SRI/USEPA-GHG-VR-33 August, 2005 Verification Report EnviroFuels Diesel Fuel Catalyzer Fuel Additive Prepared by: Greenhouse Gas Technology Center Southern Research Institute Under a Cooperative Agreement With U.S. Environmental Protection Agency ------- EPA REVIEW NOTICE This report has been peer and administratively reviewed by the U.S. Environmental Protection Agency, and approved for publication. Mention of trade names or commercial products does not constitute endorsement or recommendation for use. ------- SRI/USEPA-GHG-VR-3 3 August, 2005 Greenhouse Gas Technology Center A U.S. EPA Sponsored Environmental Technology Verification ( ETr ) Organization Verification Report EnviroFuels Diesel Fuel Catalyzer Fuel Additive Prepared By: Greenhouse Gas Technology Center Southern Research Institute PO Box 13825 Research Triangle Park, NC 27709 USA Telephone: 919/806-3456 Envirofuels, L.P. NY DEC Bureau of Mobile Sources and Technology Development Southern Research Institute Quality Assurance U.S. EPA Office of Research and Development ^ indicates comments are integrated ------- (this page intentionally left blank) ------- TABLE OF CONTENTS Page 1.0 INTRODUCTION 1-1 1.1. BACKGROUND 1-1 1.2. DIESEL FUEL CATALYZER 1-2 1.3. TEST FACILITIES 1-2 1.4. PERFORMANCE VERIFICATION OVERVIEW 1-5 1.5. MEASUREMENT EQUIPMENT 1-5 -6 -7 -7 1.5.1. AR10 Main Generator Current and Voltage 1.5.2. Fuel Supply and Return Flow Meters and Fuel Temperature Sensors. 1.5.3. DOES2 and Instrumental Analyzers 1.5.4. LPSS Particulate Sampling System 1.5.5. Opacity Meter and Auxiliary Measurement Equipment -9 2.0 VERIFICATION RESULTS 2-1 2.1. ENGINE BHP 2-3 2.2. BRAKE-SPECIFIC FUEL CONSUMPTION 2-6 2.2.1. Exhaust Gas Volumetric Flow Rate 2-9 2.2.2. Fuel Meter Results 2-10 2.3. LOCOMOTIVE EMISSIONS 2-12 2.4. TPM RESULTS AND ADDITIONAL PARTICULATE ANALYSES 2-15 2.4.1. Particulate Analyses Results 2-16 3.0 DATA QUALITY 3-1 3.1. RECONCILIATION OF DQOS AND DQIS 3-2 3.2. AUDITS 3-5 4.0 TECHNICAL AND PERFORMANCE DATA SUPPLIED BY ENVIROFUELS, LP 4-1 4.1. TPM DETERMINATIONS 4-1 4.2. BASELINE FUEL CONSUMPTION MEASUREMENT FOR NOTCHES 7 AND 8 4-2 5.0 REFERENCES 5-1 APPENDICES Page APPENDIX A Post-Test LPSS Correlations A-l APPENDIX B Test Run Results B-l LIST OF FIGURES Page Figure -1 EMD Model GP40-3 Locomotive and Test Equipment 1-3 Figure -2 Envirofuels Tote, Dosing Pump, and Skid 1-4 Figure -3 Measurement Equipment Locations 1-6 Figure -4 Supply Flowmeter 1-7 Figure -5 Return Flowmeter 1-7 Figure -6 DOES2 Sampling and Dilution Apparatus 1-8 Figure -7 Locomotive Particulate Sampling System 1-9 Figure 2-1 AR 10 Generator Performance 2-5 Figure 2-2 Baseline Run-specific BSFC 2-7 ------- Figure 2-3 Treated Fuel Run-specific BSFC 2-7 Figure 2-4 Fuel Consumption verses Brake Horsepower 2-8 Figure 2-5 Method 2 Traverse Locations 2-9 Figure 2-6 Exhaust Gas Volumetric Flow Rate as a Function of >/AP at Point 3c 2-10 Figure 2-7 Effects of Fuel Meter Calibration Error 2-11 Figure 2-8 Mean 3-second Peak Opacity 2-13 Figure 2-9 Mean 30-second Peak Opacity 2-14 Figure 2-10 Mean Steady-state Opacity 2-14 Figure 2-11 Baseline Particulate Filter, SEM Image at 300x 2-17 Figure 2-12 Treated Fuel Particulate Filter, SEM Image at 300x 2-17 Figure 2-13 Baseline XPS Results 2-18 Figure 2-14 Treated Fuel XPS Results 2-18 Figure 4-1 Baseline Percent Change from Previous Notch 4-2 Figure A-l LPSS Dilution Tunnel Flow verses Reported TPM Emissions A-2 Figure A-2 DOES2 Dilution Tunnel Flow verses Reported CO2 Emissions A-3 Figure A-3 LPSS Correlation Data A-6 LIST OF TABLES Page Table 2-1 BSFC and Brake-specific Emission Rate Change, Per Notch Values 2-1 Table 2-2 BSFC and Brake-specific Emission Rate Changes as a Percentage of Baseline 2-2 Table 2-3 Duty Cycle-weighted BSFC and Emission Rate Change 2-2 Table 2-4 CO Emission Rate Change at Idle 2-2 Table 2-5 Compensated Brake Horsepower at Engine 2-3 Table 2-6 Mean Exhaust Gas and Engine Intake Air Temperature 2-5 Table 2-7 Mean Fuel Consumption and Engine RPM Per Notch Values 2-6 Table 2-8 Mean BSFC Per Notch Values, gal/bhp-h 2-6 Table 2-9 Mean Duty Cycle-weighted BSFC, gal/bhp-h 2-8 Table 2-10 Mean Baseline Emissions, grams per minute (g/min) 2-12 Table 2-11 Mean Treated Fuel Emissions, g/min 2-12 Table 2-12 Mean Baseline Brake-specific Emissions, g/bhp-h 2-12 Table 2-13 Mean Treated Fuel Brake-specific Emissions, g/bhp-h 2-12 Table 2-14 Mean Line-haul Duty Cycle-weighted Emissions, g/bhp-h 2-13 Table 2-15. Mean Switch Duty Cycle-weighted Emissions, g/bhp-h 2-13 Table 2-16 Mean 3-second Peak Opacity 2-14 Table 2-17 Mean 30-second Peak Opacity 2-15 Table 2-18 Mean Steady-state Opacity 2-15 Table 2-19 Gravimetric Analysis and Sampling Data 2-16 Table 2-20 XPS Elemental Concentrations, Corrected for Si and F 2-19 Table 3-1 Instrument Accuracy 3-2 Table 3-2 Calibrations 3-3 Table 3-3 QA/QC Check Results 3-4 Table 3-4 Performance Evaluation Audit Results 3-5 Table 3-5 Mean CO2 Concentrations 3-6 ------- DISTRIBUTION LIST U.S. EPA David Kirchgessner Robert Wright Southern Research Institute Stephen Piccot Tim Hansen Robert G. Richards Richard Adamson EnviroFuels Mark Lay Genesee & Wyoming, St. Lawrence and Atlantic Railroad Mario Brault Jeff Eichel David Powell Environment Canada ETC Fred Hendren Greg Rideout Acknowledgments This verification could not have happened without the extensive management, financial, and technical support provided by Genesee & Wyoming, Inc. and the St. Lawrence and Atlantic Railroad. Their most important contribution to the effort was the dedication of a locomotive to be tested. This required a one- week removal of the locomotive from revenue service for each of the baseline and treated fuel test periods. The tests also required maintenance mechanic time and coordination with the railroad's busy schedule. The GHG Center would especially like to thank Carl Belke of Genesee & Wyoming, George King II, Jeff Eichel, and Craig Rush of St. Lawrence and Atlantic Railroad for their generous help. in ------- List of Acronyms and Abbreviations A amperes blip brake horsepower BSFC brake-specific fuel consumption CO Carbon monoxide CO2 Carbon dioxide DQO data quality objective DQI data quality indicator ETC Environment Canada Environmental Technology Centre ETV Environmental Technology Verification FTP federal test procedure g/bhp-h grams per brake horsepower hour g/h grams per hour g/min grams per minute gal/bhp-h gallons per brake horsepower hour GHG Center Southern Research Institute Greenhouse Gas Technology Center gph gallons per hour kW kilowatt mA milliamperes NOX nitrogen oxides ppmv parts per million by volume QA/QC quality assurance / quality control QMP Quality Management Plan sn-i sample standard deviation SLA St. Lawrence and Atlantic Railroad SO2 sulfur dioxide SO4 sulfates THC total unburned hydrocarbons TPM total particulate matter V volts A delta (differential or change in a value) IV ------- 1.0 INTRODUCTION 1.1. BACKGROUND The U.S. Environmental Protection Agency's Office of Research and Development operates the Environmental Technology Verification (ETV) program to facilitate the deployment of innovative technologies. The program's goal is to further environmental protection by accelerating the acceptance and use of these technologies. Primary ETV activities are independent performance verification and information dissemination. Congress established ETV in response to the belief that many viable environmental technologies exist that are not being used for the lack of credible third-party performance data. With performance data developed under this program, technology buyers, financiers, and permitters will be better equipped to make informed decisions regarding new technology purchases and use. The Greenhouse Gas Technology Center (GHG Center) is one of several ETV organizations. EPA's ETV partner, Southern Research Institute, manages the GHG Center. The GHG Center conducts independent verification of promising GHG mitigation and monitoring technologies. It develops Verification Test and Quality Assurance Plans (test plans), conducts field tests, collects and interprets field and other data, obtains independent peer-review input, reports findings, and publicizes verifications through numerous outreach efforts. The GHG Center conducts verifications according to the externally reviewed test plans and recognized quality assurance / quality control (QA/QC) protocols. Volunteer stakeholder groups guide the GHG Center's ETV activities. These stakeholders advise on appropriate technologies for testing, help disseminate results, and review test plans and reports. National and international environmental policy, technology, and regulatory experts participate in the GHG Center's Executive Stakeholder Group. The group includes industry trade organizations, environmental technology finance groups, governmental organizations, and other interested parties. Industry-specific stakeholders provide testing strategy guidance within their expertise and peer-review key documents prepared by the GHG Center. GHG Center stakeholders are particularly interested in transportation technologies with the potential to increase fuel economy and reduce GHG and criteria pollutant emissions. The Department of Energy reports that transportation carbon dioxide (CO2) emissions were 32 percent of the total from all sectors during 2002 [1]. Railroad locomotives represent a significant fraction of the total. In 2002, railroads used approximately 7.5 percent of all diesel fuel in the transportation sector. In that year, railroad diesel fuel consumption was about 9.49 x 107 barrels crude oil equivalent, or 3.98 x 109 gallons [2]. Even incremental fuel efficiency or emission rate improvements would have a significant beneficial impact on nationwide air quality and railroad economics. Each 1 percent diesel fuel consumption reduction would reduce CO2 emissions and fuel costs approximately 1 percent. EnviroFuels, L.P. manufactures a diesel fuel additive and markets it to heavy-duty vehicle, off-road diesel engine, and railroad locomotive operators as the Diesel Fuel Catalyzer (catalyzer). The catalyzer's various embodiments are either patented or subject to patents pending. The catalyzer is a suitable verification candidate considering its potential environmental benefits and ETV stakeholder interest. Based on in-house testing on heavy-duty diesel vehicles, EnviroFuels claims that proper use of the catalyzer can reduce: • fuel consumption (and corresponding CO2 emissions) by 5 percent • nitrogen oxide (NOX) emissions by 12 to 18 percent • unburned total hydrocarbon (THC) emissions up to 30 percent. 1-1 ------- The GHG Center verified fuel consumption and pollutant emission changes attributable to the catalyzer during baseline and treated-fuel tests of an EMD GP-40-3 line-haul locomotive. Baseline testing occurred during late August, 2004 at the St. Lawrence and Atlantic Railroad (SLA) switchyard in Auburn, ME while the locomotive was operating on a controlled lot of normal diesel fuel. Railroad maintenance personnel then treated the locomotive's fuel with the EnviroFuels catalyzer according to the manufacturer's instructions for a nine week break-in period. The test team returned and tested the locomotive's performance while operating on the treated fuel in late October, 2004. The Test and Quality Assurance Plan—EnviroFuels Diesel Fuel Catalyzer Fuel Additive [3] (test plan) was the guiding document for the test campaign. It is available from the GHG Center Internet site at www.sri-rtp.com or the ETV Program site at www.epa.gov/etv. The test plan describes the verification's rationale, experimental design, testing procedures, data quality, and QA/QC goals. The vendor, peer- reviewers, testing contractors, the host facility, and the EPA Quality Assurance Team reviewed the test plan and the GHG Center revised it to address their comments prior to beginning the field work. The test plan meets the GHG Center's Quality Management Plan (QMP) requirements and also satisfies ETV QMP requirements. The remainder of Section 1.0 describes the EnviroFuels catalyzer technology, the test locomotive, and provides an overview of the performance verification test campaign. 1.2. DIESEL FUEL CATALYZER EnviroFuels literature states that the key to the catalyzer's performance is a compound that triggers chemical reactions which create inorganic polymer complexes of phosphorus and nitrogen on the surface of ferrous and non-ferrous metals. The formulators add the proprietary compound to refined mineral oil which, in turn, users administer to standard #2 diesel fuel. The complexes, according to EnviroFuels statements, smooth and passivate the metal surface, improve reflectivity (or emissivity), and reduce oxygen reactivity. EnviroFuels states that the reduced oxygen reactivity reduces NOX formation while the improved emissivity enhances combustion through reduced radiative losses from the flame front. This, combined with improved lubricity, reduces fuel consumption. EnviroFuels' research indicates that at least six to eight weeks of regular service are required from the initial fuel treatment for the performance improvements to be fully realized in locomotive service. During this break-in period, EnviroFuels recommends a dosing rate of 640:1 in most locomotive applications. After that, the fuel must be treated at the normal 1280:1 ratio on an ongoing basis to maintain the effects. 1.3. TEST FACILITIES The St. Lawrence and Atlantic Railroad, a division of Genesee and Wyoming, Inc., provided the test locomotive, resistive load bank, plant facilities, coordination with the test fuel supplier, and technical, mechanical, and managerial support. 1-2 ------- The locomotive was built in 1980 and remanufactured to Title 40 CFR 92 Tier 0 standards in 2003. Its powerplant is an EMD 645 E3 two-cycle diesel engine rated at 3000 brake horsepower (bhp). Figure 1-1 shows the locomotive, the emissions test duct and equipment enclosure, the resistive load bank, the yard's main fuel tank, and other site features. Opacity Monitor and Enclosure Figure 1-1. EMD Model GP-40-3 Locomotive and Test Equipment The locomotive serves as the lead unit in a "mother - daughter" pair. The daughter is unpowered and its primary function is to spread the locomotive's tractive effort over more driving wheels. Some pertinent information is as follows: Locomotive Horsepower Length, over couplers Width, over grab irons Height, to top of cooling fan guards Approximate dry weight... 3000 bhp 59' 2" 10' 3 1/8" 15' 4 7/16" 256,000 Ib Main generator Model. Companion alternator Model Auxiliary generator Voltage.. Rating.... ARID D14 74VDC 10 kW Engine Model 645E3 Cylinders 16 Bore x stroke 9 1/16" x 10" Nominal idle speed 315 RPM Nominal full speed 900 RPM Operating 2-cycle, turbocharged, Principle unit injector Family 3GETK0645MFA Air compressor Cylinders 3 Air compressor Capacity (900 RPM) 254ft3/min 1-3 ------- SLA maintenance personnel connected the main generator directly to the resistive load bank which provided the electrical load. The test contractor, Environment Canada's Emissions Technology Centre (ETC) installed the test duct onto the locomotive's exhaust duct and located the opacity monitor adjacent to the test duct. Heated umbilicals conveyed the exhaust gas samples from the test duct probes to the emissions test equipment enclosure at ground level. During all tests, SLA maintenance personnel connected the locomotive's air system to the shop air supply to prevent the air compressor from cycling unpredictably. All DC circuit breakers, except for the emergency shutdown and engine operating systems, were opened. This provided a constant, low-level load at the auxiliary generator. These provisions and the test team's direct measurements of the power supplied to the cooling fans (which were the only loads on the companion alternator) minimized the effects of changing parasitic loads on the test run results. EnviroFuels provided the fuel catalyzer in a tote placed on a skid which incorporated its own secondary containment. A positive-displacement dosing pump was part of the skid. SLA personnel enabled it following the baseline tests. The yard's main fuel tank pump power supply controlled the dosing pump, which injected the catalyzer at the manufacturer's specified rate into the main fuel hose and nozzle assembly. This allowed a controlled amount of additive to be mixed in the fuel hose as SLA personnel refueled the locomotive over the break-in period and during the treated fuel tests. Figure 1-2 illustrates the catalyzer tote, skid, and dosing pump. Figure 1-2. EnviroFuels Tote, Dosing Pump, and Skid EnviroFuels Fuel Catalyzer Dosing Pump in Secured Main Fuel Pump and Hose Reel Shed Skid with secondary containment 1-4 ------- 1.4. PERFORMANCE VERIFICATION OVERVIEW The EnviroFuels Diesel Fuel Catalyzer performance verification parameters are brake horsepower- specific fuel economy, pollutant, and GHG emission changes associated with catalyzer use in the test locomotive. Section 2.0 of this report provides detailed test results on a "per notch" basis and as a weighted average using line-haul and switch service weightings. Reported parameters are: • brake-specific fuel consumption rates, BSFQ, for baseline and treated fuel, and the change, ABSFCj, for each notch j, gallons per brake horsepower hour (gal/bhp-h) • line-haul and switch duty-cycle weighted brake-specific fuel consumption rates, BSFCoc, and the change, ABSFCDC, gal/bhp-h • brake-specific mass emission rates, E1J5 for baseline and treated fuel, and the change, AEjj, for each pollutant or GHG species i at each notch j, grams per brake horsepower hour, g/bhp-h • line-haul duty-cycle weighted brake-specific mass emission rates, ElDC, and the change, AElDC for each emitted pollutant or GHG species i, g/bhp-h Emissions measured during the tests were: • CO2, volume% • Carbon monoxide (CO), parts per million by volume (ppmv) • NOX, ppmv • total non-methane hydrocarbons, ppmv • methane, ppmv • total hydrocarbons (THC), ppmv • total particulate matter (TPM), ppmv • smoke opacity, % The primary locomotive parameters of concern were: • main generator (AR10) voltage • main generator current • engine fuel consumption, gallons per hour (gph) • cooling fan power consumption, kilowatts (kW) 1.5. MEASUREMENT EQUIPMENT Figure 1-3 is a summary schematic of the measurement equipment locations. 1-5 ------- Generator and Air Compartment QAR10 current ©AR10 voltage ©Supply fuel gph ©Return fuel gph ©Supply fuel temperature ©Return fuel temperature ±2) Engine intake air temperature ©Fixed pitot delta P ©Fixed pitot stack temperature © Cooling fan kW § Ambient barometric pressure Ambient relative humidity Ambient temperature Figure 1-3. Measurement Equipment Locations 1.5.1. AR10 Main Generator Current and Voltage The AR10 main generator electrical control cabinet contains the external resistive load bank connection bus bar. The field team leader installed the current and voltage sensors directly on the bus bar. The Flex-Core CTL-502S/4KY106/CTA215N current sensor span was 0 - 4000 amperes (A). The July 9, 2004 calibration certificate showed that the 95% confidence interval for achieved accuracy was ± 0.046% of reading. The Flex-Core VT8-014E voltage sensor span was 0 - 1000 volts (V). The July 9, 2004 calibration certificate showed that average calibration accuracy was ± 0.055% of reading. 1-6 ------- Both sensors output a 4 - 20 milliamp (mA) signal to the ION 7600 datalogger whose March 18, 2004 calibration certificate indicates a ± 0.3% full scale port conversion accuracy. This is ± 0.06 mA, or ± 1.5% at a 4 mA input level. 1.5.2. Fuel Supply and Return Flow Meters and Fuel Temperature Sensors The field team leader installed a Flow Technologies, Inc. FuelCom model FC05 flow meter into the engine's supply pipeline just downstream of the electric fuel circulation pump. He installed the return flowmeter downstream of the return fuel manifold, just upstream of the fuel tank return fitting. Figures 1- 4 and 1-5 show the flow meter installations. Supply Line from Belly Tank Fuel Meter Supply Line to Engine Air Eliminator (removed for tests) Restrictor Valve I and Gage Figure 1-4. Supply Flowmeter Figure 1-5. Return Flowmeter The return flowmeter installation incorporated an air eliminator, restrictor valve, and pressure gauge as provisions to minimize air bubbles at the return flowmeter. The return fuel flow, as checked at the three- way valve, proved to be free of bubbles and the air eliminator later failed in service prior to the baseline tests, so it was removed. External type K thermocouples, taped to the steel portion of the fuel pipelines and wrapped with insulation, served as fuel temperature sensors. The field team leader logged fuel temperatures at each notch with a Fluke model 52 thermocouple meter. Analysts used the average fuel temperature for engine horsepower fuel temperature compensation. 1.5.3. DOES2 and Instrumental Analyzers Figure 1-6 shows the Dynamic Offroad Emissions Sampling System (DOES2) as installed in the field. The DOES2 is a partial-flow portable dilution sampling system for gaseous emissions. ETC developed the system as a modification of standard FTP methods (primarily 40 CFR 86 and 40 CFR 92) specifically designed for field testing of in-use vehicles. The DOES2 provides a dilute, conditioned sample to a portable instrumental analyzer bench. The analyzer bench is not in view in Figure 1-6. The test plan provides a DOES2 system schematic, a description, and discusses its relationship to 40 CFR 92 locomotive FTP test equipment specifications. 1-7 ------- Figure 1-6. DOES2 Sampling and Dilution Apparatus The analyzer bench contained the gaseous emissions analyzers, sample and calibration gas manifolds, and the necessary controls and sample pumps. California Analytical Instruments, Inc. manufactured the THC analyzer; others were by Horiba Instruments, Inc. Figure 1-6 also shows the sulfur dioxide (SO2) and sulfate (SO4) teflon filter holder. The DOES2 moved a controlled volume of diluted stack gas through the filters for later laboratory analysis. Testers conducted SO2 and SO4 sampling for information only. 1.5.4. Locomotive Particulate Sampling System Figure 1-7 shows the locomotive particulate sampling system (LPSS). Like the DOES2, it is a partial- flow dilution apparatus, but it passes a larger aliquot of dilute exhaust gas directly through the gravimetric TPM filters. ETC developed the LPSS as a modification of 40 CFR 92 test methods specifically for field TPM emissions determinations from larger vehicles. The test plan provides a system schematic, a description, and discusses the relationship between the LPSS and locomotive FTP test equipment specifications. 1-8 ------- LPSS System Exhaust Duct Figure 1-7. Locomotive Particulate Sampling System 1.5.5. Opacity Meter and Auxiliary Measurement Equipment The Bosch - RT100A opacity meter extracted a partial exhaust sample from a probe installed in the test duct. The meter's sample pump conveyed the exhaust sample through a short length (about 3 feet) of teflon tubing through the opacity measurement cell. Testers shut the sampling pump off immediately following each 6-minute test period, which prevented fouling and reduced maintenance requirements. Test personnel performed pre- and post-test stack gas volumetric flow rate traverses with a Type S pitot tube and thermocouple. They then installed the pitot at a fixed location and recorded stack temperature and velocity at that point throughout all test runs. Section 2.2.1 describes the stack gas volumetric flow rate determination as derived from this data set. Testers installed a type K thermocouple in the engine's intake air plenum which was connected to a spare DOES2 temperature measurement channel. Analysts used the recorded air temperature during each test run and notch for engine horsepower air temperature compensation. ETC personnel also recorded ambient barometric pressure, relative humidity, and temperature as determined by a Visala model HM141 handheld instrument. The field team leader recorded cooling fan real power consumption during each test run and notch as measured by an Extech model HVAC Trms Clamp Meter. The meter's accuracy for real power measurements was ±5.0 percent. 1-9 ------- 1-10 ------- 2.0 VERIFICATION RESULTS Although test personnel did measure fuel consumption directly as required by the locomotive FTP [4] and the test plan, significant calibration, accuracy, and operations problems with the fuel meters rendered the data invalid. This represented a significant departure from the FTP and test plan requirements. See Section 2.2.2 for a detailed discussion. The test results, however, are valid for the baseline / treated fuel comparisons. The "carbon balance method," presented at §86.1382-94 in the diesel heavy-duty engine FTP [5], is the basis for all brake horsepower-specific results presented here. This method requires exhaust gas volumetric flow determinations with a constant volume sampling (CVS) system. The results reported here employed the 40 CFR 60 Appendix A Method 2 traverses and stationary pitot monitoring specified in the test plan's Table 3-3 instead of a CVS system. Section 3.1 of this report discusses the accuracy differences between the CVS system and the Method 2 techniques. The results reported here represent the brake-specific fuel consumption (BSFC) and emission rate changes seen during the test locomotive's operations under field conditions at the host facility. These results may differ from those at other locomotives, test methods, or host facilities. BSFC and brake- specific gaseous emissions showed statistically significant improvements at the majority of the operating notches. Line-haul duty cycle-weighted BSFC and gaseous emissions (except for NOX, which was not statistically significant) also improved. Switch duty cycle-weighted BSFC and all gaseous emissions showed statistically significant improvements. TPM emissions, however, increased during the treated fuel tests. The following tables present the changes between the baseline and treated fuel BSFC as gallons per brake horsepower hour (gal/bhp-h) and for brake-specific emissions as grams per brake horsepower hour (g/bhp-h). Positive numbers indicate a BSFC improvement or emission rate increase. Negative numbers indicate an emission rate decrease. For example, notch 2 BSFC improved by 0.009 ± 0.003 gal/bhp-h, CO emissions decreased by 0.20 ± 0.07 g/bhp-h, and TPM increased by 0.09 ± 0.04 g/bhp-h. Uncertainty values are the 95 percent confidence interval about the mean results for six baseline and six treated fuel test runs. Student's T test, evaluated at 95 percent certainty, provided the estimate of statistical significance. Table 2-1. BSFC and Brake-Specific Emission Rate Change, Per Notch Values Notch BSFC, gal/bhp-h CO, g/bhp-h CO2, g/bhp-h NOX, g/bhp-h THC, g/bhp-h TPMa, g/bhp-h 1 * -0.34 + 0.17 * * -0.11 + 0.04 0.07 +0.06 2 0.009 + 0.003 -0.20 + 0.07 -80 + 20 -1.0 + 0.9 -0.09 + 0.07 0.09 +0.04 3 0.010 + 0.004 -0.36 + 0.08 -90 + 30 -1.5 + 0.8 * 0.11 +0.04 4 0.009 + 0.003 -1.00 + 0.19 -70 + 30 -0.9 + 0.5 -0.06 + 0.03 0.11 +0.04 5 0.005 + 0.003 -1.3 + 0.6 -40 + 30 * -0.03 + 0.02 0.13 +0.04 6 0.010 + 0.007 -1.2 + 0.8 -90 + 60 * -0.06 + 0.02 0.18 +0.07 1 0.004 + 0.003 -1.2 + 0.7 -30 + 30 * -0.05 + 0.02 0.28 +0.07 8 * -0.51 + 0.08 * * -0.03 + 0.02 0.30 +0.07 * Not statistically significant aTPM results represent increased emissions as compared to baseline tests. 2-1 ------- Table 2-2. BSFC and Brake-Specific Emission Rate Change, Per Notch Percentage of Baseline Notch BSFC CO C02 NOX THC TPMa 1 * -33 + 17% * * -32 + 12% 40 +40% 2 -13 + 4% -31 + 11% -13 + 4% -9 + 7% -30 + 30% 60 +30% 3 - 15 + 6% -36 + 9% - 15 + 6% - 14 + 8% * 42 +17% 4 -13 + 4% -50 + 10% -13 + 5% -8 + 5% -27 + 12% 42 +16% 5 -8 + 5% -40 + 20% -8 + 5% * - 13 + 10% 50 +18% 6 -15 + 11% -30 + 20% -15 + 11% * -22 + 9% 70 +30% 1 -1 + 5% -50 + 30% -6 + 5% * -22 + 10% 140 +30% 8 * -50 + 8% * * - 17 + 12% 770 +40% * Not statistically significant aTPM results represent increased emissions as compared to baseline tests. Duty cycle-weighted emissions in Table 2-3 result from weighting factors applied to the emissions and bhp produced during each notch. Title 40 CFR 92.132 provides the line-haul and switch duty weighting factors and the test plan included them for reference. Table 2-3. Duty Cycle- Weighted BSFC and Emission Rate Change Line-haul Duty Cycle Parameter Delta Percentage of baseline BSFC, gal/bhp-h 0.003 + 0.002 5 + 4% CO, g/bhp-h -0.75 + 0.14 -44 + 8% CO2, g/bhp-h -30 + 20 -5 + 4% NOX, g/bhp-h * * THC, g/bhp-h -0.06 + 0.03 -22 + 12% TPMa, g/bhp-h 0.23 +0.08 100 +40% Switch Duty Cycle Delta Percentage of baseline 0.008 + 0.003 10 + 4% -0.9 + 0.3 -39 + 12% -70 + 30 - 10 + 4% -1.2 + 0.9 -9 + 7% -0.12 + 0.8 -27 + 18% 0.12 +0.04 46 +18% * Not statistically significant aTPM results represent increased emissions as compared to baseline tests. TPM emissions remained below the Tier 0 standards (0.60 and 0.72 g/bhp-h for line-haul and switch duty cycles, respectively) for all baseline and treated fuel test runs. The test campaign did not quantify engine bhp at the low and high idle notches, so this report does not include those brake horsepower-specific results. Table 2-4 shows the changes in CO emissions for the idle notches. Other emissions changes were not statistically significant for the idle notches. Table 2-4. CO Emission Rate Change at Idle Delta, g/bhp-h Percentage of baseline Low Idle -100 + 50 -34 + 16% High Idle -110 + 40 -37 + 14% In general, smoke emissions improved over the baseline with statistically significant changes occurring for notches 3 through 7, depending on the averaging algorithm. For example, baseline opacities ranged between approximately 25 and 30 percent for notches 5 and 6 and treated fuel opacity ranged between approximately 10 and 17 percent for those notches. Section 2.3 presents the results as charts. 2-2 ------- The GHG Center's field team leader and ETC personnel installed all measurement equipment prior to the test campaign. SLA also conducted the locomotive's normal 92-day Federal Railroad Administration safety inspection. SLA and EnviroFuels coordinated setup of the fuel catalyzer skid and acquisition of test support equipment (generator, manlift, etc.). SLA emptied the locomotive's belly tank and had it cleaned prior to filling it with fuel from a controlled lot. Irving Oil, the fuel supplier, controlled the fuel source by providing all the railroad's fuel from a single bulk tank located in Portland, ME throughout the baseline, break-in, and treated fuel test periods. Irving Oil certified that all fuel delivered to SLA's Auburn facility came from this controlled lot. Testing began on August 16, 2004, with Title 40 CFR 60, Appendix A, Method 2 stack gas velocity traverses and cyclonic flow angle measurements while the locomotive was operating at each notch, under load. The test crew then completed six valid test runs on August 20, 2004. At the completion of the baseline tests, SLA personnel administered the EnviroFuels fuel catalyzer to the fuel remaining in the locomotive's belly tank and enabled the dosing pump. The break-in period, which incorporated all the locomotive's normal over-the-road operations, extended from August 21 through October 23, 2004. The locomotive consumed approximately 35,000 gallons of treated fuel during this period and required no maintenance or repair other than daily inspections. SLA personnel logged the dosing pump's counter at the end of each refueling and forwarded the results to the GHG Center. At EnviroFuels' recommendation, SLA changed the dosing ratio from approximately 640:1 to approximately 1280:1 on October 10. This allowed the locomotive to burn approximately 6700 gallons of fuel at the latter ratio prior to the treated fuel test runs. Treated fuel test runs began on October 24, 2004, after ETC had set up their equipment on October 23. The tests series was the same as that for the baseline runs: a series of Method 2 traverses at each notch under load, followed by six valid test runs, finishing with a final series of Method 2 traverses on October 28, 2004. A locomotive warmup cycle preceded each test run. The warmup cycle consisted of operating the locomotive under load for 3 minutes at each notch (6 minutes at notch 8), starting at low idle. The operator then returned to low idle over 1 minute. Each test run then commenced within 15 minutes. Test runs began at low idle, cycling through each of the notches in turn. The locomotive operated at each notch for 20 minutes (15 minutes at notch 8), with particulate sampling during the first 6 minutes. Testers obtained gaseous emissions, opacity, and cooling fan power consumption data during the 4th through 6th minute for the idle notches, the 6th minute for notches 1 through 7, and the 15th minute for notch 8. The locomotive's physical and electrical configuration prevented gathering data during the dynamic braking mode. 2.1. ENGINE BHP Table 2-5 presents the compensated gross engine brake horsepower for the baseline and treated fuel tests. Table 2-5. Compensated Brake Horsepower at Engine Notch Baseline mean bhp Sample standard deviation (s^) Treated fuel mean bhp Sn-l 1 288 4 293 9 2 502 4 540 20 3 866 5 920 20 4 1157 6 1226 15 5 1555 11 1645 19 6 2100 200 2320 40 7 2675 17 2870 20 8 2962 14 2905 5 2-3 ------- The locomotive produced more power during the treated fuel tests, except at notch 8. It was difficult to discern performance changes between notches 7 and 8 for the treated fuel tests, except that the engine seemed to run more smoothly at notch 8. The relationship between the AR10 generator power demand and the engine's governor caused speed variations (or "hunting") at notches 6 and 7 throughout all the tests. This was especially evident at notch 6 during the baseline tests, as shown by the sample standard deviation in Table 2-5. The test plan equation for brake horsepower used 0.715 for the generator efficiency and 0.7457 kW per bhp. This is incorrect. The locomotive manufacturer states that 0.715 is the combined value for the ARlO's efficiency and the kW to bhp conversion factor. The correct equation for engine bhp is: Eqn.2-1 4 0.715 Where: = mean mechanical power for mode j, bhp kWARio = mean main generator power output, kW (note that kWARio is VARio ' AAR10 / 1000) 0.715 = combined AR10 electrical efficiency and kW to horsepower conversion The test plan also included constant default load values for the mechanical accessory horsepower, such as the main air blower, traction motor blower, unloaded air compressor, and unloaded auxiliary DC generator. These loads cannot be constant at each notch because the engine speed varied from about 254 to 914 revolutions per minute between low idle and notch 8. Use of a single default value for the unloaded air compressor, for example, is not realistic. These parasitic loads did not vary between the baseline and treated fuel tests, so the verification results were not affected by them. Analysts therefore did not allow for them in the results. The reader should note, however, that locomotive emissions test results often include mechanical accessory horsepower default values for regulatory purposes (see 40 CFR92.2). The results have been compensated with factors provided by the manufacturer, per industry practice, to 31.8 °API gravity, 68 °F engine intake air temperature, and 29.85 "Hg absolute atmospheric pressure. Figure 2-1 shows the AR10 voltage and current traces for a typical individual test run. 2-4 ------- 4000.0 3500.0 3000.0 2500.0 E 2000.0 1500.0 1000.0 500.0 Baseline Run 3 Current Baseline Run 3 Voltage 900 - 800 - 700 - 600 - 500 - 400 - 300 - 200 -- 100 Figure 2-1. AR10 Generator Performance It was sometimes possible to stop the engine's hunting during notches 6 and 7 by applying manual force to the governor control bar at certain points in the hunting cycle. Figure 2-1 shows this effect at notch 7. Note, however, that the performance results quoted here do not include time periods during which the engine's operation was manually forced. Cooling fan power consumption ranged between approximately 10 and 120 horsepower (depending on the notch setting) for the baseline tests. The fans consumed between 0 and approximately 90 horsepower during the treated fuel tests. For reference, Table 2-6 shows the mean exhaust gas temperatures as measured at point number 3c in the temporary test duct (see Figure 2-5) and mean engine intake air temperatures. Table 2-6. Mean Exhaust Gas and Engine Intake Air Temperatures Notch Baseline exhaust, °F Sn-l, °F Engine intake air, °F Sn-l, °F Treated ehaust, °F Sn-l, °F Engine intake air, °F Sn-l, °F Lo Idle 223 8 76 6 239 32 49 8 Hi Idle 201 2 76 5 172 7 49 8 1 297 3 77 5 230 26 49 7 2 388 12 77 9 315 35 50 6 3 489 10 77 2 424 32 52 6 4 581 8 78 2 511 28 52 6 5 669 4 77 2 599 29 55 7 6 732 6 76 2 655 96 58 6 7 718 4 77 3 667 92 60 6 8 720 6 77 4 671 91 60 4 2-5 ------- 2.2. BRAKE-SPECIFIC FUEL CONSUMPTION The FTP procedures for calculating fuel consumption correlate the exhaust gas carbon content with the actual exhaust gas volumetric flow in standard cubic feet per minute, the carbon available in the fuel, and the fuel's density, to yield the engine's fuel consumption rate in gph. This is known as the carbon balance method. The DOES2 analyzers provided the THC, CO, and CO2 carbon content (Section 2.3.1). The following subsection discusses acquisition of the volumetric flow rate data. The test fuel met all 40 CFR 92.113 specifications except that fuel density was 31.8 °API instead of 32 °API as specified by the CFR. ETC used 86.5 mass percent carbon and 13.8 mass percent hydrogen based on #2 diesel fuel analyses performed in 2003 for a New York City project. For reference, §86.1342-94 (d) (1) (ii) (C) cites the average carbon to hydrogen ratio as 1:00 : 1.80, or approximately 86.96 and 13.00 mass percent carbon and hydrogen, respectively. The GHG Center considers the fuel density and fuel carbon values to be identical between the baseline and treated fuel tests because the supplier lifted all fuel from the same storage tank during the test campaign. The fuel consumption rate, divided by the compensated bhp (Section 2.1), yields the BSFC. The following tables provide the test results. This report cites the carbon balance method rather than the directly-measured fuel consumption results for the reasons noted in Section 2.2.2. Note that the tables omit BSFC for the idle notches because the AR10 generator was producing negligible power and the engine's frictional and parasitic loads were not quantified. This means that a BSFC calculation would be meaningless for those individual notches. Table 2-7. Mean Fuel Consumption and Engine RPM Per Notch Values Notch Baseline gph Sn-l Engine RPM Treated Fuel gph Vl Engine RPM Lo Idle 4.4 0.8 254 4.9 0.2 254 Hi Idle 5.3 0.4 320 5.3 0.3 319 1 21 1.6 300 19.9 1.2 317 2 34.5 0.9 384 32.0 1.5 388 3 60 3 492 54.4 1.6 498 4 77 3 568 71 2 573 5 99 2 651 96 4 655 6 144 8 732 132 7 733 7 154 6 828 155 8 830 8 154 6 912 154 7 914 Table 2-8. Mean BSFC Per Notch Values, gal/bhp-h Notch Baseline Sn-l Treated Fuel Sn-l 1 0.075 0.006 0.068 0.004 2 0.0688 0.0019 0.060 0.002 3 0.070 0.004 0.0593 0.0017 4 0.067 0.002 0.058 0.002 5 0.064 0.002 0.058 0.003 6 0.067 0.007 0.057 0.004 7 0.0577 0.0018 0.054 0.003 8 0.0521 0.0018 0.053 0.002 Figures 2-2 and 2-3 illustrate the per-notch BSFC for each test run. 2-6 ------- 0.080 0.070 0.060 0.050 0.040 0.030 0.020 0.010 0.000 0.080 0.070 0.060 0.050 -- 0.040 0.030 0.020 0.010 0.000 -•-Run 1 BSFC -•-Run 2 BSFC A Run 3 BSFC -*-Run4BSFC -as-Run 5 BSFC -•-Run 6 BSFC Notch 1 Notch 2 Notch 3 Notch 4 Notch 5 Notch 6 Notch 7 Notch 8 Figure 2-2. Baseline Run-Specific BSFC Notch 1 Notch 2 Notch 3 Notch 4 Notch 5 Notch 6 Notch 7 Notch 8 Figure 2-3. Treated Fuel Run-Specific BSFC 2-7 ------- Table 2-9 provides the duty cycle-weighted BSFC. Table 2-9. Mean Duty Cycle-weighted BSFC, gal/bhp-h Baseline Sn-l Treated Fuel Sn-l Line-Haul 0.0600 0.0011 0.057 0.002 Switch 0.076 0.002 0.068 0.002 Table 2-9 incorporates data from 6 runs for the baseline fuel and 5 runs from the treated fuel. The treated fuel results omit data from Run 4. Instrumental analyzer problems occurred during notch 1 of this run so the duty cycle-weighted BSFC calculation is invalid. Figure 2-4 shows the relationship between fuel consumption and total compensated bhp for both fuel conditions. The figure highlights possibly anomalous results for the baseline tests because it appears that mean bhp increased from notch 7 to notch 8 while fuel consumption remained approximately the same. 3000 2500 2000 1500 1000 500 100 120 140 160 180 Figure 2-4. Fuel Consumption verses Brake Horsepower The error bars, however, indicate that fuel consumption could also have either increased or decreased between notches 7 and 8. Isolated results like these should be interpreted with caution. For example, several thunderstorms moved through the area during some baseline test runs. Even though all test parameters remained within valid limits, this could have affected baseline variability. SLA personnel noted that the locomotive's control algorithms had been customized for the mother / daughter application, and this may have affected performance. Quantification of the effects of any of these influences is impossible without further testing. 2-8 ------- 2.2.1. Exhaust Gas Volumetric Flow Rate Test personnel performed complete Method 2 traverses with a type S pitot and type K thermocouple at each notch: • immediately before the first baseline test run • immediately before the first treated fuel test run • immediately following the last treated fuel test run The standard locomotive warmup cycle (Section 2.0) preceded each traverse and the elapsed time for each notch was approximately the same as for a regular test run. Testers allowed the engine to equilibrate for at least 6 minutes at each notch to ensure stable operating conditions before starting the traverse. The traverses included differential pressure (AP) and temperature measurements at 24 regularly-spaced points (4 locations at each of 6 test ports) across the test duct. Figure 2-5 illustrates the pitot measurement locations. They then installed the pitot at a fixed location which best represented the flow (designated "3c") and recorded AP and temperature readings during each test run. 46 in -Sample Collection /^Pitot Measurement 42 in 12.125 2 center channels slightly larger Figure 2-5. Method 2 Traverse Locations 2-9 ------- Volumetric flow is proportional to the mean of the square root of the pitot AP. Figure 2-6 shows the volumetric flow data from the traverses as a function of the square root of AP at point 3c. The correlation coefficient (R2) of 0.9966 indicates that the square root of AP at point 3c is a good predictor of total stack gas flow. The 95 percent confidence interval for flow, as predicted from a AP reading at 3c at every notch, is approximately 2.2 percent. 12000.0 -i 10000.0 8000.0 6000.0 4000.0 2000.0 0.0 y = 43 58.6x + 9£4.8 = 0.9966 0.5 1 1.5 Sqrt DeltaP 2.5 Figure 2-6. Exhaust Gas Volumetric Flow Rate as a Function of vAP at Point 3c 2.2.2. Fuel Meter Results The fuel meters did not perform as anticipated. Their response changed unpredictably during the August 21 through October 23, 2004 break-in period. This was particularly evident while the locomotive was idling. At idle, the maximum amount of fuel (approximately 380 gph) passed through both meters with a small amount being drawn off by the engine. The meters reported net idle fuel consumption as varying randomly between 17.5 gph and -16.4 gph over the break-in period. This indicates that the idle and low notch data from these meters are invalid and the results at the higher notches have large unquantified inaccuracies, over and above calibration and random sampling error. The manufacturer's sales literature stated that accuracy on the net fuel consumption would be ± 1.0 percent. Actual absolute compounded accuracy for the meters alone, as documented by the pre-test calibration certificates, was ± 0.80 gph. The fuel meters alone would have met the ±1.0 percent specification only at net fuel consumption rates greater than 80 gph, or at notch 5 and above for the test locomotive. Overall absolute compounded accuracy (including the datalogger's port accuracy), as documented by the fuel meters' pre- and post-test calibrations was ± 2.04 gph for the baseline tests and ± 2.99 gph for the treated fuel. Compounded absolute accuracy of the net fuel consumption was 3.62 gph, not including sampling error. 2-10 ------- GHG Center analysts undertook an extensive review of the pre- and post-test fuel meter calibrations to see if the calibration changes could be corrected, but this proved to be impossible. For example, the as- reported post-test calibrations showed significant changes in the return fuel meter, both in overall accuracy and the trend (or slope) at each calibration point. The changes profoundly affected the treated fuel test results. Also, between the end of the test runs and the calibration exercise, test personnel: • dismounted both meters from the locomotive • shipped them to the GHG Center • performed bench-top evaluations • shipped the meters to the calibration facility Calibration facility operators then passed an unknown quantity of clean calibration fluid through the meters. All of this means that the calibration changes during the actual tests are completely unknown at all notches and could have been much larger (or smaller). Figure 2-7 illustrates how the meters' documented accuracy affected the net fuel consumption results. The BSFC change would have to be larger than the random sampling error compounded with the two meters' calibration error to show statistical significance. This amounts to about 17.0 percent at notch 2 or 4.0 percent at notch 7 and means that it was impossible to quantify small changes in net fuel consumption with the fuel meters. 0.065 0.055 0.045 0.04 0.035 Baseline Brake-Specific Fuel Consumption Baseline Compounded Calibration and Random Error Treated Fuel Brake-Specific Fuel Consumption Treated Fuel Compounded Calibration and Random Error 4 5 Notch Figure 2-7. Effects of Fuel Meter Calibration Error The manufacturer calibrated the fuel meter digital outputs at multiple fuel flows and temperatures. The calibration, however, does not document the correspondence of the calibration flow rates with the meters' analog outputs. This means that the analog outputs, as recorded by the GHG Center's datalogger, cannot be shown to have a traceable link to the multipoint calibration procedure. GHG Center analysts therefore invalidated the fuel meter data and used the carbon balance method to calculate fuel consumption. 2-11 ------- 2.3. LOCOMOTIVE EMISSIONS The following tables present the emissions test results. Table 2-10. Mean Baseline Emissions, grams per minute (g/min) Pollutant CO Sn-l C02 Sn-l NOX Sn-l THC Sn-l TPM Sn-l Lo Idle 4.9 0.6 630 110 17.0 1.6 1.3 0.3 0.20 0.07 Hi Idle 5.9 0.6 760 60 19 3 1.6 0.2 0.26 0.07 Notch 1 4.9 0.7 3100 200 64 6 1.6 0.1 0.77 0.12 Notch 2 5.4 0.4 5030 130 98 5 2.3 0.6 1.3 0.2 Notch 3 14.3 0.8 8800 500 150 10 3.9 1.8 3.7 0.4 Notch 4 38 4 11200 400 185 7 4.3 0.3 5.0 0.6 Notch 5 82 17 14300 300 226 9 5.2 0.3 6.6 0.8 Notch 6 130 20 20800 1200 380 20 9.2 0.6 8.7 1.4 Notch 7 100 30 22400 800 440 40 10.8 0.6 8.5 1.1 Notch 8 49.0 1.8 22500 800 460 30 10.6 0.8 8.7 1.3 Table 2-11. Mean Treated Fuel Emissions, g/min Pollutant CO Sn-l CO2 Sn-l NOX Sn-l THC Sn-l TPM Sn-l Lo Idle 3.3 0.5 710 30 16.2 0.8 1.1 0.3 0.29 0.15 Hi Idle 4.1 0.3 770 40 17.2 0.9 1.3 0.3 0.31 0.10 Notch 1 3.4 0.2 2900 180 63 4 1.11 0.11 1.1 0.3 Notch 2 4.0 0.4 4700 200 95 10 1.6 0.3 2.2 0.3 Notch 3 9.6 1.2 7900 200 136 7 2.24 0.15 5.5 0.6 Notch 4 20 2 10400 300 177 8 3.3 0.4 7.5 0.7 Notch 5 52 5 13900 600 231 8 4.8 0.5 10.5 1.1 Notch 6 93 17 19200 1000 377 16 7.7 0.7 16 2 Notch 7 54 13 22500 1100 460 14 9.1 1.1 22 3 Notch 8 24 4 22500 1000 449 14 8.6 1.1 23 3 Table 2-12. Mean Baseline Brake-Specific Emissions, g/bhp-h Pollutant CO Sn-l C02 Sn-l NOX Sn-l THC Sn-l TPM Sn-l Notch 1 1.02 0.16 650 50 13.3 1.4 0.34 0.03 0.16 0.02 Notch 2 0.65 0.06 601 17 11.8 0.8 0.28 0.07 0.15 0.03 Notch 3 0.99 0.06 610 30 10.4 0.7 0.27 0.13 0.24 0.03 Notch 4 1.99 0.19 580 20 9.6 0.4 0.222 0.018 0.26 0.03 Notch 5 3.2 0.7 551 13 8.7 0.4 0.200 0.011 0.26 0.03 Notch 6 3.6 0.8 580 60 10.6 1.0 1.257 0.012 0.25 0.05 Notch 7 2.3 0.7 502 17 9.8 0.9 0.243 0.011 0.19 0.02 Notch 8 0.99 0.04 455 16 9.3 0.5 0.214 0.015 0.18 0.03 Table 2-13. Mean Treated Fuel Brake-Specific Emissions, g/bh Pollutant CO Sn-l C02 sn-l NOX Sn-l THC Sn-l TPM Sn-l Notch 1 0.69 0.07 590 30 11.8 0.6 0.23 0.03 0.24 0.05 Notch 2 0.45 0.06 524 19 10.7 0.7 0.18 0.03 0.23 0.03 Notch 3 0.63 0.07 519 15 8.9 0.3 0.147 0.013 0.36 0.03 Notch 4 0.99 0.10 507 21 8.7 0.3 0.16 0.02 0.37 0.03 Notch 5 1.9 0.2 500 30 8.4 0.4 0.17 0.02 0.38 0.04 Notch 6 2.4 0.5 500 30 9.8 0.5 0.20 0.02 0.42 0.06 p-h Notch 7 1.1 0.3 470 20 9.6 0.3 0.19 0.02 0.47 0.06 Notch 8 0.49 0.08 460 20 9.3 0.3 0.18 0.02 0.47 0.07 2-12 ------- Table 2-14. Mean Line-haul Duty Cycle-Weighted Emissions, g/bhp-h Emission Baseline Vi Treated Sn-l CO 1.71 0.08 0.96 0.13 C02 520 10 497 18 NOX 10.2 0.5 9.7 0.3 THC 0.27 0.02 0.21 0.03 TPM 0.22 0.02 0.45 0.06 Table 2-15 Mean Switch Duty Cycle-Weighted Emissions, g/bhp-h Emission Baseline Sn-l Treated sn-i CO 2.4 0.3 1.45 0.12 C02 660 20 600 20 NOX 12.6 0.8 11.4 0.4 THC 0.42 0.06 0.31 0.06 TPM 0.259 0.012 0.38 0.04 Tables 2-13 and 2-14 incorporate analyzer data from 6 runs for the baseline fuel and 5 runs from the treated fuel. The treated fuel results omit notch 1 data from Run 4 because of instrumental analyzer problems. The tables incorporate TPM data from 4 baseline and 5 treated fuel runs, respectively. Test operators mis-handled filters for baseline run 3, high idle; run 6, notch 1 and notch 2; and treated fuel run 2, notch 1 and notch 2. This means that the duty cycle-weighted results for these runs are not valid. Figures 2-8, 2-9, and 2-10 show the mean 3-second peak, 30-second peak, and steady state opacity or smoke emissions. Opacity is the amount of ambient light which is blocked by the exhaust plume. 35- Low Idle Idle Notch 1 Notch 2 Notch 3 Notch 4 Notch 5 Notch 6 Notch 7 Notch 8 Figure 2-8. Mean 3-second Peak Opacity 2-13 ------- Low Idle Idle Notch 1 Notch 2 Notch 3 Notch 4 Notch 5 Notch 6 Notch 7 Notch 8 Figure 2-9. Mean 30-second Peak Opacity Low Idle Idle Notch 1 Notch 2 Notch 3 Notch 4 Notch 5 Notch 6 Notch 7 Notch 3 Figure 2-10. Mean Steady-State Opacity Tables 2-15 through 2-17 provide the opacity numerical results. Table 2-16. Mean 3-second Peak Opacity Notch Baseline% sn-l Treated% sn-l Lo Idle 4 4 4 2 Hi Idle 4 2 4 2 1 10 3 8.8 1.4 2 14 3 11.9 1.7 3 19 3 13.6 1.1 4 25 4 15.4 1.6 5 29 6 16 2 6 29 6 18 2 7 20 7 11 3 8 11 4 7.5 1.5 2-14 ------- Table 2-17. Mean 30-second Peak Opacity Notch Baseline% Sn-l Treated% Sn-l Lo Idle 3 4 4 2 Hi Idle 3 2 3 2 1 8 2 7.2 1.3 2 9 2 7.5 .9 3 16 3 11.7 1.1 4 22 4 13.5 1.5 5 25 5 14 2 6 26 5 13.5 1.0 7 15 4 8.4 1.6 8 6 3 3.9 1.4 Table 2-18. Mean Steady-State Opacity Notch Baseline% sn-l Treated% sn-l Lo Idle 4 5 4 2 Hi Idle 4 2 3 3 1 7 2 6.0 1.8 2 8 2 7.2 1.0 3 15 3 11.0 1.1 4 21 4 13.5 1.5 5 25 5 14 2 6 22 5 10 2 7 11 3 5.9 0.8 8 4 3 3.5 1.8 Mean SO2 emissions at notch 8 were 0.48 and 0.72 g/bhp-h for the baseline and treated fuel, respectively. The difference was statistically significant, but is based on a limited number of samples. Analysts provided results for three of the baseline runs and two of the treated fuel runs. The increase amounted to 0.24 ±0.19 g/bhp-h. Mean SO4 (sulfate) emissions were 0.007 and 0.009 g/bhp-h for the baseline and treated fuel, respectively, based on three analyses each. The difference was not statistically significant. This report includes these SO2 and SO4 results for information only. The SO2 increase reported here may merit further analysis because it was highly unlikely that fuel sulfur or other properties changed. As explained above, the supplier lifted all fuel from the same lot during the test campaign. Also, Envirofuels has stated that the catalyzer contains no sulfur compounds, so it is difficult to account for the apparent SO2 emissions increases. 2.4. TPM RESULTS AND ADDITIONAL PARTICULATE ANALYSES The verification test results show increased TPM emissions while the locomotive was operating on the treated fuel as compared to baseline emissions. Duty cycle-weighted emissions, however, were significantly less than the Tier 0 standards for both fuel conditions. The results are considered valid, but they were unexpected based on the decreased gaseous pollutant, smoke (opacity) emissions, and non-ETV tests performed at other venues. In an effort to understand the significant TPM emissions increases while observing reductions in all other emissions, the GHG Center and ETC investigated LPSS performance, dilution ratios, and the possible effects of sampling conditions on TPM as related to opacity. Appendix A provides the discussion. EnviroFuels and the GHG Center hypothesized that knowledge of the particulate composition or morphology may help explain whether the reported increase was real, a sampling artifact, or suggest its causes. Elemental verses organic carbon data and other elemental analyses (especially for iron and phosphorus) may also be useful. The GHG Center, therefore, undertook additional analyses of the particulate caught on the TPM filters. These analyses took place about 4 months after the test campaign. Southern personnel selected notch 5 primary filters from both fuel conditions for analysis. The selected filters most closely represented the overall mean results for THC and TPM. Analytical methods were: • scanning electron microscopy with energy dispersive X-ray spectroscopy (SEM / EDS) with magnifications of lOOx, 300x, and lOOOx (by Rocky Mountain Laboratories, Golden, CO) • X-ray photoelectron spectrometry (XPS, by Rocky Mountain Laboratories) 2-15 ------- SW-846 Method 8270 organic extraction and gas chromatography with selective detector (Method 8270 by Enthalpy Analytical, Inc., Durham, NC) mass SEM / EDS provided a qualitative assessment of the particle morphology combined with a list of the elements present on the filter (except for H, He, Li, and Be). XPS supplied quantitative elemental data (except for H and He) while Method 8270 yielded an assessment of elemental verses organic carbon. Results of all the post-test investigations into the cause of the increased TPM emissions were inconclusive. 2.4.1. Particulate Analyses Results SEM micrographs showed that the particulate loading on the filters was higher for the baseline tests. Table 2-19 presents the relevant filter and test run data for the TPM filters discussed here. Note that only the primary filters were analyzed; the laboratories have archived the backup filters. Table 2-19. Gravimetric Analyses and Sampling Data SEM/ EDS; XPS Method 8270 Filter ID 082057A 102747B 081827A 102637B Description Baseline run 5, notch 5 Treated run 4, notch 5 Baseline run 2, notch 5 Treated run 2, notch 5 TPM Mass, mg 4.837 3.915 5.878 3.276 Dilution Tunnel Flow, 1/m 448.4 369.6 485.3 360.9 Dilution Air Flow, 1/m 300.2 303.3 300.0 302.8 Exhaust Sample Flow, 1/m 148.2 66.3 185.1 58.1 Dilution Ratio 3.02 5.58 2.62 6.21 Sample Flow Rate (at Filter), 1/m 60.1 54.0 60.0 52.8 Table 2-19 shows that the locomotive particulate sampling system dilution ratios varied between the baseline and treated fuels. This is why reported TPM g/h emissions were higher for the treated fuel than for the baseline, even though less particulate mass was caught on the treated fuel filters. The varying volumetric flow rate through the system also led to different sample residence times, ranging between approximately 1.3 and 1.7 s for the baseline and treated fuel, respectively. Figures 2-11 and 2-12 show the SEM micrographs for the baseline and treated fuel filters. There are no apparent morphological differences, other than that the higher TPM mass on the baseline filter provides more extensive coverage of the filter media. 2-16 ------- Figure 2-11. Baseline Particulate Filter, SEM Image at 300X Figure 2-12. Treated Fuel Particulate Filter, SEM Image at 300X 2-17 ------- The XPS data included peaks for C, N, O, F, Na, Si, S, and Ca. Fe and P were absent. Figures 2-13 and 2-14 provide the spectrograms and present the data. E70-2176 082057A "Notch 5" Baseline Name Pos. FWHM Area At% C1s 2844 2.654 31256.9 86.4 N1s 4014 3.157 335.0 01s 532.4 3.492 F1s 6924 5.499 Si2p 105.4 6.028 S2p 169.4 2.987 Ca2p 348.4 2.477 . 600 Binding Energy (ev) Figure 2-13. Baseline XPS Results » 111'' 90. 80. 60^ uj sn Q. Du- O 40. 30. 20_ 10. DE70-41 102747B "Notch 5" Treated Fuel Li- Name Pos. FWHM Area At% C1s 284.7 2.687 24290.4 646 N1S 401.7 2.908 653.3 10 01s 531.7 3.281 8905.2 8.4 F1s 6897 2984 312672 231 Na 1s 1071.7 3.427 508.5 0.2 Si 2p 1037 2.934 742.4 1.7 S2p 168.7 2.987 714.9 0.8 Ca2p 347.7 2.801 219.1 01 1 I •^ ^ U z ° yv\M _ -*— -vV— -^ '" \ — \ c \ 1 ^~*~^— -*-/\ a C 1 d „ - z ^ i-<-l 0 « <1'ffi S5 C^ 600 finding Energy (eV) Figure 2-14. Treated Fuel XPS Results 2-18 ------- The TPM filter medium was Teflon-bonded borosilicate glass ("Emfab", Pall Corporation). This is the most likely cause of the Si and F indications in the XPS spectrograms. The higher TPM coverage in the baseline filter likely screened the underlying filter fibers, which would lead to the smaller F signal shown in Figure 2-13. Table 2-20 shows the relative C, N, O, Na, S, and Ca concentrations after correcting for Si and F. Table 2-20. XPS Elemental Concentrations, Corrected for Si and F Baseline atom% Treated atom% Baseline weight% Treated weight% C 92 86 90 81 N <1 1 <1 1 0 6 11 8 14 Na -- <1 — <1 S <1 1 ~ 1 £3 1 3 Ca <1 <1 <1 <1 The elevated S and O in the treated fuel particulate (Table 2-20) could represent increased sulfate deposited on the filter, but not enough to account for the overall TPM increase reported. Method 8270 showed little change in extractable organic matter between the two fuel conditions on the primary filters. The backup filters were not analyzed. Total hydrocarbons were 0.018 and 0.015 mg, which represented 3.1 and 4.6 percent of the total particulate catch, for the baseline and treated fuel respectively. This implies that, when analyzed, most of the TPM on the primary filters was pure carbon. It is unknown, however, whether deposited organic compounds may have volatilized during the period (about 4 months) between sampling and the 8270 analysis. In one study [6], for example, analysts immediately stored particulate filters in a freezer, handled, and analyzed them under yellow light to reduce volatilization and oxidation. This was not done for the verification tests, although all filters were refrigerated after the gravimetric analyses. The proportion of organics deposited on the primary filter, as compared to the backup filters (which were not analyzed) may also have varied. Recent work [7] has shown that this proportion can vary due to filter media selection. 2-19 ------- 2-20 ------- 3.0 DATA QUALITY The GHG Center selects methodologies and instruments for all ETV verifications to ensure a stated level of data quality in the final results. The test plan described these data quality objectives (DQOs). The test plan also listed contributing measurements, their accuracy requirements, QA/QC checks, and other data quality indicators (DQIs) that, if met, would ensure achievement of the DQOs. Section 2.5 of the test plan and 2.0 of this report discussed the differences between the Title 40 CFR 92 Subpart B FTP and the field activities. The differences are significant but they have no impact on these baseline - to - treated fuel comparisons because test personnel used identical methods and equipment for each test series. Test activities met all the requirements listed in the test plan, with the exception of the FuelCom fuel meter performance (See Section 2.2.2). This invalidated the direct fuel consumption measurements required by the test plan. Also, substitution of the Method 2 traverses and carbon balance method for the fuel meters departed from the Locomotive FTP. This portion of the field tests therefore did not meet the test plan's DQO that all field activities would conform to the FTP requirements for locomotive emissions determinations except as noted. See the discussion following Table 3-1 for the relevant citations. The test plan also proposed implicit DQOs that the data show statistical significance, variance similarity, and that the 95 percent confidence interval be refined as much as possible up to a maximum of 6 test runs. Early in the test campaign, the field team leader determined that 6 test runs for each fuel condition would be required to meet these goals, and he scheduled field activities accordingly. The results presented in Section 2.1 showed achievement of statistical significance for all parameters except for: Parameter BSFC Brake-specific CO2 Brake-specific NOX Brake-specific THC Notch 1,8 1,8 1, 5, 6, 7, 3 Variance similarity could not be shown for the following cases: Parameter Notch BSFC 3 Brake-specific CO 5, 7 Brake-specific NOX 3, 7 Brake-specific THC 3 Brake-specific TPM 7, 8 In these instances, analysts applied Satterthwaite's approximation [8] to calculate a revised T distribution value. They then compared Ttest to the revised T distribution value to determine statistical significance and to calculate the confidence interval. The following activities and procedures supported the achievement of this verification's objectives: • on-site QA/QC checks to reconcile the achieved DQIs with the DQOs • audit of data quality • on-site performance evaluation audit • on-site technical systems audit 3-1 ------- The following subsections describe reconciliation of the DQIs with the DQOs, the QA/QC checks, and audits. 3.1. RECONCILIATION OF DQOS AND DQIS A fundamental component of all ETV verifications is the reconciliation of the collected data and their DQIs with the DQOs. For this verification, assessment of the qualitative DQO consists of evaluation of whether the stated methods were followed, if the measurement instruments met the proper specifications, and if the QA/QC checks and calibrations described in the test plan yielded satisfactory results. Achievement of these DQIs implies that the DQOs were met. The following tables show the DQI data for the test campaign. The achieved instrument accuracies provided in Table 3-1 are primarily the result of multipoint laboratory calibrations performed on the individual instrument. Table 3-1. Instrument Accuracy Measurement Variable Main traction generator voltage Main traction generator current Fuel flow rate* Exhaust gas flow rate via Method 2 DOES2 main flowrate DOES2 dilution air flowrate DOES2 analyzer sample flowrate LPSS main flowrate LPSS dilution air flowrate Temperature LPSS main Diff. pressure, LPSS/DOES Ambient temperature Ambient pressure Humidity, ambient CO Observed Operating Range 0 - 840 V 0 - 2470 A 220 - 380 gph 2400 - 10700 scfm 50 - 60 1pm 40 - 55 1pm 3-4 1pm 350 - 450 1pm 298 - 305 1pm 110-140°F not used 35-85°F 14.4- 14.8psia 20 - 100% RH 0 - 50 ppmv: < 50 ppmvc 0 - 300 ppmv: < 300 ppmvc Instrument Range 0 - 1000 V 0 - 4000 A 50 - 500 gph n/a 0 - 100 1pm 0 - 100 1pm 0-5 1pm, each 10 1pm, total 0 - 8500 1pm 0 - 500 1pm 32 - 392 °F 0- 10"H2O 39 - 212 °F 0-15 psia 0 - 100% RH 0-50 ppmv, Lo Idle to Notch 4; 0 - 300 ppmv, Notch 5 to Notch 8 Specification + 0.25% FS + 1.0% of point + 1.0% of point for differential flow rates + 5.5% [9] + 1.0%FS + 1.0%FS + 1.0%FS + 1.0%FS + 1.0%FS + 0.9°F + 0.5% FS + 0.2% FS + 0.25% FS + 1.0%FS + 1.0% of point Results + 0.056% of point (sensor only), + 0.84% total" + 0.048% of point (sensor only), + 1.10% total" Baseline: + 0.52% to + 5.64% of point Treated: + 1.53% to + 15.0% of point < + 5.5% Baseline: + 0.86% Treated: + 0.25% Baseline: + 0.72% Treated: + 0.28% Baseline: + 0.93% Treated: + 0.62% + 1.0%FS + 1.0%FS + 0.1°F not used + 0.13%FS + 0.01%FS + 0.5%FS 0-50 ppmv: Baseline: +0.21% Treated: + 0.24% 0 - 300 ppmv: Baseline: +0.1 5% Treated: + 0.25% How Verified / Determined Factory calibration Factory calibration Factory / laboratory calibration Factory / laboratory calibration Factory calibration Factory / laboratory calibration Factory calibration Factory, laboratory, field calibration and drift checks 3-2 ------- Table 3-1. Instrument Accuracy Measurement Variable C02 NOX THC PM Mass Opacity Observed Operating Range <0-3.0%c 0-100 ppmv: < 100 ppmvc 0 - 300 ppmv: < 300 ppmvc < 30 ppmvc 0-6 mg 0 - 30% Instrument Range 0 - 3.0% 0-100 ppmv, Lo Idle to Notch 1; 0 - 300 ppmv, Notch 2 to Notch 8 0-30 ppmv 0 - 2000 mg 0 - 100% Specification + 1.0% of point + 1.0% of point + 1.0% of point + 20ug precision (std. deviation) + 1.0% Results Baseline: + 0.22% Treated: + 0.22% 0-100 ppmv: Baseline: +0.1 5% Treated: + 0.24% 0 - 300 ppmv: Baseline: +0.15% Treated: + 0.25% Baseline: +0.18% Treated: + 0.26% + 5.7 ug std. deviation + 0.7% How Verified / Determined Factory, laboratory, field calibration and drift checks Factory, laboratory, field calibration and drift checks Factory, laboratory, field calibration and drift checks Daily calibration Standard filters Includes both sensor error and datalogger analog / digital conversion error *The fuel meters did not perform satisfactorily. See Sections 2.2.1 and 2.2.2. cAnalyzer operating ranges as observed while sampling diluted exhaust emissions The test results for fuel consumption are based on Method 2 velocity traverses and the carbon balance method. 40 CFR 92.114(3)(1) allows this through references to Title 40 CFR 86, Subpart N [5]. The Method 2 traverses showed a sampling variability of approximately ±2.2 percent as discussed in Section 2.2.2. Table 3-1 reports overall Method 2 accuracy as better than 5.5% because the achieved accuracy of each individual measurement exceeded the method requirements [9]. This compares favorably with the measurement methods specified in §86.1319(4). For example, the 40 CFR 86 flow metering element accuracy specification is ± 5.0 percent alone, not including barometric pressure, temperature, or other instrument accuracies. This means that the Method 2 traverses, with accuracies similar to the 40 CFR 86 methods, are a reasonable substitute for the direct fuel consumption measurements. Specifications and accuracies for all other instruments, such as the gaseous analyzers, were either identical to or significantly exceeded those required for the 40 CFR 86 methods. Table 3-2. Calibrations System or Parameter Main traction generator voltage Main traction generator current DOES2 main flowrate DOES2 dilution air flowrate DOES2 analyzer sample flowrate LPSS main flowrate LPSS dilution air flowrate Temperature LPSS main Description/ Procedure NIST-traceable calibration with as-found data NIST-traceable calibration with as-found data Calibration against Gilibrator standard bubble flow meter or Drycal piston-type calibrator Calibration against Meriam laminar flow element Calibration against Gold seal mass flow controller Calibration against Omega temperature calibrator Date Performed 07/09/2004 07/09/2004 Baseline: 07/19/2004 Treated: 10/19/2004 Baseline: 08/04/2004 Treated: 10/19/2004 10/21/2004 Date Required Within 18 months of test Immediately prior to travel OK? V V V V V V 3-3 ------- Table 3-2. Calibrations System or Parameter Diff. Pressure, LPSS/DOES Temperature, ambient Pressure, ambient (BP) Humidity, ambient CO CO2 NOX THC CO CO C02 NOX PM mass smoke Description/ Procedure Calibration against Druck pressure calibrator Calibrated against laboratory standard Calibration against Druck pressure calibrator Calibrated against laboratory standard Gas divider calibration with protocol calibration gases at 1 1 points evenly spaced throughout span (including zero) CO2 interference check Water interference check Water interference check Converter efficiency check Balance calibrated by control weights calibration withNIST traceable ND filters at 0, 10, 20, 40% opacity Date Performed not used 02/23/2004 10/19/2004 02/23/2004 Baseline: 07/07/2004 Treated: 10/18/2004 Baseline: 07/27/2004 Treated: 09/22/2004 Baseline: 07/08/2004 Treated: 10/18/2004 Baseline: 07/07/2004 Treated: 10/18/2004 Baseline: 07/07/2004 Treated: 09/22/2004 Daily 08/17/2004 Date Required Annually Immediately prior to travel Annually Every 4 weeks or before analyzer leaves for field Monthly Daily within 6 months of test OK? n/a V V V V V V V V V V V V Table 3-3 QA/QC Check Results System or Parameter Main traction generator voltage Main traction generator power Test duct cyclonic flow Exhaust gas flow rate DOES2 leak checks DOES2 flowrate check LPSS leak checks QA/QC Check Meter reasonableness check vs. digital voltmeter (DVM) Reasonableness: voltage and current within manufacturer's specifications Method 1 cyclonic flow determination Exhaust gas delta P monitoring with stationary pilot at representative sampling location Tunnel is capped and drawn from by main pump piston-type calibrator comparison Tunnel is capped and drawn from by sample pump When Performed/ Frequency Performed prior to and during test series Prior to first test run Throughout all test runs Performed daily prior to test Performed prior to testing Performed daily prior to test Achieved All within + 0.9% ofFS All logged data within «+ 4.3% of onboard digital control" mean = 5.1° cyclonic flow Maximum error relative to the mean delta P was + 4.4% <0.5 1pm <1.0%FS < 6.9 1pm Allowable Result V values within + 2.0% ofFS Power within 10% of nominal for notch < 20° cyclonic flow Within + 15% of the mean Method 2 delta P at that traverse point for each notch < 1 1pm + 1.0% ofFS or + 2.0% of point < 10 1pm 3-4 ------- Table 3-3 QA/QC Check Results System or Parameter LPSS flowrate check Temperature LPSS main LPSS / DOES2 moisture condensation Tunnel blank Ambient Pollutant Levels Analyzer zero and span drift check QA/QC Check Each flow device is removed from the system and compared to a calibrated laminar flow element Each temperature probe is removed and calibrated against a temperature calibrator. Inspection of filter holders for moisture Run simulation test sequence Disconnect from exhaust probe and run test trace also serves as warm up run. Analyzer is zeroed and spanned before each reading using on site calibration gases When Performed/ Frequency Performed prior to travel Performed prior to travel Immediately following each test run at each mode One blank taken per day One sample per test series Each test run Achieved <1.0%FS + 0.6°C No moisture observed Blank included in filter analysis; exceeded 5.0% Reasonable ambient levels <2.0%FS Allowable Result + 1.0%ofFSor + 2.0% of point + 1.7°C No visible moisture on the internal surface of any fitting, housing, or filter Include blank in filter analysis if > 5.0% of sample weight Reasonable ambient levels Post-test zero or span drift shall not exceed + 2.0% FS "Locomotive had been re-engineered for mother / daughter service. Nominal data was not available. 3.2. AUDITS The GHG Center's QA manager performed the audit of data quality by randomly selecting at least 10 percent of the data, implementing an independent analysis, and comparing the results to those cited in this report. The QA manager then drafted a report which describes the audit and submitted it directly to the GHG Center director. In general, the audit results were satisfactory. Robert S. Wright of the EPA Air Pollution Prevention and Control Division and John R. Albritton of the Research Triangle Institute's Center for Energy Technology performed an on-site technical systems audit during the treated fuel test series. This audit's objective was to independently verify that the equipment, procedures, and calibrations were as specified in the test plan. The audit results were satisfactory. The field team leader conducted a performance evaluation audit of the DOES2 and gaseous emissions analyzers by introducing an audit gas with a known concentration of CO2 in air to the DOES2 sample train, both at the test duct (which challenged the whole system) and while bypassing the heated umbilical. The system operator knew only that the concentration would be between 0.5 and 4.0 percent CO2 in air. Table 3-4 provides the results. Table 3-4. Performance Evaluation Audit Date 08/19/2004 10/26/2004 Analyzer Response 2.10%C02 % difference" -16.0 System Response 2.10%CO2 1.97%C02 % difference" -16.0 -21.2 "Audit gas concentration was 2.50% CO2 in air The individual audits represent a single challenge at one concentration, so no statistical inferences may be drawn, but the audit results indicate that the system may have responded with a negative offset during both the baseline and treated fuel tests. The offsets are of similar magnitudes and it can be noted that the 3-5 ------- difference between the two audits (0.13% CO2) is less than the standard deviation of CO2 concentration for most notches. Some examples are as follows: Table 3-5. Mean CO2 Concentrations Baseline Notch 1 3 5 7 C02% 1.93 3.34 4.37 4.35 Sn-1% 0.08 0.13 0.09 0.16 Treated C02% 1.84 3.26 4.26 4.18 Sn-1% 0.10 0.12 0.22 0.22 This means that possible system response differences between the baseline and treated fuels were, in general, similar to or hidden within the observed sample variation. This did not impact the ability to perform the baseline / treated fuel comparisons. 3-6 ------- 4.0 TECHNICAL AND PERFORMANCE DATA SUPPLIED BY ENVIROFUELS, LP EnviroFuels, L.P. submitted the contents of this section. They are reproduced in their entirety except for minor changes intended to preserve editorial consistency (formatting, section numbering, etc.). In accordance to ETV program goals, this section provides an opportunity for Envirofuels, LP to respond to the verification results and to provide additional comments, in-house data, anecdotes, or other information regarding the Diesel Fuel Catalyzer, its applications, or effects not addressed elsewhere in this report. The GHG Center did not peer review the vendor's submittal and has not independently verified the statements made in this section. The information presented in this section does not affect the overall verification results. 4.1. TPM DETERMINATIONS EnviroFuels, L.P. has doubts about the validity of the TPM data reported in this verification because of questions about the LPSS calibrations. This conclusion is based upon the following observations: 1. In several hundred laboratory and field tests of the catalyzer, no case has been observed in which the particulate increased concomitant with a decrease in CO and THC emissions. Such a result would be inconsistent with the chemistry underlying the mechanism of catalyzer effectiveness. 2. The opacity measurements, made directly through exhaust stack gas sampling, are consistent with expected TPM decreases which would accompany lower CO and THC treated fuel emissions. The single scattering albedo for black carbon (soot) particles is about 0.5 [10], so substantial amounts of absorption and scattering by soot particles occur. With reference to the opacity measurements, then, it is difficult to conceive of additional particles which would lower the opacity; negative absorption (emission of light) is a physical improbability in this case and negative scattering is without physical meaning. 3. Filters from the ETV testing have been subjected to several tests that have failed to detect additional components of the particulate. SEM / EDS and XPS analyses at Rocky Mountain Laboratories revealed only increased particulate, most of which is soot, on the Notch 5 baseline filters. Less soot occurs on the Notch 5 treated filters, and little difference exists between the other components in the baseline and treated cases. The S content in both cases, for example, is about 0.1 atom% (uncorrected for filter material). Enthalpy, Inc., extracted filter samples from the baseline and treated fuel experiments and subjected the extracts to GC/MS analysis. Those analyses revealed very low percentages of hydrocarbons which similar experiments over the years have shown to be typical components of soot particles from the combustion of carbonaceous fuels [11, 12]. Thus, we have been able to find no evidence for components of the particulate emitted by the catalyzer-treated fuel that are not present in that emitted by the baseline fuel. The solution to this dilemma may lie in the determination of TPM with the LPSS. The two different LPSS operators selected significantly different sample dilution ratios for the baseline and treated fuel tests. The reported TPM emissions should not vary with different dilution ratios, 4-1 ------- assuming the same actual emission rates. EnviroFuels questions this assumption because of the apparent correlation between the TPM and dilution ratios as discussed in Appendix A. Wall effects and sedimentation, functions of aerosol mass density, number density and flow rate, were almost certainly different in the two cases. Although later laboratory work appears to show no correlation effects (see Appendix A), field conditions varied widely by comparison. Different engine type, size, ambient conditions, and exhaust gas temperatures all may have induced changes in the field-reported TPM emission rates which would not have been observed in the laboratory. 4.2. BASELINE FUEL CONSUMPTION MEASUREMENT FOR NOTCHES 7 AND 8 The EMD engine for the EnviroFuels, L.P. ETV test used mechanical fuel injection. Fuel injection into the cylinders of the engine is a direct function of the RPM of the engine and a mechanically adjusted injector rack setting for each individual fuel injector. The injectors inject approximately the same amount of fuel with each stroke unless the injector rack length is shortened by the electro-hydraulic control system of the engine's governor to reduce the power output of the engine. The governor receives electrical control signals from the locomotive's main generator output control system and controls the rack setting as required to produce the requested power. The governor also balances the rack settings against the electrical system's power limiting parameters and the engine's mechanical limitations. The engine power output is a direct result of the amount of fuel injected. During baseline testing the engine showed the correlation among the increase in fuel, RPM change and power output change for notches 1 to 7 shown in Figure 4-1. The power increase and RPM increase between notch 7 and notch 8 with no related fuel consumption increase is inconsistent with the operation of this type of EMD engine and cannot be explained. 70.0% Notch Setting Figure 4-1. Baseline Percent Change from Previous Notch 4-2 ------- This inconsistency—more power without an increase in fuel consumption under the same conditions—occurred in each of the six baseline runs. Keeping in mind that the engine operated in each notch for at least 6 minutes, the data show that on the same day, typically under the same weather conditions, using the same fuel, the engine's power output increased by ten percent with no change in fuel consumption. It is not possible to explain this change with the data available. If the notch 8 efficiency was, in fact, the same as notch 7 efficiency, then the reported fuel economy improvement for notch 8 would be approximately 7 percent instead of 0 percent. Similarly, fuel efficiency for the Line Haul Duty Cycle would be approximately 9 percent instead of 5 percent. 4-3 ------- 4-4 ------- 5.0 REFERENCES [1] Emissions of Greenhouse Gases in the United States 2002, Energy Information Administration, Washington, DC. 2003 [2] Transportation Energy Data Book: Edition 24, Oak Ridge National Laboratory, Oak Ridge, TN. 2004 [3] Test and Quality Assurance Plan—EnviroFuels Diesel Fuel Catalyzer Fuel Additive, SRI/USEPA- GHG-QAP-33, August, 2004 [4] Title 40 CFR 92—Control of Air Pollution from Locomotives and Locomotive Engines, Environmental Protection Agency, Washington, DC. Adopted at Federal Register Vol. 63, No. 73, April 16, 1998 [5] Title 40 CFR 86, Subpart N—Emission Regulations for New Otto-Cycle and Diesel Heavy-Duty Engines; Gaseous and Paniculate Exhaust Test Procedures, Environmental Protection Agency, Washington, DC. Adopted at 62 FR 47135, 5 September 1997 [6] On-Road Emissions of Paniculate Polycyclic Aromatic Hydrocarbons and Black Carbon from Gasoline and Diesel Vehicles, A. H. Miguel, T. W. Kirchstetter, R. A. Harley, S. V. Hering, Environmental Science and Technology, Vol. 32, No. 4, pp 450 - 455. 1998 [7] PM Measurement Artifact: Organic Vapor Deposition on Different Filter Media, R. E. Chase, G. J. Duszkiewicz, J. F. O. Richert, D. Lewis, M. M. Marcq, N. Xu, Society of Automotive Engineers, Paper No. 2004-01-0967, presented at the SAE World Congress, Detroit, MI. 2004 [8] Statistics Concepts and Applications, D. R. Anderson, E. J. Sweeney, T. A. Williams. West Publishing Company, St. Paul, MN. 1986 [9] Significance of Errors in Stack Sampling Measurements, R. T. Shigehara, W. F. Todd, W. S. Smith, National Air Pollution Control Administration. Presented at the Annual Meeting of the Air Pollution Control Association, St. Louis, MO. 1970 [10] Black Carbon in The Environment, E. D. Goldberg, Wiley-Interscience, New York, NY. 1985, pp 134-136 [11] The Structure ofHexane soot II: Extraction Studies, Akhter, M.S., Chughtai, A.R., Smith, D.M., AppliedSpectroscopy, Vol. 39, 154-167, 1985. [12] Effects of Air/fuel Combustion Ratio on the Polycyclic Aromatic Hydrocarbon Content of Carbonaceous Soots from Selected Fuels, Jones, C.C., Chughtai, A.R., Murugaverl, B., Smith, D.M., Carbon, Vol. 42, 2471-2484, 2004 5-1 ------- ------- Appendix A Post-Test LPSS Correlations ------- Introduction The TPM results in Sections 2.1 and 2.3 showed increased emissions even though all gaseous and visible emissions (smoke opacity) decreased significantly. The results are valid and the increases are reported as real. This is because "mass tends to be conserved during the dilution and sampling process" [Al], but consideration of the factors that could have affected the results is useful. TPM as Related to Opacity The increased TPM emissions at lower opacity is of interest. Opacity at higher levels can have a known relationship to particulate emissions if the particle size distribution is known accurately [A2]. The relationship breaks down quickly at low opacity levels [A3], such as those seen during the test campaign, and if the size distribution changes. Fuel sulfur content [A4], sampling conditions such as residence times combined with ultimate dilution ratios [A5, A6, A7], sulfur saturation ratios experienced in the sampling system [A6], and other factors all have synergistic effects on particle size distribution and number. These changes may have affected light scattering and the resultant smoke visibility [Al]. Exhaust gas temperatures, for example, were lower during the treated fuel tests (see Table 2-6), which could have had unknown effects on the collected TPM. Exhaust Gas and Engine Intake Air Temperature Changes Many factors, other than use of the fuel catalyzer, could have contributed to the increased TPM emissions. For example, Table 2-6 showed that the exhaust gas and engine intake air temperatures were lower for the treated fuel tests. It is possible that the temperature changes could have affected the particulate emissions, such as by changing condensation behavior. The quantitative effects, however, are unknown. LPSS Operations LPSS operations may have introduced sampling artifacts even though the equipment met the DQIs listed in Tables 3-1 through 3-3. Table 2-19 showed that operators used different dilution ratios for the baseline and treated fuel tests. Figure A-l shows that the LPSS response appears to have changed at different dilution ratios, especially in the higher operating notches. This effect became more pronounced at higher TPM emission rates and lower tunnel flow rates, as shown by the changing slopes of the trend lines. Al ------- 30 25 20 I c i 0) Q. (/) re O 10 • • R2=0.4426x 7 / / /• • / * R2 = 0.852AX X R2= 0.7023 • v^ •" R2 = 0.1863 izi R2 = o: «^-*^^ «r>^ *R^O R" * Y * X R2 = + ^ T ^624-^ .B87S- = 0.0249 X X 0.5455 •If. 325 375 475 425 Liters per Minute Figure A-l. LPSS Dilution Tunnel Flow verses Reported TPM Emissions The correlations shown in Figure A-l, however, do not necessarily prove that the changing sample dilution ratios actually caused the reported TPM to change. For example, TPM as reported by the LPSS also appears to be correlated to changing exhaust gas and inlet air temperatures. While the changing LPSS response shown here is not sufficient to invalidate the TPM data, the GHG Center or ETC cannot definitively state whether these are sampling artifacts, effects of engine operations changes, due to other factors, or truly representative of the particulate emissions. Note that ETC performed post-test laboratory comparisons between the LPSS and a constant volume sampling system. The results, quoted below, indicate little correlation between dilution ratios and reported TPM. As a comparison, gaseous emission rates as reported by the DOES2 appear to have little dependence on the dilution tunnel flow. Figure A-2 shows the DOES2 system response for CO2. A2 ------- 20000 - 0] 15000 - c i °- 5 O 10000 - 5000 - . _f >4i^ _^^ _^^ R^TZTC- R2 = 085^1 ====^ KX H- 5^ ^ J16985- « Baseline Notch 8 • Treated Notch 8 Baseline Notch 5 XTreated Notch 5 X Baseline Notch 3 • Treated Notch 3 + Baseline Notch 1 -Treated Notch 1 58 60 62 68 70 72 64 66 Liters per Minute Figure A-2. DOES2 Dilution Tunnel Flow verses Reported CO2 Emissions ETC performed a series of correlation studies in response to these concerns. The following memorandum presents the results of the study. A3 ------- Date: 10.05.2005 Emissions Research and Measurement Division Environment Canada Environmental Technology Centre 335 River Road Ottawa Ontario Canada K1A OH3 Greenhouse Gas Technology Center Southern Research Institute Attention: Bob Richards Subject: Correlation and Validation of the Locomotive Particulate Sampling System (LPSS) Technology Dear Sir: The Emissions Research and Measurement Division's (ERMD) LPSS has recently completed a follow-up cross correlation study comparing the test system used for particulate collection during the locomotive field testing, known as the LPSS, and the ERMD's Heavy Duty Engine Emissions Test Cell #1 (HD cell) which is used to conduct diesel emissions research and technology verifications. This testing was conducted on May 6th 2005. The LPSS was designed to collect diluted exhaust samples in order to measure total particulate matter (TPM). The HD cell employs constant volume sampling (CVS) which conforms to the Code of Federal Regulations (CFR) Title 40 Part 86. The LPSS was tested in an "as found" condition meaning that no calibration settings were altered or verified prior to testing. A leak check was performed prior to the commencement of testing to replicate field procedures. This letter summarizes the observations and results that were obtained from this validation work. Heavy Duty Cell Correlation A Mack AI 300A engine running on an ultra low sulfur diesel (ULSD) fuel was used to generate the exhaust emissions for the correlation between the heavy-duty test cell equipment and the LPSS. The engine was tested using a steady state mode with an engine set point of 900rpm and 50% throttle. Double Emfab 70mm filters were used to collect the TPM and these filters were allowed to stabilize in a humidity and temperature controlled room before and after testing. The engine air intake was measured using a 2500 scfm Laminar Flow Element (LFE) in order to calculate the mass emission rate. Due to the large amount of exhaust the LPSS draws, testing for the LPSS and HD cell does not occur simultaneously so as not to affect the HD cell results used for comparison. Sample collection took place in the following order: HD cell #1, LPSS #1-7, HD cell #2 and #3. Since this study was initiated in order to compare the mass emission rates at different tunnel flow set points, three tests were completed using the same tunnel flow rate as used in the 'Treated' test series during the field testing, followed by three repeats using the same tunnel flow rates as seen in the 'Baseline' testing portion of the field project. A seventh test was performed in order to gather data on a mid range setting in the event that any trends did appear. The following tables present the results of testing. A4 ------- May 6th, 2005 testing LPSS Steady State Test Results Test run ID LPSS 1ST #1 LPSS 1ST #2 LPSS 1ST #3 LPSS 1ST #4 LPSS 1ST #5 LPSS 1ST #6 LPSS 1ST #7 Average Stdev cov LPSS Tunnel flow set point (scfm) 13.0 13.0 13.0 17.0 17.0 17.0 14.7 Measured LPSS Tunnel flow (slpm) 369.72 368.77 369.26 467.67 464.99 464.61 420.98 Measured LPSS Exhaust flow (slpm) 68.01 67.10 67.55 161.38 158.28 157.03 119.22 Engine Air Intake Flow (scfm) 190.80 189.40 190.77 191.31 191.31 193.65 192.14 Test Duration (sees) 480.00 363.00 360.00 360.00 360.00 360.00 359.00 Mass emission rate g/bhp-hr 0.1422 0.1295 0.1269 0.1307 0.1264 0.1284 0.1206 0.1292 0.0066 5.1% March 9th. 2004 testing HD Cell Steady State Test results Test run ID HD cell #1 HD cell #1 HD cell #1 Average % difference from LPSS Total flow through CVS (SCF) 28198 13970 13967 Test Duration (sees) 600 300 300 Mass emission rate g/bhp-hr 0.1223 0.1311 0.1308 0.1281 0.86% Note that the% difference = (LPSS- HD cell)/HD cell Leak Check Prior to correlation testing a leak check was conducted on the LPSS system including the heated line. The leak check was conducted under a vacuum and showed a leak in the range of 0.41 to 0.25 1pm. This leak check passes the standard set out in the Locomotive test plan. Recommendations and Observations 1. The mass emission rates stated above do not include a correction for tunnel background. A tunnel blank was taken for the LPSS, however the number exceeded all tunnel blanks seen in the field by three times and therefore it was not considered representative of the sampling conditions seen in the field. It is theorized that the tunnel blank was compromised by the set up procedures and the leak check of the LPSS. During the set-up double filters were not installed thereby allowing particulate to collect on the filter holder. The filter holder was cleaned prior to LPSS A5 ------- TST # 1. Also, no tunnel background was taken for the HD cell and it would not be appropriate to correct one sample for tunnel background and not the other. 2. The LPSS correlated to the Heavy Duty Test cell to within less then a 1% difference when looking at the average mass emission rates of the two test systems. 3. Since the main goal of the correlation testing was to verify whether the tunnel flow rate through the LPSS artificially affects the mass emission rate, it is important to note that when comparing the flow rates at the 13.0 and 17.0 set points, with the corresponding mass emission rates - no trends evolved as seen in the following chart. An ANOVA test was performed and confirmed that there was no statistically significant difference between the mass emission rates at the two set points. Total Tunnel Flow vs. g/bhp-hr 0.1450 ^ 0.1400 »_ £ Q. .Q ™ 0.1350 13 O 0.1300 I LLJ 0.1250 0.1200 1st test of comparison study 350.00 370.00 390.00 410.00 430.00 Tunnel Flow SCFM 450.00 470.00 490.00 Figure A-3. LPSS Correlation Data If you require more information, please do not hesitate to contact me. Sincerely, Jillian Hendren, ERMD Environment Canada c.c. Fred Hendren, Chief ERMD Greg Rideout, Head Toxic Emissions Research & Field Studies, ERMD Chris Beregszaszy, Project Engineer, Heavy Duty test cell A6 ------- Appendix A References [Al] Engines and Nanoparticles: A Review, D. B. Kittleson, Ph.D., Journal of Aerosol Sciences, Vol. 29, No. 5/6, pp. 575-588. 1998 [A2] Plume Opacity and Paniculate Mass Concentration, Pilat, M. J., Ensor, D. S., Atmospheric Environment, Vol. 4, pp. 163-173. 1970 [A3] Plume Opacity Related to Particle Mass Concentration and Size Distribution, Thielke, J. F., Pilat, M. J., Atmospheric Environment, Vol. 12, pp. 2349-2447. 1978 [A4] Diesel Fuel Effects on Locomotive Exhaust Emissions, S. G. Fritz, P.E., T. Brasil, P.E., International Council on Combustion congress, Hamburg, Germany. 2001 International Council on Combustion Engines (CIMAC), Paper No. 7A-05, presented at the 23rd CIMAC [A5] Evolution of Particle Number Distribution Near Roadways—Part I: Analysis of Aerosol Dynamics and its Implications for Engine Emission Measurement, K. M. Zhang, A. S. Wexler, Atmospheric Environment, No. 38, pp 6643 - 6653. 2004 [A6] Review of Diesel Paniculate Matter Sampling Methods—Final Report, D. B. Kittleson, Ph.D., M. Arnold, W. F. Watts, Jr., Ph.D, University of Minnesota, Minneapolis, MN. 1999 [A7] Paniculate Mass Measurements of Heavy-Duty Diesel Engine Exhaust Using 2007 CVS PM Sampling Parallel to QCM and TEOM—Final Report, I. A. Khalek, Ph.D., U.S. Environmental Protection Agency, Ann Arbor, MI. 2003 A7 ------- Appendix B Test Run Results ------- Table B-l. Baseline Fuel Consumption (carbon balance method), gph Run / Notch 1 2 3 4 5 6 Mean Std Dev Lo Idle 4.10 4.36 5.15 4.52 5.01 3.02 4.36 0.77 Hi Idle 4.88 5.13 5.84 5.33 5.77 4.82 5.30 0.44 1 19.48 20.39 22.46 20.98 23.95 21.29 21.43 1.58 2 34.73 33.35 35.73 34.85 33.59 34.70 34.49 0.88 3 59.64 57.01 56.41 64.31 62.78 62.13 60.38 3.22 4 73.19 75.00 78.68 77.43 77.46 80.43 77.03 2.59 5 97.72 97.13 97.08 102.24 97.41 100.46 98.67 2.16 6 144.48 128.30 145.27 148.75 152.75 142.84 143.73 8.34 7 150.91 147.41 159.59 153.81 162.07 152.11 154.32 5.52 8 162.36 154.51 156.75 154.76 153.00 144.60 154.33 5.78 Table B-2. Treated Fuel Consumption (carbon balance method), gph Run / Notch 1 2 o J 4 5 6 Mean Std Dev Lo Idle 4.63 4.85 4.68 5.00 5.23 5.03 4.90 0.23 Hi Idle 5.01 5.45 4.97 5.25 5.66 5.44 5.30 0.27 1 18.55 20.68 18.61 N/A 20.27 21.22 19.87 1.22 2 29.75 32.46 31.24 31.86 32.49 34.38 32.03 1.54 3 52.13 53.04 54.49 54.56 55.68 56.40 54.38 1.59 4 70.60 69.30 73.81 72.75 72.51 67.96 71.16 2.25 5 94.50 92.04 98.56 100.94 97.44 91.17 95.77 3.84 6 125.26 125.00 138.74 141.38 136.33 128.47 132.53 7.17 7 143.57 155.92 157.71 163.67 159.43 147.10 154.57 7.68 8 142.44 152.31 159.82 162.13 154.03 153.52 154.04 6.88 Table B-3. Baseline bhp Run / Notch 1 2 3 4 5 6 Mean Std Dev 1 290.7 292.4 288.7 282.1 285.5 286.6 287.7 3.7 2 504.3 503.4 503.9 499.8 504.5 494.4 501.7 4.0 3 874.7 868.3 866.7 865.2 863.9 858.7 866.3 5.3 4 1165.6 1162.0 1157.2 1151.7 1150.2 1157.9 1157.4 5.9 5 1568.2 1551.5 1559.0 1557.3 1551.9 1536.1 1554.0 10.6 6 2387.2 1974.3 2299.3 2322.1 1949.0 1958.9 2148.5 207.8 7 2686.8 2654.1 2698.5 2667.4 2682.3 2661.9 2675.2 16.8 8 2971.9 2970.2 2973.1 2964.3 2938.2 2951.3 2961.5 13.9 Bl ------- Table B-4. Treated bhp Run / Notch 1 2 o 3 4 5 6 Mean Std Dev 1 297.6 298.3 280.8 294.4 284.0 304.3 293.2 9.0 2 531.1 529.4 524.0 526.6 522.8 577.6 535.2 21.0 3 913.8 916.3 902.6 905.8 903.6 962.5 917.4 22.8 4 1229.0 1224.2 1214.6 1217.8 1218.0 1254.6 1226.4 14.8 5 1664.1 1649.2 1623.3 1630.4 1636.2 1669.0 1645.4 18.6 6 2339.0 2341.8 2270.8 2278.7 2333.7 2354.2 2319.7 35.6 7 2889.4 2877.6 2822.6 2882.3 2877.7 2869.2 2869.8 24.1 8 2909.0 2902.1 2912.6 2904.0 2901.7 2901.1 2905.1 4.6 Table B-5. Baseline CO g/m Run/Notch 1 2 3 4 5 6 Mean Std Dev Lo Idle 3.6833 5.2487 5.1983 5.0392 5.2148 5.2216 4.9343 0.617392 Hi Idle 4.7589 5.5454 6.2430 6.0248 6.4966 6.3419 5.9018 0.649988 1 3.5669 4.7024 4.9505 5.1139 5.5656 5.4401 4.8899 0.720904 2 4.8299 5.1756 5.4637 5.2686 5.5574 6.1580 5.4089 0.446195 3 13.8269 14.1493 13.2343 14.5596 14.2929 15.5453 14.2680 0.773856 4 33.6921 40.5721 35.5568 38.5811 38.0594 43.7638 38.3709 3.574372 5 51.0595 78.3031 96.7614 92.0241 81.3535 91.9923 81.9156 16.67084 6 116.6610 110.0549 129.6962 122.2616 164.7529 117.4745 126.8169 19.69553 7 135.9270 125.0941 75.1477 131.4441 78.3384 73.7032 103.2758 30.40787 8 48.7499 47.1276 51.2079 48.1980 51.1965 47.4468 48.9878 1.806821 Table B-6. Treated CO g/m Run/Notch 1 2 3 4 5 6 Mean Std Dev Lo Idle 4.2791 2.9453 3.2772 2.9767 3.1058 3.0177 3.2670 0.5099628 Hi Idle 4.4962 3.8042 3.8533 4.3920 3.8850 3.9548 4.0643 0.300078 1 3.4194 3.0084 3.6239 — 3.4814 3.1600 3.3386 0.249643 2 3.3822 3.7385 4.1359 4.7185 4.0745 3.8463 3.9826 0.449899 3 8.3766 8.1492 9.9807 10.2752 9.6127 11.4523 9.6411 1.234798 4 17.9507 18.7042 22.4876 22.6223 20.2513 19.1631 20.1965 1.973586 5 49.9118 49.8591 57.3790 59.2268 51.6940 45.1399 52.2018 5.234801 6 76.9784 86.8480 116.5676 112.5722 82.8139 81.4676 92.8746 17.144693 7 39.2637 53.5400 75.8448 58.8581 52.7315 41.7008 53.6565 13.19347 8 17.4043 22.8939 27.4145 27.9258 24.6798 21.1760 23.5824 3.979641 B2 ------- Table B-7. Baseline CO2 g/m Run/Notch 1 2 3 4 5 6 Mean Std Dev Loldle 589.91 624.58 740.32 647.96 721.56 430.98 625.88 111.372 Hildle 700.77 722.77 838.43 764.45 828.59 690.63 757.61 64.105 1 2837.84 2968.35 3270.43 3054.82 3488.05 3100.02 3119.92 230.368 2 5063.71 4857.69 5207.93 5078.92 4897.19 5057.62 5027.17 129.021 3 8686.95 8304.13 8217.08 9355.64 9148.02 9051.08 8793.82 467.147 4 10634.24 10889.92 11434.16 11246.40 11253.84 11677.90 11189.41 375.189 5 14191.49 14062.89 14024.48 14786.20 14099.30 14528.50 14282.14 306.881 6 20911.82 18559.33 21005.17 21525.32 22046.87 20673.11 20786.94 1197.586 7 21818.06 21323.99 23179.52 22248.56 23539.76 22092.45 22367.06 838.351 8 23628.23 22482.71 22803.38 22519.25 22257.26 21039.57 22455.07 842.054 Table B-8. Treated CO2 g/m Run/Notch 1 2 o 3 4 5 6 Mean Std Dev Loldle 665.64 700.86 675.99 722.48 755.90 728.31 708.20 34.018 Hildle 719.25 807.19 716.69 756.53 817.20 786.78 767.27 43.466 1 2703.02 3015.80 2711.22 — 2954.74 3094.46 2895.85 179.287 2 4337.98 4734.76 4556.08 4644.63 4738.98 5017.46 4671.65 225.177 o J 7602.14 7735.14 7944.08 7953.80 8118.21 8222.91 7929.38 231.277 4 10283.03 10092.16 10746.60 10590.92 10559.64 9899.31 10361.94 326.349 5 13722.95 13363.56 14304.83 14648.39 14151.28 13248.05 13906.51 553.355 6 18169.20 18116.75 20075.83 20467.60 19779.93 18636.06 19207.56 1026.048 7 20904.99 22680.87 22908.92 23806.95 23198.02 21419.53 22486.55 1105.048 8 20776.47 22202.88 23292.69 23634.06 22455.21 22390.62 22458.66 997.698 Table B-9. Baseline NOx g/m Run/Notch 1 2 3 4 5 6 Mean Std Dev Loldle 14.165 16.568 18.370 17.112 18.707 16.799 16.953 1.6160 Hildle 13.625 19.040 19.864 20.004 19.809 19.881 18.704 2.5121 1 53.652 59.342 66.538 64.244 70.694 66.919 63.565 6.1235 2 93.655 90.811 102.611 97.897 96.804 104.227 97.668 5.1259 3 137.097 143.971 142.838 160.618 157.498 159.057 150.180 10.0493 4 176.822 179.990 181.156 190.084 185.876 195.031 184.827 6.8386 5 215.371 219.196 222.406 237.298 222.753 236.452 225.579 9.1494 6 379.667 340.091 375.733 414.008 373.248 391.229 378.996 24.2206 7 395.722 394.655 466.166 426.255 486.428 462.435 438.610 38.8267 8 458.255 446.234 454.432 514.568 450.324 445.007 461.470 26.4827 B3 ------- Table B-10. Treated NOx g/m Run/Notch 1 2 3 4 5 6 Mean Std Dev Loldle 15.262 15.583 15.817 17.204 17.190 16.409 16.244 0.8280 Hildle 15.625 17.070 17.118 17.997 18.074 17.312 17.199 0.8848 1 54.108 59.814 54.460 — 57.616 62.647 62.576 3.6176 2 90.139 91.974 89.105 94.349 91.510 115.154 95.372 9.8538 3 132.127 135.388 139.988 131.202 130.413 149.787 136.484 7.4051 4 168.476 169.013 178.664 177.832 176.999 190.364 176.891 7.9805 5 222.850 224.555 233.974 243.482 233.204 225.746 230.635 7.8009 6 367.297 352.938 369.272 389.670 393.657 388.712 376.924 16.1740 7 444.469 459.500 444.145 477.454 470.761 465.269 460.266 13.7157 8 429.372 437.856 450.800 461.138 447.914 468.620 449.284 14.4614 Table B-ll. Baseline THC g/m Run/Notch 1 2 3 4 5 6 Mean Std Dev Loldle .2062 .4721 .5520 .5156 .0045 0.8870 1.2729 0.283501 Hildle .5255 .6567 .9256 .8395 .5704 .3099 1.6379 0.222954 1 1.5489 1.5481 1.8339 1.6666 1.6203 1.4146 1.6054 0.140776 2 2.2743 3.3546 2.5044 2.4962 1.5487 1.8445 2.3371 0.625572 3 3.4425 3.0660 3.2651 7.5950 2.9783 2.8440 3.8651 1.839476 4 4.4934 4.1375 4.5536 4.6910 3.7965 4.0305 4.2838 0.348011 5 5.1786 5.0873 5.5659 5.5371 4.8631 4.9261 5.1930 0.299661 6 9.3959 8.6909 9.7531 9.8553 8.8179 8.5805 9.1823 0.558704 7 10.7570 10.4446 11.7961 10.9244 10.9227 10.1843 10.8382 0.551578 8 11.0834 10.7893 11.3099 10.5140 10.6174 9.0942 10.5680 0.780065 Table B-12. Treated THC g/m Run/Notch 1 2 3 4 5 6 Mean Std Dev Loldle 1.5523 1.1962 0.9160 1.0807 1.0355 0.6626 1.0739 0.296453 Hildle .7537 .4218 .2533 .3962 .1564 0.8423 1.3040 0.304003 1 1.1909 1.1395 1.0892 — 1.2075 0.9249 1.1104 0.113574 2 1.9441 1.7648 1.5603 1.8203 1.5540 1.1770 1.6367 0.271536 3 2.1984 2.3754 2.2673 2.3170 2.3357 1.9647 2.2431 0.14942 4 3.6081 3.6795 3.4340 3.2890 3.2874 2.4415 3.2899 0.445811 5 4.8961 4.9269 4.9373 5.3224 4.7254 3.7850 4.7655 0.518782 6 7.5692 7.6627 8.4216 8.5260 7.5571 6.4722 7.7015 0.741513 7 7.8794 10.1692 9.7386 9.8726 9.5527 7.4780 9.1151 1.137721 8 7.2715 9.6396 9.9794 8.6835 8.7907 7.4071 8.6286 1.114432 B4 ------- Table B-13. Baseline TPM g/m Run/Notch 1 2 3 4 5 6 Mean Std Dev Loldle 0.22354 0.20090 0.16834 0.17574 0.33802 0.11788 0.20407 0.074617 Hildle 0.29247 0.30205 0.27061 0.30339 0.12798 0.25930 0.074572 1 0.81087 0.86890 0.57652 0.84171 0.77358 — 0.77431 0.11613 2 1.45507 1.47894 0.94248 1.32253 1.22327 — 1.28446 0.217413 o J 3.67758 3.77941 2.86055 3.67139 3.71691 4.19927 3.65085 0.435285 4 5.06325 5.71156 4.23285 5.43872 5.22991 4.22765 4.98399 0.62276 5 6.87389 7.40327 5.82316 7.14004 6.94766 5.55494 6.62383 0.751662 6 7.91973 10.74562 6.81528 9.84217 8.81205 8.03041 8.69421 1.422028 7 8.90640 9.90038 8.07628 9.09528 8.33556 6.66067 8.49576 1.101835 8 9.20165 10.97464 8.07667 7.81088 8.70294 7.40686 8.69561 1.28661 Table B-14. Treated TPM, g/m Run/Notch 1 2 3 4 5 6 Mean Std Dev Loldle 0.2382 0.2424 0.2955 0.5564 0.1135 0.2728 0.2865 0.1464942 Hildle 0.2896 0.3689 0.2616 0.4551 0.3214 0.1510 0.3080 0.102664 1 1.5535 1.0970 0.8340 1.3450 1.0306 0.9840 1.1407 0.262583 2 2.1041 — 1.6803 2.4339 2.1552 2.5031 2.1753 0.325892 3 4.7730 — 5.0635 5.5492 5.8125 6.3120 5.5020 0.607955 4 6.3857 7.3891 7.2658 8.0061 7.7994 8.2087 7.5091 0.656709 5 8.3957 10.6331 10.1478 11.0248 11.2015 11.5060 10.4848 1.126778 6 13.9702 15.0642 14.4036 18.9022 17.4596 18.2054 16.3342 2.1114216 7 18.3239 21.8134 19.4659 23.4480 25.0533 25.8815 22.3310 3.0265 8 18.6820 20.6544 20.6783 23.7695 26.3077 27.0281 22.8533 3.381343 B5 ------- Table B-15. Peak Opacity Baseline Notch Lo Idle Hi Idle 1 2 3 4 5 6 7 8 Mean 4.01 3.99 9.86 14.46 18.76 25.34 28.98 28.98 19.98 10.78 Std Dev 4.46 2.34 2.75 3.11 3.42 4.24 5.98 6.14 6.89 3.97 Treated Notch Lo Idle Hi Idle 1 2 3 4 5 6 7 8 Mean 4.42 3.81 8.84 11.87 13.59 15.45 15.98 17.88 11.04 7.52 Std Dev 2.43 1.83 1.35 1.73 1.11 1.56 2.14 1.96 2.67 1.46 Table B-16. 30-Second Peak Opacity Baseline Notch Lo Idle Hi Idle 1 2 3 4 5 6 7 8 Mean 3.48 3.04 7.99 8.76 15.55 21.91 25.48 25.73 14.62 5.65 Std Dev 4.40 2.48 2.26 2.30 3.00 3.88 5.16 5.38 4.36 3.48 Treated Notch Lo Idle Hi Idle 1 2 3 4 5 6 7 8 Mean 4.18 2.58 7.20 7.54 11.68 13.52 14.15 13.47 8.39 3.86 Std Dev 2.33 2.17 1.34 0.91 1.14 1.50 2.03 1.00 1.63 1.38 B6 ------- Table B-17. Steady-State Opacity Baseline Notch Lo Idle Hi Idle 1 2 3 4 5 6 7 8 Mean 3.78 3.75 7.11 8.32 14.66 21.38 24.61 22.22 11.10 4.39 Std Dev 4.57 2.32 2.31 2.43 2.79 3.50 5.07 5.16 2.72 3.46 Treated Notch Lo Idle Hi Idle 1 2 3 4 5 6 7 8 Mean 4.31 2.75 6.05 7.16 11.02 13.52 14.22 10.48 5.88 3.53 Std Dev 2.40 2.67 1.77 0.96 1.09 1.53 2.34 2.11 0.84 1.77 Table B-18. Baseline RPM Run/ Notch 1 2 3 4 5 6 Averages Std Dev Loldle 254 254 253 254 253 254 0.49 Idle 321 320 320 319 319 320 0.75 1 304 302 303 297 296 300 3.26 2 384 383 383 383 382 386 384 1.26 3 492 489 491 492 495 493 492 1.83 4 565 569 569 566 567 569 568 1.61 5 653 651 651 651 650 651 651 0.90 6 729 730 732 737 731 731 732 2.56 7 828 825 830 829 829 829 828 1.60 8 910 910 914 911 913 912 1.62 B7 ------- Table B-19. Treated RPM Run/ Notch 1 2 3 4 5 6 Averages Std Dev Loldle 254 254 253 253 253 254 254 0.55 Idle 320 318 318 319 317 320 319 1.21 1 319 318 317 316 316 316 317 1.26 2 389 388 388 387 387 387 388 0.82 3 499 498 498 499 498 496 498 1.10 4 573 574 574 573 573 573 573 0.52 5 656 655 656 652 653 655 655 1.64 6 733 733 732 733 733 732 733 0.52 7 830 830 — 830 831 830 830 0.45 8 913 913 915 914 915 916 914 1.21 Table B-20. Baseline Main Generator Voltage, V Run/ Notch 1 2 3 4 5 6 Loldle 2.9 3.4 3.1 3.4 3.2 2.7 Idle 3.7 3.9 3.9 3.9 3.9 3.7 Averages Std Dev 1 263.3 259.2 262.3 258.7 260.4 257.4 260.2 2.2 2 343.2 342.3 343.2 341.4 343.0 339.8 342.2 1.3 3 454.1 452.0 452.3 451.5 451.0 450.0 451.8 1.4 4 525.2 520.2 524.1 522.2 521.4 520.1 522.2 2.1 5 606.0 607.5 604.8 603.9 603.2 605.5 605.2 1.6 6 754.1 681.4 739.6 743.4 677.1 679.7 712.6 36.7 7 797.6 794.3 803.4 796.4 796.4 796.4 797.4 3.1 8 840.3 841.0 840.7 840.5 839.3 839.7 840.3 0.7 Table B-21. Baseline Main Generator Current, A Run/ Notch 1 2 3 4 5 6 Loldle 6.0 8.5 6.9 8.5 7.2 7.2 Idle 8.5 11.0 9.6 11.0 9.7 9.7 Averages Std Dev 1 804.0 792.1 801.3 791.0 796.0 786.4 795.1 6.6 2 1046.1 1041.6 1045.2 1040.3 1045.3 1034.5 1042.2 4.4 3 1375.7 1366.8 1367.3 1366.8 1365.4 1360.9 1367.1 4.8 4 1583.6 1566.4 1574.7 1573.2 1571.0 1566.4 1572.5 6.4 5 1818.8 1819.7 1811.6 1811.0 1807.1 1814.3 1813.7 4.8 6 2235.9 2030.2 2192.7 2205.7 2024.7 2025.1 2119.0 102.2 7 2358.4 2339.6 2367.3 2349.8 2339.3 2346.5 2350.2 11.0 8 2467.4 2468.9 2467.0 2469.7 2447.4 2464.1 2464.1 8.4 B8 ------- Table B-22. Treated Main Generator Voltage, V Run/ Notch 1 2 3 4 5 6 Loldle 1.9 2.4 2.6 2.7 2.7 2.4 Idle 2.7 3.4 3.4 3.5 3.7 3.4 Averages Std Dev 1 266.5 266.9 259.0 265.2 261.0 270.4 264.8 4.2 2 351.0 350.5 348.8 349.9 349.2 367.6 352.8 7.3 3 463.8 464.5 461.0 462.4 462.2 476.5 465.1 5.7 4 539.5 539.1 536.8 537.5 538.5 546.7 539.7 3.6 5 625.8 623.8 622.7 624.8 626.5 633.9 626.2 4.0 6 753.1 748.4 741.4 743.1 747.4 756.5 748.3 5.7 7 833.1 833.4 822.6 835.0 834.4 831.7 831.7 4.6 8 835.4 836.4 837.8 836.4 836.3 834.7 836.1 1.1 Table B-23. Treated Main Generator Current, A Run/ Notch 1 2 3 4 5 6 Loldle 2.8 4.6 5.0 3.7 5.0 4.2 Idle 5.1 7.2 7.2 6.0 7.2 6.1 Averages Std Dev 1 817.8 819.3 792.4 809.4 796.1 826.8 810.3 13.6 2 1074.4 1073.1 1065.0 1064.5 1062.6 1120.7 1076.7 22.1 3 1409.5 1412.3 1398.2 1398.4 1398.1 1446.4 1410.5 18.7 4 1633.3 1630.5 1621.0 1620.5 1622.2 1651.9 1629.9 12.0 5 1885.4 1875.6 1870.4 1873.4 1877.5 1899.3 1880.2 10.6 6 2241.7 2224.8 2205.0 2206.4 2222.0 2251.9 2225.3 18.7 7 2463.6 2460.0 2430.4 2456.2 2457.1 2460.0 2454.6 12.1 8 2469.0 2466.1 2466.2 2462.4 2461.0 2467.8 2465.4 3.1 Table B-24. Baseline Fan Hp Run/ Notch 1 2 o J 4 5 6 Averages Std Dev 1 0.0 8.9 0.0 0.0 0.0 8.3 2.9 4.4 2 11.2 11.2 11.2 11.0 11.0 11.1 11.1 0.1 3 16.0 16.2 16.2 15.9 15.8 16.4 16.1 0.2 4 21.5 39.3 21.3 20.6 20.9 38.9 27.1 9.3 5 51.6 27.7 51.8 52.5 51.7 27.2 43.8 12.6 6 66.5 68.5 67.2 66.3 62.8 68.8 66.7 2.2 7 95.4 95.4 81.1 94.3 119.4 96.5 97.0 12.4 8 113.4 110.9 112.9 110.6 112.7 111.9 112.1 1.1 B9 ------- Table B-25. Treated Fan Hp Run/ notch 1 2 3 4 5 6 Averages Std Dev 1 0.0 0.0 0.0 1.3 0.0 0.0 0.2 0.5 2 16.4 16.7 16.1 17.9 16.1 16.9 16.7 0.7 3 21.4 21.8 20.9 22.8 21.1 21.3 21.5 0.7 4 25.3 25.1 24.7 26.4 24.9 24.7 25.2 0.7 5 53.3 53.8 29.0 29.0 28.8 28.8 37.1 12.7 6 32.3 68.4 32.0 34.8 62.4 31.2 43.5 17.1 7 79.5 75.1 85.0 76.4 75.3 78.7 78.3 3.7 8 87.0 82.8 84.2 88.5 89.3 87.8 86.6 2.6 Table B-26. Baseline Exhaust Temperatures, °C Run/ Notch 1 2 3 4 5 6 Loldle 103 106 104 105 102 114 Idle 94 94 92 94 92 95 Averages Std Dev 1 150 148 145 148 145 146 147 1.8 2 194 198 196 196 211 191 198 6.8 3 253 260 253 246 258 114 231 57.2 4 299 311 302 305 306 309 305 4.5 5 355 351 355 355 354 351 354 2.1 6 384 393 390 388 391 387 389 3.3 7 382 328 383 381 383 377 372 21.7 8 384 383 385 378 383 378 382 3.2 Table B-27. Treated Exhaust Temperatures, °C Run/ Notch 1 2 3 4 5 6 Loldle 84 113 134 128 121 111 Idle 84 74 78 79 78 75 Averages Std Dev 1 139 102 103 103 105 106 110 14.2 2 196 147 143 151 147 158 157 19.7 3 253 209 206 213 210 214 218 17.8 4 297 256 256 262 260 264 266 15.6 5 347 311 306 313 308 304 315 16.2 6 458 326 331 333 328 320 349 53.2 7 458 331 334 339 332 326 353 51.3 8 458 336 337 338 334 328 355 50.4 BIO ------- Table B-28. Baseline Intake Air Temperatures, °C Run/ Notch 1 2 3 4 5 6 Loldle 19.7 29.6 21.5 26.1 25.6 24.9 Idle 20.5 28.7 21.8 26.0 25.5 24.4 Averages Std Dev 1 22.2 28.8 22.1 26.1 25.8 24.0 24.8 2.57 2 23.3 28.5 22.9 24.6 25.5 23.7 24.8 2.07 3 24.1 27.2 24.2 24.6 25.8 24.2 25.0 1.26 4 24.8 26.5 25.3 25.4 27.2 23.2 25.4 1.39 5 24.9 26.9 25.0 24.6 25.3 22.5 24.9 1.41 6 25.2 26.4 25.1 24.1 25.0 22.4 24.7 1.34 7 26.4 25.8 25.3 24.0 25.0 22.1 24.8 1.55 8 27.4 25.4 26.8 23.6 24.7 22.0 25.0 2.02 Table B-29. Treated Intake Air Temperatures, °C Run/ Notch 1 2 3 4 5 6 Loldle 9.2 6.6 14.1 10.8 14.2 2.2 Idle 8.8 6.4 14.3 11.1 12.5 2.2 Averages Std Dev 1 8.8 7.0 13.9 11.2 12.7 4.1 9.6 3.68 2 8.9 7.4 14.0 12.0 12.0 4.4 9.8 3.54 3 9.7 9.7 15.5 12.5 12.3 5.8 10.9 3.31 4 9.7 10.0 15.8 13.3 11.9 7.0 11.3 3.07 5 10.6 10.0 17.9 16.3 13.0 8.2 12.7 3.80 6 12.7 11.7 18.3 17.5 15.3 9.8 14.2 3.39 7 17.2 14.0 18.2 19.0 14.6 10.3 15.6 3.25 8 16.8 14.5 18.1 16.4 14.0 12.3 15.4 2.13 Table B-30. Baseline Ambient Pressure, (mmHg) Run/ Notch 1 2 3 4 5 6 Loldle 757.7 746.4 754.9 747.2 748.1 747.9 Idle 757.5 746.4 754.8 747.0 747.5 748.2 Averages Std Dev 1 756.8 746.4 754.4 747.0 747.5 748.5 750.1 4.37 2 755.0 746.3 753.6 747.2 747.1 749.1 749.7 3.70 3 752.4 746.0 751.6 747.2 747.0 749.3 748.9 2.64 4 748.8 745.9 749.7 746.5 747.0 749.6 747.9 1.65 5 747.3 746.6 749.6 746.1 747.3 750.1 747.8 1.62 6 747.2 747.0 749.0 746.1 747.8 750.8 748.0 1.69 7 747.2 744.8 749.0 746.8 747.9 751.3 747.8 2.19 8 746.3 741.6 748.3 746.6 747.8 751.5 747.0 3.24 Bll ------- Table B-31. Treated Ambient Pressure, (mmHg) Run/ Notch 1 2 3 4 5 6 Loldle 749.2 757.6 748.6 757.3 756.1 764.6 Idle 748.8 757.1 748.6 756.3 755.5 764.6 Averages Std Dev 1 749.6 756.3 748.8 755.3 755.7 764.0 755.0 5.49 2 749.6 755.3 749.9 754.6 755.5 763.8 754.8 5.15 3 750.3 754.0 751.5 754.4 755.1 763.0 754.7 4.45 4 750.1 753.0 751.7 754.8 754.9 762.8 754.6 4.44 5 750.5 752.6 751.7 755.3 754.9 763.0 754.7 4.48 6 750.7 752.8 751.7 755.7 754.6 762.8 754.7 4.36 7 750.1 752.6 750.9 755.1 754.4 762.1 754.2 4.32 8 750.3 751.9 750.7 755.5 754.4 761.7 754.1 4.26 B12 ------- |