From: Jim McDonald [JMcDonald@Rypos.com]

Sent: Friday, May 13, 2011 9:03 AM

To: Tanya Parise

Subject: RE: RE: DPF info for engines in rural Alaska

Attachments: RH406-L 8-8 EIEO.pdf; RH408-L 8-8 EISO.pdf

Tanya,

I apologize that this took longer than I had hoped. I have filled in our responses to you questions below and in most cases

they match the responses we sent to the Customer on very similar questions.

·I believe you mentioned capital costs between $12,000-$18,000. How much would you estimate that

installation costs would be for an engine located in a remote area of Alaska?

oThe filter pricing relayed to the customer on the smaller engines (197HP-284HP was less than $20,000

and some additional quantity discounts may apply). The larger engines 442HP and 617HP were closer

to $30K. I have attached some drawings of the units and as you can see they have flanged ends to

either replace or go in-line with the existing silencer (muffler). The weight of the units are 250-480

pounds so the additional supports would be minimal. That being said each application will be different

and special circumstances may require that the installation be more costly than anticipated. On a

packaged (enclosed) unit where our device when on top of the unit we would the estimated installation

costs to be less than $10,000.

·

If used oil is blended into the fuel that is burned, what are some of the issues you mentioned that could occur?

Specifically, what would be the impact if using fuels mixed with used lubricating oil (up to 1.75% of the total

fuel, with the sulfur content of the used lubricating oil being <200 ppm and meeting the on-specification levels

and properties for used oil in 40 CFR 279.11).

oEven with knowing the details regarding what is being fueled to the engine it is hard to estimate the

actual sulfur deposits that will be created post combustion. The good news is that we have many proven

installations on standard Number 2 Diesel fuel so we do not required Ultra Low Sulfur fuel Specs.

What was relayed to the customer was: “Burning waste oil will affect the rate of ash accumulation in

the filter and may require the inspection interval to be adjusted. Non-catalyzed RYPOS Active Diesel

Particulate Filters (ADPFTM) are effective in reducing solid particulate emissions in applications

running high sulfur content diesel fuel”

·

We’ve gotten some concerns from Alaska indicating that space is a premium at some of their power plants.

What are the space requirements for the Rypos trap?

oSee Drawings Attached

·

Lastly, we also got some concerns about the disposal of the waste from the filter after cleaning it. One concern

was that there may not be facilities to handle the waste and that it could be hazardous. Can you speak to how

this could be addressed in remote portions of Alaska?

oSince the local laws will be case by case our response to the customer was: “The ash that accumulates in

diesel engine DPFs is classified as hazardous waste in some states and must be handled in accordance

with state and federal regulations. Representative ash handling guidelines are available at:

http://www.arb.ca.gov/msprog/decsinstall/decsinstall.htm.”

The volume of ash accumulated from our filter should be lower than that of a passive design due to the

high surface temperatures associated with our active regen. Burning the used Lube Oil does create

some unknowns but most of our customers are only faced with the disposing of the ash once a year due

to the low volume created.
Thanks again and please let me know if this answers most of your questions.

Regards,

Jim McDonald

NSM- Powergen

Rypos, Inc.

Fort Washington, PA. 19034

T- 267.513.1747

C-215.407.9001

From: Tanya Parise [mailto:parise.tanya@ecrweb.com]

Sent: Monday, May 09, 2011 10:23 PM

To: Jim McDonald

Subject: RE: RE: DPF info for engines in rural Alaska

Importance: High

Hi Jim,

I’m following up for Melanie King to get some additional information on DPF. I was on the call where you presented

information about the Rypos trap. I believe you mentioned capital costs between $12,000-$18,000. How much would

you estimate that installation costs would be for an engine located in a remote area of Alaska?

If used oil is blended into the fuel that is burned, what are some of the issues you mentioned that could occur?

Specifically, what would be the impact if using fuels mixed with used lubricating oil (up to 1.75% of the total fuel,

with the sulfur content of the used lubricating oil being <200 ppm and meeting the on-specification levels and

properties for used oil in 40 CFR 279.11).

We’ve gotten some concerns from Alaska indicating that space is a premium at some of their power plants. What are

the space requirements for the Rypos trap?

Lastly, we also got some concerns about the disposal of the waste from the filter after cleaning it. One concern was

that there may not be facilities to handle the waste and that it could be hazardous. Can you speak to how this could be

addressed in remote portions of Alaska?

Thanks and I appreciate any information you can provide and light you can shed on these issues

Tanya Parise

Tanya Parise

EC/R Incorporated

Chemical Engineer

501 Eastowne Drive, Suite 250

Chapel Hill, NC 27514

(919) 484-0417
From: "Jim McDonald" <JMcDonald@Rypos.com>

Date: 04/01/2011 04:30PM

Subject: RE: DPF info for engines in rural Alaska

Melanie,

Certainly whatever you think works for me. Presenting to a small group

is just fine.

Thanks for your help,

Jim McDonald

NSM- Powergen

Rypos, Inc.

Fort Washington, PA. 19034 

T- 267.513.1747

C-215.407.9001

-----Original Message-----

From: King.Melanie@epamail.epa.gov [mailto:King.Melanie@epamail.epa.gov]

Sent: Friday, April 01, 2011 4:28 PM

To: Jim McDonald

Subject: RE: DPF info for engines in rural Alaska

Hi,

We could wait until Friday, that's no problem. Unfortunately Michael is

based up in D.C., so it would just be myself, Tanya if she's available,

and possibly my group leader, so I don't know if it would be worthwhile

to you for a small group. I could also extend an invitation to others

who aren't necessarily working with engines but may be interested in

learning about the technology

Melanie King

Energy Strategies Group

Sector Policies and Programs Division

Office of Air Quality Planning and Standards

U.S. Environmental Protection Agency

Mail Code D243-01

RTP, NC 27711

Phone: (919) 541-2469

Fax: (919) 541-5450

king.melanie@epa.gov

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Melanie,

Another thought I had was if your group was available next Friday

Morning (the 8th) I could give a presentation in person on how the

system works and show a lot of install pics etc.. I need to be in

Charlotte on Thursday and could just drive over for a morning meeting.

Could the meeting wait that long?

Please let me know when you get a chance.

Thanks,

Jim McDonald

NSM- Powergen
Rypos, Inc.

Fort Washington, PA. 19034

T- 267.513.1747

C-215.407.9001

-----Original Message-----

From: King.Melanie@epamail.epa.gov [mailto:King.Melanie@epamail.epa.gov]

Sent: Friday, April 01, 2011 2:51 PM

To: Jim McDonald

Subject: RE: DPF info for engines in rural Alaska

Thanks, talk to you Tuesday morning. Hope you have a good weekend as

well.

Melanie King

Energy Strategies Group

Sector Policies and Programs Division

Office of Air Quality Planning and Standards

U.S. Environmental Protection Agency

Mail Code D243-01

RTP, NC 27711

Phone: (919) 541-2469

Fax: (919) 541-5450

king.melanie@epa.gov

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Melanie,

Thanks works just fine. I will review the document and probably have

some questions on Monday.

Have a great weekend!

Jim McDonald

NSM- Powergen

Rypos, Inc.

Fort Washington, PA. 19034

T- 267.513.1747

C-215.407.9001

-----Original Message-----

From: King.Melanie@epamail.epa.gov [mailto:King.Melanie@epamail.epa.gov]

Sent: Friday, April 01, 2011 10:58 AM

To: Jim McDonald

Subject: RE: DPF info for engines in rural Alaska

Hi,

Would 10 a.m. EDT on Tuesday work for you? It would just be EPA folks

on the call, I've invited another person from EPA who is working with me

on the rule, his name is Michael Horowitz, and also a contractor who is

working with us on the rule, her name is Tanya Parise, I think you've

talked to her in the past. I set up a call-in number for the call, it
is 919-541-4486. The line doesn't open until I dial in, so if you call

and get a busy signal, just try back in a couple of minutes.

To give some more background, attached is the letter we received from

the Alaska Energy Authority, and on p. 2-3 you will see the estimates

for DPF maintenance costs that they received. The engine sizes they are

looking at are 117 kW, 229 kW, and 372 kW. The engines would be used

for prime power generation in the rural villages in Alaska. We're

trying to determine whether these maintenance costs are what the

villages should reasonably expect to incur with these systems.

(See attached file: NSPS Alaska Implementaion Plan 3-16-11.pdf)

Melanie King

Energy Strategies Group

Sector Policies and Programs Division

Office of Air Quality Planning and Standards U.S. Environmental

Protection Agency

Mail Code D243-01

RTP, NC 27711

Phone: (919) 541-2469

Fax: (919) 541-5450

king.melanie@epa.gov

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Melanie,

That would be great. Is there a time on Tuesday that might work? Would

the operators also be on the line?

Thanks and have a great weekend,

Jim McDonald

NSM- Powergen

Rypos, Inc.

Fort Washington, PA. 19034

T- 267.513.1747

C-215.407.9001

-----Original Message-----

From: King.Melanie@epamail.epa.gov [mailto:King.Melanie@epamail.epa.gov]

Sent: Friday, April 01, 2011 9:45 AM

To: Jim McDonald

Subject: Fw: DPF info for engines in rural Alaska

Jim,

Do you have some time available next week for a short call to discuss

this issue with me?

Melanie King

Energy Strategies Group

Sector Policies and Programs Division

Office of Air Quality Planning and Standards U.S. Environmental

Protection Agency
Mail Code D243-01

RTP, NC 27711

Phone: (919) 541-2469

Fax: (919) 541-5450

king.melanie@epa.gov

----- Forwarded by Melanie King/RTP/USEPA/US on 04/01/2011 09:43 AM

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Thanks Jim.

Melanie King

Energy Strategies Group

Sector Policies and Programs Division

Office of Air Quality Planning and Standards U.S. Environmental

Protection Agency

Mail Code D243-01

RTP, NC 27711

Phone: (919) 541-2469

Fax: (919) 541-5450

king.melanie@epa.gov

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Melanie,

Thanks so much for the note and I would be glad to help.

I think our mentioned that our DPF systems have a capital cost that is

typically 10-15% higher than their Passive counterparts but the

maintenance costs are so much less that they typically pay for

themselves in 12-18 months.

Specifically the engine will not need to be loaded to increase exhaust

temperatures to burn off the soot and due to the high regen temperature

the isolated wire mesh media achieves(about 1100F) the unburnt ash

accumulation is also much less.

I am out traveling today but if they would like to either send me a note

or give me a call next week on my cell I can go through the particulars.

Thanks again,

Jim McDonald

NSM- Powergen

Rypos, Inc.

Fort Washington, PA. 19034

T- 267.513.1747

C-215.407.9001

-----Original Message-----

From: King.Melanie@epamail.epa.gov [mailto:King.Melanie@epamail.epa.gov]

Sent: Thursday, March 24, 2011 3:51 PM

To: Jim McDonald

Subject: DPF info for engines in rural Alaska

Hi Jim, hope you are doing well. I was recently contacted by Chris

Mello and Steve Stassel of the Alaska Energy Authority regarding some

concerns they have about the costs of meeting the stationary engine NSPS

for engines located in rural Alaska. As you may have heard, last year

we proposed to amend the NSPS for stationary compression ignition (CI)

engines (part 60 subpart IIII) to include special provisions for new CI

engines located in rural Alaska. We proposed to amend the rule to
remove the requirement that engines meet the Tier 4 NOx standards.

Instead, they would be able to use Tier 3 engines (or Tier 2 for the

sizes where there was no Tier 3), but they would also have to install

controls on the engine to reduce their PM emissions by 85%. So what I

envision when Tier 4 is fully in place is that they would have to get a

Tier 2/3 certified emergency engine and install a DPF that would meet

the 85% PM reduction requirement. Of course, this is all assuming the

amendment to the rule is finalized as proposed.

Chris and Steve have done some checking with a couple of the engine

manufacturers regarding the estimated costs of the DPF systems, and some

of the feedback they've gotten includes some pretty high maintenance

costs for the systems, due to the remote locations of the engines. I

recommended that they check with some of the DPF vendors to get some

other quotes for DPF systems that could be installed on new Tier 2/3

engines that would meet 85% PM reduction. I told them that I had some

contact names for some of the vendors who had systems that had been

verified by CARB, so I wanted to check and see if you would be

interested in talking to them about their particular needs? Obviously I

don't recommend specific technologies to people, so my purpose here is

just to put them in touch with folks at some of the different vendors

who might be able to help them with some information. Let me know if

you would be willing to talk to them and I will pass along your contact

information (or if there is someone else at Rypos they could talk to).

Melanie King

Energy Strategies Group

Sector Policies and Programs Division

Office of Air Quality Planning and Standards U.S. Environmental

Protection Agency

Mail Code D243-01

RTP, NC 27711

Phone: (919) 541-2469

Fax: (919) 541-5450

king.melanie@epa.gov
30.0

5.30

5.30

7.50

ANSI 8 FLANGE

INLET AND OUTLET 70.0

28.00

BODY OD

21.75

MOUNTING AREA

SEE NOTE 4

SEE NOTE 4

NOTES:

1. UNIT MUST BE ORIENTED AS SHOWN- HORIZONTAL WITH ELECTRONICS ON THE SIDE.

2. SUGGESTED MOUNTING AREA SHOWN - CRADLE MOUNT UNIT.

3. UNIT TO BE SUPPORTED INDEPENDENTLY FROM DOC AND PIPING.

4. 1/2 NPT SMAPLING PORTS PROVIDED ON INLET AND OUTLET PIPES.

PRELIMINARY

FLOW DIRECTION

REVISIONS

ZONE REV. DESCRIPTION DATE APPROVED

X4 2/13/2009

D

C

B

A

B

C

D

8 7 6 5 4 3 2 1

8 7 6 5 4 3 2 1

E

F

E

F

960-0020-00-00

SHEET 1 OF 1

TOP LEVEL ASSEMBLY - RH406-L-C FLOW THRU

02/13/09

xx/xx/xx

xx/xx/xx

xx/xx/xx

xxx xx/xx/xx

xxx

xxx

xxx

JES

X4

UNLESS OTHERWISE SPECIFIED

SCALE: 1:12 WEIGHT: 254.37 LBS

DWG. NO. REV

C

SIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

SEE LIST OF MATERIAL

SEE LIST OF MATERIAL

FINISH

MATERIAL

PROPRIETARY AND CONFIDENTIAL

A

DO NOT SCALE DRAWING

THE INFORMATION 

CONTAINED IN THIS 

DRAWING IS THE SOLE 

PROPERTY OF RYPOS, INC. 

ANY REPRODUCTION IN 

PART OR AS A WHOLE 

WITHOUT THE WRITTEN 

PERMISSION OF RYPOS, 

INC. IS PROHIBITED.

RYPOS

Advanced Diesel Emission Control Systems

RYPOS, INC.

260 HOPPING BROOK RD

HOLLISTON, MA 01746

INTERPRET GEOMETRIC TOL PER: 

ASME Y14.5M-1994

DIMENSIONS ARE IN: INCHES

TOLERANCES:

FRACTIONAL: 1/64

ANGULAR: MACH 0.5 BEND 0.5

TWO PLACE DECIMAL: 0.010

THREE PLACE DECIMAL: 0.005
34.00

54.00

R15.00

75.75

13.50

FLOW OUT

FLOW IN

REMOVABLE COVER

ELECTRONIC CONNECTIONS

SUGGESTED SUPPORT

AREA

13.50

ANSI 8 INLET AND OUTLET

29.00

28.00

D

C

B

A

B

C

D

8 7 6 5 4 3 2 1

8 7 6 5 4 3 2 1

E

F

E

F

960-0003-00-00

SHEET 2 OF 3

RYPOS ASSEMBLY, RH-408-L

04/15/08

xx/xx/xx

xx/xx/xx

xx/xx/xx

xxx xx/xx/xx

xxx

xxx

xxx

JES

X5

UNLESS OTHERWISE SPECIFIED

SCALE: 1:12 WEIGHT: 468.80 LBS

DWG. NO. REV

C

SIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

SEE LIST OF MATERIAL

SEE LIST OF MATERIAL

FINISH

MATERIAL

PROPRIETARY AND CONFIDENTIAL

A

DO NOT SCALE DRAWING

THE INFORMATION 

CONTAINED IN THIS 

DRAWING IS THE SOLE 

PROPERTY OF RYPOS, INC. 

ANY REPRODUCTION IN 

PART OR AS A WHOLE 

WITHOUT THE WRITTEN 

PERMISSION OF RYPOS, 

INC. IS PROHIBITED.

RYPOS

Advanced Diesel Emission Control Systems

RYPOS, INC.

260 HOPPING BROOK RD

HOLLISTON, MA 01746

INTERPRET GEOMETRIC TOL PER: 

ASME Y14.5M-1994

DIMENSIONS ARE IN: INCHES

TOLERANCES:

FRACTIONAL: 1/64

ANGULAR: MACH 0.5 BEND 0.5

TWO PLACE DECIMAL: 0.010

THREE PLACE DECIMAL: 0.005

Preliminary