Dana EGR System 41% 28% 34% 1.5% 10-31 11-1 AVG. .45 .29 .37 55.04 28.60 41.82 2.60 2.16 2.38 4.9 6.4 5.6 EGR + UOP cat. EGR + UOP cat. EGR + UOP cat. % Reduction from Baseline for Dana EGR & UOP Catalyst System 94% 56% 70% 12-4 2.06 48.6 % Reduction from Baseline after 4000 miles 8.32 14% 5.8 Full Systems + 4000 miles 67% 50% -6% 12% ------- TABLE II Summary of Test Results Using Dana.EGR Systems and UOP Catalysts Ford F-250 Pick-up Truck Date 9-21 9-24 AVG. 9-27 9-28 AVG. HC (gm/mi) 2.81 2.65 2.73 3.86 2.72 3.29 CO (gm/mi) 55.91 57.00 51.45 90.73 66.70 83.71 NOx (gm/mi) 5.73 6.08 5.90 4.88 3.60 4.24 MPG 9.3 9.3 9.3 6.7 9.1 7.9 .Remarks Baseline Baseline Baseline Dana EGR Dana EGR Dana EGR % Reduction from Baseline for Dana EGR System -20% -59% 28% 15% 10-11 10-12 AVG. .59 .69 .64 11.44 11.47 11.46 3.13 3.42 3.27 9.2 8.9 9.1 EGR + UOP--cat. EGR + UOP cat. EGR + UOP cat. % Reduction from Baseline for Dana EGR & UOP Catalyst System 76% 78% 44% 2% 11-1 11-2 AVG. 2.60 2.37 2.48 77.41 62.63 70.02 4.06 4.27 4.16 8.7 9.0 8.9 % Reduction from Baseline after 4000 miles 9% -27%* 30% *A minus sign indicates an increase rather than reduction, 4% Full system -»- 4000 miles ------- |