doc 7 - mammoth equipment & exhausts presentation - email version... · the passive...
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MAMMOTH OVERVIEW
• A private company established in 1974.
• Mammoth is part of the fast growing MEI Group and is fully Australian owned and
operated.
• Specialists in developing & manufacturing standard and customised replacement
exhaust components for all brands of marine, transport, earth moving and mining
equipment. In many cases we have improved original OEM designs.
• Due to our extensive industry knowledge we can develop products that fit correctly
and work on the first go, not trial and error.
• We have products that are PROVEN in the industry.
• Innovative and Flexible design capabilities to meet specific vehicle requirements,
operating conditions and environmental legislation.
• Warehouses in Western Australia & Queensland and distributors in other states.
MAMMOTH OVERVIEW
• DIESEL PARTICULATE FILTERS
• Replacement Exhaust Products
• Air Intake Components
• Diesel Exhaust Purifiers
• Custom Built Silencers
• SCR Silencers
• Universal Exhaust Products
• Thermal Products & Accessories Blankets, Lagging, Double Skinned Pipework
• Exhaust Testing Equipment
• AdBlue
• AdBlue Storage & Dispensing
Equipment
HOW CAN DIESEL PARTICULATES
BE REDUCED?
Retrofit of DPF – remove DPM at the source
Mammoth Equipment and Exhausts has successfully
developed many standard retro-fit DPF’s as a cost-effective
solution for both heavy-duty and ancillary equipment. The
filters have been proven in many applications and are renown
for their effectiveness and reliability.
The filter has been very consistent in achieving high reductions
of DPM in many varied applications. Tailpipe testing has
demonstrated reductions at the source of 60-91% for the
Sintered Metal Filters and 93-99% for the Diesel Particulate
Filter.
THE FILTER TYPES
DIESEL PARTICULATE FILTER (DPF)
• Diesel Oxidation Catalyst (DOC) and
Diesel Particulate Filter (DPF).
FEATURES
• Very durable substrate – withstands high
temperatures
• Backpressure is within OEM
specifications.
• High soot load capabilities.
• No regeneration aids or fuel additives.
• Eliminates opacimetric acceleration
smoke.
• Suits heavy duty cycle.
• Very low maintenance.
• Industry proven technology.
SINTERED METAL FILTER (SMF)
• Diesel Oxidation Catalyst (DOC) and
Sintered Metal Filter (SMF).
FEATURES
• Enhanced durability due to the metallic
substrate.
• Simultaneous noise reduction.
• Easy integration into exhaust system due
to compact filter size.
• Light duty cycle.
• Less likely to block when used in low
exhaust gas temperatures.
• Maintenance free
DPF SNAPSHOT
WALL FLOW FILTER
DIESEL OXIDATION CATALYST
The passive regeneration ZERO filter is a very efficient cleaning system of diesel exhaust.
This DPF removes up to 99% of diesel particulates. The system consists of an oxidation
catalyst upstream of the wall flow filter substrate. The highly durable ZERO filter is
available to suit most heavy diesel equipment.
SMF SNAPSHOT
PARTIAL OXIDATION CATALYST
DIESEL OXIDATION CATALYST
The ZERO Sintered Metal Filter is a new oxidation catalyst concept that is ideal
for use on light vehicles and ancillary equipment as it does not require high
engine use to regenerate.
Sooted Inlet (DOC) Clean Outlet (POC)
DPF CASE STUDIES – Atlas Copco MT6020
AFTER 4000 HOURS
ADVANTAGES
• 99.8% PM reduction.
• No site modifications.
• Easy to fit.
• Very low maintenance.
• Back pressure within OEM specifications.
No evidence of soot
AFTER DPF FITTED
-2
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
0 10 20 30 40 50 60 70
Pa
rtic
le C
on
cen
tra
tio
n (
mg
/m³)
Time (seconds)
ATLAS COPCO MT6020
Series1
Series2
DPF CASE STUDIES – Atlas Copco MT6020
TESTING INFORMATION
99.8%
Reduction
DPF CASE STUDIES – CAT AD55B
BEFORE DPF FITTED AFTER DPF FITTED
• 98% DPM reduction
• No site modifications
• Easy to install
• Reduced impact design.
• minimalmaintenance
Note above filter, manufactured as reduced impact
design. OEM design was notorious for recurring impact
damage.
ADVANTAGES
DPF CASE STUDIES - CAT AD55B
TESTING INFORMATION
0
2
4
6
0 10 20 30 40 50 60
Par
ticl
e C
on
cen
trat
ion
(m
g/m
³)
Time (seconds)
AD55B DPF FILTER COMPARISON TEST
98%
Reduction
DPF CASE STUDIES – CAT AD55B
TESTING PHOTOS
Test conducted with Mammoth DPF fitted to a CAT
AD55B Dump Truck with CAT Acert C27 engine.
Inlet photos after 20 minutes operation under full load Photo of clean outlet after 20
minutes of operation under full load.
CERTIFICATIONS; ABOUT THE VERT TEST
• VERT® is a Swiss based organisation focused on Diesel Particle Filter Testing,
Certification and Quality Control Systems, with 15 years of international emissions
experience.
• VERT® certification represents Best Available Technology (BAT).
• The VERT® test evaluates filtration efficiency, and thoroughly controls possible secondary
emissions and tests endurance. Due to the stringent requirements of the VERT® tests,
only a small number of filter substrates have achieved VERT® certification globally.
VERT® Test Protocols:
• Test BC ultrafine particle number (PN) concentration.
• Test Particle Size Influence.
• Test Space Velocity Sensitivity.
• Test Regeneration and Emissions during Regeneration.
• Test Soot Loading Influence and Backpressure.
• Test Reliability under Rough Field Operation.
• Test Long Endurance and Aging.
• Test Worst Case Conditions.
• Monitor Emission Stability.
• Monitor Manufacturing Stability.
CONCLUSION – WHAT VERT SAID
ABOUT OUR FILTER SUBSTRATE
• ‘with the investigated DPF there is a very efficient
filtration of Nano particulates (up to 99.99%)’.
• ‘the used DPF eliminates very well the opacimetric
acceleration smoke’.
• ‘The regeneration of the DPF worked very well’
• ‘due to the catalytic activity of the used trap there
are: strong reduction of HC, elimination of CO,
with minimal increase of NO2.
CERTIFICATIONS
• VERT I
• VERT II + III (Feb ’09)
• London LEZ
• CARB (Feb ‘09)
• MSHA approved system
SMF CASE STUDIES: LANDCRUISER
• ‘Fit and Forget’
• Bolt-on exchange
• 91% DPM Reduction with Sintered
Metal Filter (SMF)
• No filter blockages
• Very cost effective
• Maintenance free
CASE STUDY: WA MINE
STAGE 1: DP Filters fitted to:
6 x CAT R2900G boggers
1 x CAT AD45B
2 x CAT AD55
Average DPM exposure before start of filter fit out – 0.16mg/TWA
At Stage 1: Average DPM exposure after filter fit out – 0.09mg/TWA
RESULT: 56% of heavy vehicle fleet fitted with a Mammoth DPF resulted in 44% overall TWA reduction.
STAGE 2 (To be completed):
DP Filters fitted to:
7 x CAT AD55B
INSTALLATION
Caterpillar AD45B underground
dump truck with OEM exhaust system.
OEM exhaust system removed.
New DPF installed. Exhaust system fits original brackets
with no modifications necessary.
Less than 60 minutes later
Close-up view of DPF.
What is involved in installing the filter?
The filter is installed within the footprint of the muffler and uses the existing brackets and mounting points.
LIFE EXPECTANCY & SERVICING
The ZERO DPF has proven to be extremely durable and reliable in the harsh
underground environment. Some of our DPF’s have been in operation for
between 10 000 and 15 000 hours.
R2900 DPF after 8000 hours New R2900 DPF
It is recommended to rotate the filter every 1000 hours. This is a simple process that
can be carried out as part of the regular maintenance schedule.
BACKPRESSURE
All Filters are designed and manufactured to ensure they perform within
OEM specifications.
Backpressure testing conducted on Atlas Copco MT6020 with and without
ZERO filter.
RESULT:
Atlas Copco MT6020 (standard muffler) - 13 inches H20
Atlas Copco MT6020 with ZERO DPF - 10 inches H20
OPTIONS: CUSTOMISED PRODUCTS &
SERVICES
• Sound Suppression
• Thermal Blankets and Lagging
• Back Pressure Monitors
Customised Products Services
• Tail-Pipe DPM Gas
testing.
APPLICATIONS
Machines fitted with Mammoth ZERO filter to date:
ATLAS COPCO
TRUCKS
MT5010, MT6020
CATERPILLAR – ELPHINSTONE
TRUCKS
AD40, AD45B, AD55A, AD55B
BOGGERS
R1300, R1500, R1600G, R1700G, R2900, R2900G
IT LOADERS
972G, 966G, 966H, 924G, 930G, 930H
SKID STEERS
232B, 246C
DOZERS
D10R
FRANNA CRANES
20T Model
NORMET
1610B, 6605B
TORO - SANDVIK
TRUCKS
T50+, TH660H
LOADERS
T11, 006, 0010, LH514, LH517, 1400
TOYOTA
HZJ79 LHD, HZJ79 RHD, VDJ76
‘We can make the ANY filter to suit any off-road
machine or engine’
SUMMARY
• Mammoth Diesel Particulate Filters are a tried and proven solution.
• Diesel Particulate Matter is managed at the source.
• Fuels, Oils and Additives are not essential to filter.
• We have technology available which dramatically reduces Diesel Particulate Matter
• Diesel engines can effectively be fitted with after treatment devices.
• Retrofit, Standard and Customised solutions.
• Manufactured by experienced heavy duty exhaust specialist. We have been in the industry
for 38 years.
• Innovative company that is willing to adapt any new challenges.
• Looking for opportunity to prove our technology in coal mines
Freecall: 1300 310 340
Email: [email protected]
Web: www.mammothequip.com.au
Owner and manufacturer of the following product brands: