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?

o The 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).

o Even 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?

o See 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?

o Since 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) 484-0417From: "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- PowergenRypos, 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, itis 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 AgencyMail 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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|RE: DPF info for engines in rural Alaska |

>----------------------------------------------------------------------- ---------------------------------------------------------------------|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 toremove 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: UNIT MUST BE ORIENTED AS SHOWN- HORIZONTAL WITH ELECTRONICS ON THE SIDE. 1. SUGGESTED MOUNTING AREA SHOWN - CRADLE MOUNT UNIT. 2. UNIT TO BE SUPPORTED INDEPENDENTLY FROM DOC AND PIPING. 3. 1/2 NPT SMAPLING PORTS PROVIDED ON INLET AND OUTLET PIPES. 4. 

# PRELIMINARY

FLOW DIRECTION REVISIONS

ZONE REV. DESCRIPTION DATE APPROVED

X4 2/13/2009

D

C

B

A B C D

1 2 3 4 5 6 7 8 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

xx/xx/xx xxx xxx xxx xxx JES



# X4 UNLESS OTHERWISE SPECIFIED

SCALE: 1:12 WEIGHT: 254.37 LBS REV DWG. NO. 

# 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

R 15.00

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

1 2 3 4 5 6 7 8 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

xx/xx/xx xxx xxx xxx xxx JES



# X5 UNLESS OTHERWISE SPECIFIED

SCALE: 1:12 WEIGHT: 468.80 LBS REV DWG. NO. 

# 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