complete catalytic catalog 106

106

• Toll Free: 800-775-2466

• Phone: 402-323-7272

• Fax: 402-323-7270

• E-mail: [email protected]

• Web Site: www.gtexhaustsystems.com

GT Exhaust Systems, Inc.

Lincoln, Nebraska

EmmisionSilencer Catalog

106


Complete Product Line for the Industrial Engine Market Power Generation, Gas Compression, Power Units

• 3-Way Catalysts Providing NOX, CO and HC control for rich burn gas engines

• Oxidation Catalysts Providing CO and HC control for lean burn gas and Diesel engines

• Catalyzed Soot Filters Providing Self Cleaning Particulate, CO and HC control for Diesel engines

A Variety of Silencer Options and Configuration

• Stainless , Aluminized , or Carbon Steel Construction

• End or Side Inlet tailored to your installation requirements

• Available with dual inlets

• Designed to meet your application

• Special Sizes available when space is a problem

• Special construction minimizes potential damage from backfire

• Modular catalytic elements

• Designed with easy access for cleaning and maintenance

• Sampling and control instrument ports provided

2Note: Most HC (hydrocarbon) considerations exclude methane and ethane hydrocarbons. Consult factory for these concerns. 402-323-7272 Toll Free 1-800-775-2466 Fax 402-323-7270 Email [email protected] 106 Technical Assistance 903-758-3624 or 402-323-7298


Oxidation and 3-Way Catalysts

Note: Most HC (hydrocarbon) considerations exclude methane and ethane hydrocarbons. Consult factory for these concerns.

3

Catalytic elements provide a continuous on-line corrugating, catalyst coating and honeycomb process, which produces an even coating of catalyst material both axially and around the cell walls. Eliminates uneven coating distribution encountered on many post-coating products. Result is longer life with effective utilization of catalyst materials, while at the same time maintaining wider cell openings to minimize blocking. The herringbone corrugation patterns provide superior emission reduction efficiency with minimal pressure drop. Catalyst features angled channels that create turbulence and a complex gas path that promotes mixing. This provides 45 to 50% higher mass transfer rate than the laminar flow that occurs in narrow parallel channels. Channels are designed to enhance gas mixing, while, at the same time, protect against plugging.

Gas Flow

The herringbone corrugation pattern provides stronger stacking for catalytic abatement applications, and prevents nesting of catalyst. Herringbone Gives Lower Pressure Drop Than Straight

Honeycombs to achieve the same Conversion

90 91 92 93 94 95 96 97 98 99

0.50 0.70 0.90 1.10 Pressure Drop, inch water

CO

Con

vers

ion,

% Herringbone 155 cpsi

Straight, 230 CPSI

2 mil thickness, 24 ft/s at 650F

The Oxidation Catalysts provide hydrocarbon and CO abatement with secondary particulate reduction for diesel applications, and CO and Non-Methane Hydrocarbons (NMHC) abatement from lean burn natural gas and LPG Engines. High reduction of aldehydes removes the characteristic objectionable odor of LPG and Diesel exhaust.

402-323-7272 Toll Free 1-800-775-2466 Fax 402-323-7270 Email [email protected] 106 Technical Assistance 903-758-3624 or 402-323-7298


The 3-Way Catalyst uses non-selective catalytic reduction (NSCR) to reduce NOX and is designed for rich-burning (fuel rich) gas engines operated at or very close, to a stoichiometric air/fuel ratio. NOX catalytically is reduced to nitrogen while providing oxygen that reacts with Carbon Monoxide (CO), hydrocarbons (CXHX), aldehydes, and poly aromatic hydrocarbons (PAH), oxidizing them to carbon dioxide (CO2) and water vapor (H2O).

Catalytic Oxidation

CO2 H2O SO2 /SO3NO /NO2

CO

Aldehydes HC

PAH SO2NO

Metals

SO2+H2O

Soot

Flow through monolith with catalytic coating

CO2 CO2 + H2O CO2 + H2O

CO2 + H2O

CO + 1/2 O2 HC + O2 PAH + O2

Aldehydes + O2 Metals SO2+H2O

C2H2n+2

Soot

PAH

3-Way Catalyst Reaction Two Step Process

1. Deplete Oxygen (Oxidize CO with any “free or excess” O2 that may be in the exhaust gas; this must be no more than 0.5% excess air relative to stoichiometric)

2CO + O2 = 2CO2CmHn + (m + n/4)O2 = mCO2 + n/2H2O

2. Convert NOx (NO and NO2 are chemically reduced to Nitrogen (N2) making the oxygen available to chemically oxidize the CO to CO2)

NO + CO = 1/2N2 + CO22NO2 + 4CO = N2 + 4CO2

It should be noted that atoms are recombined (referred to as “conversion”) from emission molecules to harmless byproducts. The amount of conversion is commonly reported as reduction (percent) for internal combustion engine catalysts. The term “destruction” is also used instead of reduction, but nothing is really destroyed.

4Note: Most HC (hydrocarbon) considerations exclude methane and ethane hydrocarbons. Consult factory for these concerns. 402-323-7272 Toll Free 1-800-775-2466 Fax 402-323-7270 Email [email protected] 106 Technical Assistance 903-758-3624 or 402-323-7298


Catalytic Silencer Options and Models

GT Catalytic Silencers are available in Carbon Steel, Aluminized Carbon Steel, or Stainless Steel. Standard sizes available from 4 thru 30” Inlets & Outlets and with 1 thru 8 elements. Larger sizes available as special application designs. Special Modular Design allow selection of larger body with fewer active elements for now, providing option for increased performance by simply installing additional active elements at a later date.

Available in Conventional Round and Low Profile Special Request Designs. Designed to simplify installation while maintaining high degree of sound attenuation

Greater variety of inlet and outlet configurations. Internal blast plate minimizes (virtually precludes) damage to elements due to backfire.

Rental fleet owners have option of removing elements for safe storage where catalytic action is not required.

Part Number Identification System

201V3-4-300-4118-2-xxxxx

Style – Inlet and Outlet Configuration

Ma

this“R”

Silencer Des

201 Round Si211 Dual Inle216 Dual Inle218 Dual Inle

501 Oval Bod511 Dual Inle516 Dual Inle518 Dual Inle

ment2

1 Our Industrial 11diameter as shown2 Blank panels are3 Dimensions are f

402-323-7272Email gtexhau

Catalyst Element TypeV3 = Three Way Element VO = Oxidation Element

201V3 - 4 - 31 - 4118 - 2- xxxxx

Silencer Grade and outlet size

Print Number. Refer to this drawing number for detail specifications, special modifications, and/or add-ons.

201 signifies round body. 501 signifies oval Special Requests (See Chart Below)

ximum No. of elements unit accommodates or for 1100 Series

Number of elements installed at the factory or diameter of 1100 round element. In this example it will have: 3 full panels and one blank panel2 A “3.5” for example indicates 3 full panels, 1 half panel, and 1 blank half panel2.

ign Options lencer Body t Round Body for Cummins Engines t Round Body for Caterpillar Engines t Round Body for DDA/Kohler Engines

y (Special Requests) t Oval Body for Cummins Engines t Oval Body for Caterpillar Engines t Oval Body for DDA/Kohler Engines

00 Series features one or two (back to back) roun with the 6 inch diameter number: 201VO-R-P06

removable and can be replaced by the customeror the element only, and may not reflect retainer

Toll [email protected]

Element Options

VO Oxidation Element V3 Three Way Element

Inlet & Outlet Configuration

1 End Inlet (x) End Outlet 2 Side Inlet (x) End Outlet 3 Side Inlet (x) Side Outlet 4 End Inlet (x) Side Outlet

Panel Elements Part No’s

CE-1136 Three Way Full Panel 15.44 x 24.75 CE-1241 Three Way Half Panel 15.44 x 12.38 CE-7140 Oxidation Full Panel 15.44 x 24.75 CE-7141 Oxidation Half Panel 15.44 x 12.38

Element Dimensions3

Rectangular Oxidation or Three Way Full Panel Rectangular Oxidation or Three Way Half Panel

15.44 x 24.75 x 3.80” 15.44 x 12.38 x 3.80”

Round Elements for 1100 Series Only

Oxidation Part No Three Way Part No Nom Size

R-60 R-63 6” 6” Dia x 3.5” lg R-80 R-83 8” 8” Dia x 3.5” lg

R-100 R-103 10” 10” Dia x 3.5” lg R-120 R-123 12” 12” Dia x 3.5” lg R-140 R-143 14” 14” Dia x 3.5” lg R-160 R-163 16” 16” Dia x 3.5” lg

d elements to choose from. Its unique numbering system shows the element/silencer -1103-xxxx. “P” would be 1 or 2 for the element quantity. See page 7 for more details. with a catalytic element of the same size for additional performance. rings, brackets, frames, gaskets or other retaining devices as may be applicable.

1-800-775-2466 Fax 402-323-7270 106 Technical Assistance 903-758-3624 or 402-323-7298 5

1100 Series GT Exhaust Systems, Inc. Oxidation and Three Way Lincoln, Nebraska Compact Catalytic Converter Muffler

Inlet and Outlet Nozzles equipped with test ports Stainless Body Slotted ID Cuffs are standard in 304 Stainless. Flanges and Nipples are standard in carbon steel.

BODY DIA OAL

INLET

.50” NPT COUPLING ON INLET AND OUTLETNOZZLES

.50” DRAIN

CUFF

.50” DRAIN

BODY DIA

OAL

INLET

MALE PIPE THREADS

18 mm OXYGENSENSOR PORTON INLET NOZZLES


BODY OAL18 mm OXYGENSENSOR PORT

ElDi

TEInle

1 S

OXIDATION APPLICATION Muffler incorporates a passive system utilizing an oxidationcatalyst element to provide HC, Aldehyde and CO abatementwith visible smoke and exhaust odor reduction for diesel, leanburn natural gas and LPG Engines. THREE WAY APPLICATION Muffler incorporate a passive system utilizing a non-selectivecatalytic reduction (NSCR) to reduce NOX and oxidize CO andHC from rich-burning (fuel rich) gas engines operated at or veryclose to a stoichiometric air/fuel ratio. For optimumperformance, engines must be equipped with an air/fuel ratiocontroller. NOX catalytically is reduced to nitrogen whileproviding oxygen that reacts with Carbon Monoxide (CO) andhydrocarbons (CXHX), oxidizing them to carbon dioxide (CO2)and water vapor (H2O). Typical attenuation : 1100 Series 5 to 10 dB’A’ CONSTRUCTION All welded heavy-duty 304 stainless steel body. Slotted IDCuffs are standard in 304 Stainless Steel. Flanges and Nipplesare standard in carbon steel. Consult factory for additionalmaterial options. INLET / OUTLET CONNECTION OPTIONS ANSI or Engine Flange: 2 thru 16” Models Male Pipe Threads: 2 thru 6” Models Stainless Steel Slotted ID Cuffs: 2 thru 6” Models Please specify inlet and outlet fittings at time of order.

402-323-7272 Toll Free 1-800-775-2466 Fax 402-323-7270 Email [email protected] 106 Technical Assistance 903-758-3624 or 402-323-7298 6

INLET

DIA

FLANGE

.50” DRAIN

ON INLET NOZZLES


201-V-1100 Series1

For Both Oxidation and Three Way Catalytic Elements

ement ameter

Body Dia

Max Outlet Nozzle

OAL 1 Element 2 Elements

6 6 4 21 25 8 8 5 22 26

10 10 6 24 28 12 12 8 25 29 14 14 10 27 31 16 16 12 29 33

ST PORTS: t / Outlet Nozzles feature (1) ½” Half Coupling per nozzle. Inlet Nozzles feature (1) 18 mm Oxygen Sensor Port.

ee the following page for more part numbering details.

201V- 2100 Series GT Exhaust Systems, Inc. Oxidation & Three Way Lincoln, Nebraska Catalytic Converter Silencer

Easy access allows quick installation / removal of catalyst elements

Representative Attenuation Curve for 201V-2100 Catalytic Silencer

OCTAVE BAND

05

1015202530

63 Hz 125Hz

250Hz

500Hz

1000Hz

2000Hz

4000Hz

8000Hz

Center Frequency Hz

Inse

rtion

Los

s in

Dec

ibel

s (R

ef 0

.000

2 M

icro

bars

)

Inlet and Outlet Nozzles equipped with test ports

Ele

Ele

No

OXIDATION APPLICATION Silencers incorporate a passive system utilizing oxidationcatalyst element to provide HC, Aldehyde and CO abatementwith visible smoke and exhaust odor reduction for diesel, leanburn natural gas and LPG Engines. THREE WAY APPLICATION Silencers incorporate a passive system utilizing non-selectivecatalytic reduction (NSCR) to reduce NOX and oxidize CO andHC from rich-burning (fuel rich) gas engines operated at or veryclose to a stoichiometric air/fuel ratio. For optimumperformance, engines must be equipped with an air/fuel ratiocontroller. NOX catalytically is reduced to nitrogen whileproviding oxygen that reacts with Carbon Monoxide (CO) andhydrocarbons (CXHX), oxidizing them to carbon dioxide (CO2)and water vapor (H2O). Typical attenuation : 2100 Series 14 to 20 dB’A’ CONSTRUCTION All welded heavy-duty carbon steel body. Inlets and Outlets arestandard with 125/150# ANSI Flanges. Optional fittings areavailable upon request. Available in Stainless Steel. Consult factory for additionalmaterial options.

201V-1-2100 1 Panel Element For Oxidation and Three Way Catalytic Elements


Max ments

Outlet Dia

Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 1 4 20 52 53 2 8 28 66 73 1 5 20 52 53 2 10 28 66 73 1 6 20 52 53 Consult 2 12 28 65 73 Consult 1 8 20 51 53 Factory 2 14 28 65 73 Factory 1 10 20 51 59 2 16 30 65 73 1 12 22 51 59 2 18 30 64 85 1 14 22 51 59 2 20 30 64 85


201V-6-2100 & 201V-8-2100 6 & 8 Panel Element For Oxidation and Three Way Catalytic Elements

Max ments

Outlet Dia

Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 4 8 42 60 67 6/8 10 42 82/95 90/103 4 10 42 59 67 6/8 12 42 82/95 90/103 4 12 42 59 67 Consult 6/8 14 42 82/95 102/103 Consult 4 14 42 59 79 Factory 6/8 16 42 81/95 101/102 Factory 4 16 42 58 78 6/8 18 42 93/94 101/114 4 18 42 58 78 6/8 20 42 93/94 101/114 4 20 42 58 78 6/8 22 42 92/93 101/114 4 22 42 57 78 6/8 24 42 92/92 101/113 4 24 42 57 77 6/8 26 42 91/92 100/113

te: A 20” minimum clearance is required for removal of the element through the access opening(s) on the converter silencer.





OCTAVE BAND

05

101520253035

63 Hz 125Hz

250Hz

500Hz

1000Hz

2000Hz

4000Hz

8000Hz

Center Frequency Hz

Inse

rtion

Los

s in

Dec

ibel

s (R

ef 0

.000

2 M

icro

bars

)


Ele

Ele

No

OXIDATION APPLICATION Silencers incorporate a passive system utilizing oxidationcatalyst element to provide HC, Aldehyde and CO abatementwith visible smoke and exhaust odor reduction for diesel, leanburn natural gas and LPG Engines. THREE WAY APPLICATION Silencers incorporate a passive system utilizing non-selectivecatalytic reduction (NSCR) to reduce NOX and oxidize CO andHC from rich-burning (fuel rich) gas engines operated at or veryclose to a stoichiometric air/fuel ratio. For optimumperformance, engines must be equipped with an air/fuel ratiocontroller. NOX catalytically is reduced to nitrogen whileproviding oxygen that reacts with Carbon Monoxide (CO) andhydrocarbons (CXHX), oxidizing them to carbon dioxide (CO2)and water vapor (H2O). Typical attenuation : 4100 Series 22 to 29 dB’A’ CONSTRUCTION All welded heavy-duty carbon steel body. Inlets and Outletsare standard with 125/150# ANSI Flanges. Optional fittings areavailable upon request. Available in Stainless Steel. Consult factory for additionalmaterial options.



Max ments

Outlet Dia

Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 1 4 20 58 53 54 2 8 28 90 85 81 1 5 20 58 53 55 2 10 28 102 98 94 1 6 20 64 59 60 2 12 28 101 97 93 1 8 20 76 72 67 2 14 30 113 109 105 1 10 22 88 83 78 2 16 36 115 111 107 1 12 26 88 84 80 2 18 36 114 111 107 1 14 30 101 97 93 2 20 42 131 127 123



Max ments

Outlet Dia

Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 4 8 36 104 99 94 6/8 10 42 106/108 102/104 97/100 4 10 36 116 111 106 6/8 12 42 118/120 114/116 109112 4 12 36 116 111 106 6/8 14 42 118/120 114/116 109/112 4 14 36 128 124 120 6/8 16 42 118/120 114/116 109/112 4 16 36 128 124 120 6/8 18 42 129/131 125/127 121/123 4 18 36 140 135 130 6/8 20 42 141/143 137/139 121/135 4 20 42 142 138 134 6/8 22 48 142/145 138/141 135/137 4 22 48 144 140 136 6/8 24 54 144/145 140/141 136/137 4 24 54 145 141 137 6/8 26 60 157/160 154/156 150/152

te: A 20” minimum clearance is required for removal of the element through the access opening(s) on the converter silencer.





OCTAVE BAND

0

10

20

30

40

50

63 Hz 125Hz

250Hz

500Hz

1000Hz

2000Hz

4000Hz

8000Hz

Center Frequency Hz

Inse

rtion

Los

s in

Dec

ibel

s (R

ef 0

.000

2 M

icro

bars

)


MEle

MEle

Not

OXIDATION APPLICATION Silencers incorporate a passive system utilizing oxidation catalystelement to provide HC, Aldehyde and CO abatement with visible smoke and exhaust odor reduction for diesel, lean burn natural gasand LPG Engines. THREE WAY APPLICATION Silencers incorporate a passive system utilizing non-selective catalytic reduction (NSCR) to reduce NOX and oxidize CO and HC from rich-burning (fuel rich) gas engines operated at or very close to astoichiometric air/fuel ratio. For optimum performance, engines mustbe equipped with an air/fuel ratio controller. NOX catalytically is reduced to nitrogen while providing oxygen that reacts with CarbonMonoxide (CO) and hydrocarbons (CXHX), oxidizing them to carbondioxide (CO2) and water vapor (H2O). Typical attenuation : 5100 Series 27 to 35 dB’A’

CONSTRUCTION All welded heavy-duty carbon steel body. Inlets and Outlets arestandard with 125/150# ANSI Flanges. Optional fittings are availableupon request.

Available in Stainless Steel. Consult factory for additional materialoptions.



ax ments

Outlet Dia

Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 1 4 20 88 83 78 2 8 28 102 97 92 1 5 20 88 83 78 2 10 28 114 110 105 1 6 20 100 95 90 2 12 36 128 123 118 1 8 24 101 96 91 2 14 36 152 148 144 1 10 28 102 98 93 2 16 42 155 151 147 1 12 36 116 111 106 2 18 48 156 152 148 1 14 36 140 136 132 2 20 48 180 176 172



ax ments

Outlet Dia

Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 4 8 36 140 135 130 6/8 10 42 155/168 150/164 145/160 4 10 36 152 147 142 6/8 12 42 166/168 162/164 157/160 4 12 36 152 147 142 6/8 14 42 166/180 162/175 157/170 4 14 36 164 160 156 6/8 16 42 166/178 162/174 157/170 4 16 42 155 151 147 6/8 18 48 179/192 175/188 171/184 4 18 48 156 152 148 6/8 20 48 191/192 107/188 183/184 4 20 48 180 176 172 6/8 22 54 204/217 200/213 196/209 4 22 54 181 177 173 6/8 24 60 218/230 214/228 210/224 4 24 60 195 191 187 6/8 16 64 232/244 228/240 225/236

e: A 20” minimum clearance is required for removal of the element through the access opening(s) on the converter silencer.



Easy access allows quick installation / removal of catalyst filters


OCTAVE BAND

01020304050

63 Hz 125Hz

250Hz

500Hz

1000Hz

2000Hz

4000Hz

8000Hz

Center Frequency Hz

Inse

rtion

Los

s in

Dec

ibel

s (R

ef 0

.000

2 M

icro

bars

)


MEle

MEle

Not

OXIDATION APPLICATION Silencers incorporate a passive system utilizing oxidation catalyst element to provide HC, Aldehyde and CO abatement with visible smokeand exhaust odor reduction for diesel, lean burn natural gas and LPGEngines. THREE WAY APPLICATION Silencers incorporate a passive system utilizing non-selective catalytic reduction (NSCR) to reduce NOX and oxidize CO and HC from rich-burning (fuel rich) gas engines operated at or very close to astoichiometric air/fuel ratio. For optimum performance, engines must beequipped with an air/fuel ratio controller. NOX catalytically is reduced tonitrogen while providing oxygen that reacts with Carbon Monoxide (CO) and hydrocarbons (CXHX), oxidizing them to carbon dioxide (CO2) and water vapor (H2O). Typical attenuation : 6100 Series: 30 to 38 dB’A’

CONSTRUCTION All welded heavy-duty carbon steel body. Inlets and Outlets arestandard with 125/150# ANSI Flanges. Optional fittings are availableupon request.

Available in Stainless Steel. Consult factory for additional materialoptions.



ax ments

Outlet Dia

Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 1 4 20 88 83 78 2 8 28 126 121 116 1 5 20 100 95 90 2 10 30 138 134 130 1 6 24 101 96 91 2 12 36 140 136 132 1 8 28 114 109 104 2 14 42 154 150 146 1 10 30 126 121 116 2 16 48 168 164 160 1 12 36 128 124 120 2 18 48 168 164 160 1 14 42 142 138 134 2 20 54 193 189 185



ax ments

Outlet Dia

Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Body Dia

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 4 8 36 140 135 130 6/8 10 42 166/168 162/164 157/160 4 10 36 152 147 142 6/8 12 42 166/168 162/164 157/160 4 12 36 152 148 144 6/8 14 42 178/192 174/187 169/183 4 14 42 168 163 159 6/8 16 48 191/205 187/201 183/197 4 16 48 169 165 161 6/8 18 48 203217 199/213 195/209 4 18 48 181 177 173 6/8 20 54 205/217 201/213 197/209 4 20 54 181 177 173 6/8 22 60 218/244 214/240 210/236 4 22 60 208 204 200 6/8 24 62 221/243 217/240 213/236 4 24 62 207 203 199 6/8 26 64 244/268 241/264 238/260

e: A 20” minimum clearance is required for removal of the elements through the access opening(s) on the converter silencer


Diesel Particulate Filters GT Exhaust Systems, Inc. (Catalyzed Soot Filters) Lincoln, Nebraska

Diesel particulate matter (soot) is composed of solid as well as liquid. Particulates consist of liquid heavy hydrocarbon, carbon soot, water, and hydrated sulfuric acid. Carbon monoxide (CO), a poisonous gas produced by incomplete combustion, is created when fuel is burned. Incomplete burning results in hydrocarbon emissions (HC).

GT Silencer and Filter Combination

CAT 3516 2 MW – California generator source testing

0%

20%

40%

60%

80%

100%

CO HC DPM

Diesel with Catalyzed Particulate Filter

% Emission Reduction

Diesel emissions account for approximately 70% of all particulate matter contaminating our air, and is now classified as a toxic air contaminant by the California Air Resources Board. The longevity associated with Diesel engines will require retrofits in order to achieve ambient air pollution reductions. GT Silencers utilizes catalyzed particulate filters to dramatically reduce Diesel emissions. The advanced technology behind the catalyzed Diesel particulate filters help engines to comply with governmental emissions regulations by reducing toxic levels of Diesel particulate matter, carbon monoxide and hydrocarbons. The filter consists of a cellular ceramic substrate. Exhaust gases enter a honeycombed maze of channels that actually captures the particulates. The filter is designed to be self-regenerating. The special catalytic coatings on the filter substrate interact with the gases and carbon particles to create complex chemical reactions. The interaction between the exhaust gas and the filter creates a chemical reaction, which converts carbon monoxide and hydrocarbons into harmless carbon dioxide and water vapors. Virtually all particles larger than 35 nanometers are efficiently removed from the exhaust. Tests have shown that up to 95% of the DPM is removed. Hydrocarbons and carbon monoxide are also reduced by up to 95%.

The regeneration process is dependent on exhaust temperatures. High sulfur fuels (greater than 15 ppm sulfur content) require a minimum exhaust temperature of 375 to 390 C (approx 700 to 735 F). Ultra low sulfur fuels (less than 15 ppm sulfur content) require a minimum temperature range of 340 to 350 C (approx 645 to 665 F). GT Exhaust Systems catalyzed Diesel particulate filter silencer features a special thermal wall inserted between the double shells. This construction is modified to prevent any fiberglass from escaping into to exhaust systems or filters. The thermal wall aids in capturing and retaining the exhaust temperature while the gases pass through the silencer, allowing for optimal regeneration and performance of the catalyzed Diesel particulate filters.


Diesel Particulate Filters GT Exhaust Systems, Inc. (Catalyzed Soot Filters) Lincoln, Nebraska

Test results of GT Exhaust filters incorporated in a GT Exhaust Silencer To meet the 85% particulate reduction requirement of the California Air Resources Board (CARB) and the local AQMD, GT Exhaust filters incorporated inside a GT Exhaust critical grade, low profile silencer were installed on a MY2000 Caterpillar 3516B, 2 megawatt generator set operating on ultra low sulfur diesel fuel. Emissions source testing was performed on the generator set. Gaseous analyses for carbon monoxide (CO) and total hydrocarbon (THC) emissions were performed conforming to CARB Method 100 for Stationary Source Testing, and particulate matter (PM) analysis was performed conforming to CARB Method 5 for Stationary Sources. Method 5 is a more encompassing measurement of particulate than the EPA full-dilution method, as liquid and gaseous components in the exhaust stream are included in the PM measurement.

GT Silencer and Filter Combination

CAT 3516 2 MW – California generator source testing

The graph illustrates the high reductions for PM, carbon monoxide (CO), and total hydrocarbons (THC). Three different load operations were tested: 50% load, or 1 MW, 75% load or 1.5 MW, and 100% load or 2MW. Results from each load are presented along with the weighted ISO8178 average. The average reduction for PM is 85%, CO and THC reductions are extremely high, >95% and >90%, respectively. These high reductions confirm those obtained by other 3rd party testing on GT Exhaust System products, such as at the Southwest Research Institute in San Antonio, TX and the Motor Test Center in Sweden.

Part Number Identification System

501DF-4-4118-2-xxxxx

Style – Inlet and Outlet Configuration

Ma

Pains

Silencer Des

501 Oval Bod511 Dual Inle516 Dual Inle518 Dual Inle

402-323-7272Email gtexhau

Signifies Diesel Particulate Filter Element

501DF - 4 - 4118 - 2- xxxxx Print Number. Refer to this drawing number for detail specifications, special modifications, and/or add-ons.

501 signifies oval body

Silencer Grade and outlet sizeximum No. of Dieselrticulate Filter Elementstalled in the Silencer

ign Options

Filter Element Part No and Dimensions

DF-1500 15.78” Diameter (x) 15.38” long y t Oval Body for Cummins Engines t Oval Body for Caterpillar Engines t Oval Body for DDA/Kohler Engines

Toll Free 1-800-775-2466 Fax 402-323-7270 [email protected] 106 Technical Assistance 903-758-3624 or 402-323-7298 17

501DF- 4100 Series GT Exhaust Systems, Inc. Diesel Particulate Filter Silencers Lincoln, Nebraska

Representative Attenuation Curve for 501DF-4100 Catalytic Silencer

OCTAVE BAND

0

5

10

15

20

25

30

63 Hz 125Hz

250Hz

500Hz

1000Hz

2000Hz

4000Hz

8000Hz

Center Frequency Hz

Inse

rtion

Los

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s (R

ef 0

.000

2 M

icro

bars

)

Easy access allows quick installation / removal of filters Inlet and Outlet Nozzles equipped with test ports Variety of Inlet & Outlet Configurations

MEle

MEle

MEle

A 2size

APPLICATION Silencer incorporates a passive system utilizing filters toburn the particulates at normal Diesel exhaust temperatures. CONSTRUCTION Silencer features easy access panel(s) allowing quickinstallation and removal of the Diesel particulate filters.Standard with 125/150# ANSI flanged connections. Engineflanges may be substituted when applicable. Typical attenuation : 501DF-4100 : 22 to 29 dB’A’ Available in Stainless Steel. Consult factory for additionalmaterial options.


501DF-1-4100 1 Filter Series For Diesel Particulate Filter Silencers


ax ments

Outlet Dia

Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 2 8 25 62 70 65 60

1 6 25 46 70 65 60 2 10 25 66 82 77 72 1 8 25 48 70 65 60 2 12 25 66 82 77 72 1 10 25 50 82 77 72 2 14 25 66 94 89 84 1 12 25 50 82 77 72 2 16 25 70 94 89 84



ax ments

Outlet Dia

Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 4 12 25 88 94 89 84

3 10 25 66 82 77 72 4 14 25 88 94 89 84 3 12 25 66 82 77 72 4 16 25 88 106 101 96 3 14 25 66 94 89 84 4 18 25 88 106 101 96 3 16 25 70 94 89 84 4 20 26 88 106 101 96 3 18 25 80 94 89 84 4 22 26 88 106 101 96 3 20 26 84 106 101 96 4 24 28 88 118 113 108



ax ments

Outlet Dia

Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 5 14 41 80 94 89 84 6 16 41 88 106 101 96 5 16 41 80 106 101 96 6 18 41 93 106 101 96 5 18 41 80 106 101 96 6 20 41 93 106 101 96 5 20 41 84 106 101 96 6 22 41 93 106 101 96 5 22 41 84 106 101 96 6 24 41 93 118 113 108 5 24 41 88 118 113 108 6 26 41 93 118 113 108 5 26 41 92 118 113 108 6 28 41 93 130 125 120

0” minimum clearance is required for removal of the elements through the access opening(s) on the converter silencer. However due to the and weight of the particulate filter, GT Exhaust recommends a clearance of 26” or more.

don

19



OCTAVE BAND

05

101520253035404550

63 Hz 125Hz

250Hz

500Hz

1000Hz

2000Hz

4000Hz

8000Hz

Center Frequency Hz

Inse

rtion

Los

s in

Dec

ibel

s (R

ef 0

.000

2 M

icro

bars

)

Easy access allows quick installation / removal of filters Inlet and Outlet Nozzles equipped with test ports Packed thermal shell reduces heat loss Variety of Inlet & Outlet Configurations

MEle

MEle

MEle

A 2size

APPLICATION Silencer incorporates a passive system utilizing filters to burn theparticulates at normal Diesel exhaust temperatures. CONSTRUCTION All welded heavy duty steel. Special internal design incorporateshigh density acoustical insulation inserted between the shells.Insulation is isolated from the exhaust chambers eliminating possiblecontamination, and retains the exhaust gas heat within the silencerfor optimum catalytic performance. Silencer features easy access panel(s) allowing quick installation andremoval of the Diesel particulate filters. Standard with 125/150#ANSI flanged connections. Engine flanges may be substituted whenapplicable. Typical attenuation : 501DF-5100 : 27 to 35 dB’A’ Available in Stainless Steel. Consult factory for additional materialoptions.




ax ments

Outlet Dia

Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 2 8 27 60 82 77 72

1 6 27 48 76 71 66 2 10 27 60 82 77 72 1 8 27 48 82 77 72 2 12 27 62 94 89 84 1 10 27 52 82 77 72 2 14 27 65 94 89 84 1 12 27 62 94 89 84 2 16 27 74 106 101 96



ax ments

Outlet Dia

Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 4 12 27 90 94 89 84

3 10 27 70 82 77 72 4 14 27 90 94 89 84 3 12 27 70 94 89 84 4 16 27 90 106 101 96 3 14 27 70 94 89 84 4 18 27 90 118 113 108 3 16 27 74 106 101 96 4 20 28 90 118 113 108 3 18 27 84 118 113 108 4 22 30 92 130 125 120 3 20 28 88 118 113 108 4 24 32 92 130 125 120



ax ments

Outlet Dia

Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 5 14 45 82 94 89 84 6 16 45 97 106 101 96 5 16 45 82 106 101 96 6 18 45 97 118 113 108 5 18 45 84 118 113 108 6 20 45 97 118 113 108 5 20 45 86 118 113 108 6 22 45 97 130 125 120 5 22 45 88 130 125 120 6 24 45 97 130 125 120 5 24 45 92 130 125 120 6 26 45 97 130 125 120 5 26 45 96 130 125 120 6 28 45 97 142 137 132


don

21



OCTAVE BAND

0

5

10

15

20

25

30

35

40

45

50

63 Hz 125Hz

250Hz

500Hz

1000Hz

2000Hz

4000Hz

8000Hz

Center Frequency Hz

Inse

rtion

Los

s in

Dec

ibel

s (R

ef 0

.000

2 M

icro

bars

)

Easy access allows quick installation / removal of filters Inlet and Outlet Nozzles equipped with test ports Packed thermal shell reduces heat loss Variety of Inlet & Outlet Configurations

MEle

MEle

MEle

A 2size

APPLICATION Silencer incorporates a passive system utilizing filters to burn theparticulates at normal Diesel exhaust temperatures. CONSTRUCTION All welded heavy duty steel. Special internal design incorporateshigh density acoustical insulation inserted between the shells.Insulation is isolated from the exhaust chambers eliminating possiblecontamination, and retains the exhaust gas heat within the silencerfor optimum catalytic performance. Silencer features easy access panel(s) allowing quick installation andremoval of the Diesel particulate filters. Standard with 125/150#ANSI flanged connections. Engine flanges may be substituted whenapplicable. Typical attenuation : 501DF-6100 : 30 to 38 dB’A’ Available in Stainless Steel. Consult factory for additional materialoptions.




ax ments

Outlet Dia

Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 2 8 27 64 106 101 96

1 6 27 56 94 89 84 2 10 27 64 118 113 108 1 8 27 60 106 101 96 2 12 27 70 118 113 108 1 10 27 64 118 113 108 2 14 27 70 130 125 120 1 12 27 70 118 113 108 2 16 28 76 142 137 132



ax ments

Outlet Dia

Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 4 12 27 90 118 113 108

3 10 27 70 118 113 108 4 14 27 90 130 125 120 3 12 27 70 118 113 108 4 16 28 90 142 137 132 3 14 27 70 130 125 120 4 18 30 90 142 137 132 3 16 27 76 142 137 132 4 20 34 90 142 137 132 3 18 30 86 142 137 132 4 22 36 92 154 149 144 3 20 34 90 142 137 132 4 24 38 92 166 161 156



ax ments

Outlet Dia

Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Out Max

Elements Outlet

Dia Hgt B

Width W

OAL 1 End Inlet

OAL 2 Side Inlet

OAL 3 Side

Inlet/Outlet 5 14 45 82 130 125 120 6 16 45 97 142 137 132 5 16 45 82 142 137 132 6 18 45 97 142 137 132 5 18 45 84 142 137 132 6 20 45 97 142 137 132 5 20 45 86 142 137 132 6 22 45 97 154 149 144 5 22 45 88 154 149 144 6 24 45 97 166 161 156 5 24 45 92 166 161 156 6 26 45 97 178 173 168 5 26 45 96 178 173 168 6 28 45 97 178 173 168


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23

GT Exhaust Systems, Inc. Accessories Lincoln, Nebraska Catalytic Replacement Elements & Filters Panel Elements Diesel Particulate Filters Panel Elements

Part No Type

CE-7140 Oxidation Full Panel CE-7141 Oxidation Half Panel

CE-1136 Three Way Full Panel CE-1241 Three Way Half Panel

Diesel Particulate Filters

Part No Size

DF-1000 10.5 Dia x 12 Lg

DF-1114 11.25 Dia x 14 Lg

DF-1500 15.78 Dia x 15.38 Lg

Round Elements Replacement Gaskets

Panel Gaskets Lid

402-323-7272 Email [email protected]

Panel Gaskets

Part No For

PG-1512 Half Panel Oxidation or Three Way PG-1524 Full Panel Oxidation or Three Way

Round Elements

Part No Dia Type Part No Dia Type

RO-6 6 Oxidation R3-6 6 Three Way RO-8 8 Oxidation R3-8 8 Three Way RO-10 10 Oxidation R3-10 10 Three Way RO-12 12 Oxidation R3-12 12 Three Way RO-14 14 Oxidation R3-14 14 Three Way RO-16 16 Oxidation R3-16 16 Three Way

Gaskets

Lid Gaskets

Part No For

LG-XXX All Lids - XXX = perimeter length, inches

LG-ROLL All Lids - Full roll, 100 feet

Toll Free 1-800-775-2466 Fax 402-323-7270 106 Technical Assistance 903-758-3624 or 402-323-7298 24

GT Exhaust Systems, Inc. Terms of Sales Lincoln, Nebraska

402-323-7272 Toll Free 1-800-775-2466 Fax 402-323-7270 Email [email protected]

Terms of Sales for Catalytic Silencers

All terms of sales are subject to credit approval by GT Exhaust Systems, Inc. Actual terms may vary depending on specific conditions and customer’s credit report.

Three Way and Oxidation Catalytic Silencers

Net 30 for most orders on approval of credit. Large orders may require a deposit at time order is placed. Consult factory for specific details.

106 Technical Assistance 903-758-3624 or 402-323-7298 25

GT Exhaust Systems, Inc. Specification Sheet Lincoln, Nebraska

Phone 402-323-7272 Fax 402-323-7270 Engr Fax 402-323-7271 Email: [email protected] Web: http://www.gtexhaust.com Technical Assistance: 903-758-3624 or 402-323-7298

26

OXIDATION AND 3-WAY CATALYTIC CONVERTER-SILENCER SPECIFICATION

The Catalytic Converter Silencer shall be a model ____ V__ - __ - _ _ _ - _1_ _ as manufactured by GT Exhaust Systems, Inc. When inserted in the exhaust system of a _______________ model ___________ operating at _________ bhp/ekW @ _______ rpm, with an exhaust flow rate of ___________ (value & units) @ ______°F, and having the following exhaust emissions:

NOx ______________ (value & units), CO ______________ (value & units), NMNEHC _____________

(value & units), HCHO ______________ (value & units).

With an O2 concentration of _____ %, the converter-silencer shall be guaranteed to reduce and/or oxidize the emissions to no

more than:

NOx ______________ (value & units), CO ______________ (value & units), NMNEHC ______________

(value & units), HCHO ______________ (value & units)

The catalyst shall be provided in modular rectangular elements in full size and half size. The silencer body shall have a maximum capacity of ____ modular rectangular elements arranged to provide parallel flow paths, and shall ship with _______ full size elements and

_______ half size elements. Remaining slots shall be fitted with blank elements which may be removed and replaced with active elements should future reduction requirements change. Each full size element shall be 15.454” X 24.75” X 3.7”; each half size element shall be 15.454” X 12.375” X 3.7”. A minimum net volume of catalyst elements shall provide a calculated space velocity of no more than _____________ hr-1, based a scfh flow rate corrected to 14.7psia and 32°F. Modular Catalyst elements shall be accessed through a removable cover plate, sealed by a face gasket applied to the element frame and secured in place by a release mechanism. Individual elements shall not exceed a weight of 40 lb and be easily handled by one person without the need for any lifting devices or special tools. With the specified amount of catalyst installed, and for the stated engine exhaust gas operating conditions, the pressure drop restriction shall not exceed______ inches H2O. Installation of additional active elements shall cause the pressure drop to be less than that of the “as shipped” arrangement. The Catalytic Silencer body shall be constructed of _________ steel, and shall provide _____-_____ dB-A noise reduction. The

outlet shall be located on the _________ of the body and shall terminate with a _____ inch plate flange to match an ANSI 125/150#

pattern. The inlet(s) shall number _______, and be located on the ____________ of the body and shall terminate with a _____ inch plate flange(s) to match an ANSI 125/150# pattern. 3-Way Catalyst elements shall have the P.M. applied to a wash coat for surface area magnification. The substrate shall be stainless steel foil embossed with a herringbone pattern and folded to provide framed modular elements or half size elements as specified above. The herringbone pattern shall, when folded and assembled into a rectangular channel frame provide 320 cells per square inch (CPSI). Oxidation Catalyst elements shall have the P.M. applied to a wash coat for surface area magnification. The substrate shall be stainless steel foil embossed with a herringbone pattern and folded to provide framed modular elements or half size elements as specified above. The herringbone pattern shall, when folded and assembled into a rectangular channel frame provide 150 cells per square inch (CPSI).

complete catalytic catalog 106

Documents

exhaust gas

h2o co2

o2 co2 co2

h2o soot hc

hc control

h2o aldehydes

catalytic oxidation

diesel exhaust