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
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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
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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.
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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%
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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
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