Background
Chile has introduced emissions regulations for diesel generator sets, aligned with EU Stage V or US EPA Tier 4 Final standards for non-road mobile machinery. These standards impose limits on Particulate Matter (PM) and Nitrogen Oxides (NOx), requiring advanced exhaust after-treatment solutions.
Our customer in Chile operates diesel generator set in a space-constrained environment and needed a solution that would:
Achieve full regulatory compliance,
Integrate with existing Cummins generator sets without structural modification
Provide reliable, traceable emissions data for government auditing and environmental reporting
Leespower was engaged to design and deliver a compliant, compact, and fully monitorable emissions control solution.
The Solution
Addressing Challenge 1: High-Standard Purification Performance
Integrated Three-Stage Purification System (DOC + DPF + SCR)
Leespower implemented a fully integrated, sequential exhaust after-treatment system:
DOC (Diesel Oxidation Catalyst)
Oxidizes carbon monoxide (CO) and hydrocarbons (HC), while also supporting passive regeneration of the downstream DPF.
DPF (Diesel Particulate Filter)
Physically captures more than 99.5% of particulate matter, ensuring compliance with the extremely low PM limits required under Stage V / Tier 4 Final.
SCR (Selective Catalytic Reduction)
Using diesel exhaust fluid (DEF), the SCR system achieves over 96% NOx conversion efficiency, converting nitrogen oxides into harmless nitrogen and water.
This three-stage architecture delivers robust, stable emissions performance under varying load conditions, ensuring consistent compliance with Chile’s regulatory requirements.
Addressing Challenge 2: Compact and Non-Invasive Integration
“Form-Fitting” Modular Design
Using Computational Fluid Dynamics (CFD) simulation tailored to the specific generator model and engine room layout, Leespower developed a compact, low-backpressure purification module that fits directly into the existing exhaust line.
The optimized flow path minimizes pressure losses and thermal stress.
The modular, form-fitting design reduced installation time by approximately 40% compared to conventional retrofit solutions.
“No-Impact Integration to Base Engine” Principle
Precise backpressure control ensures the total backpressure increase remains below 3 kPa.
This guarantees no adverse impact on engine fuel consumption, rated power output, or dynamic response.
The generator’s core structure and performance characteristics remain unchanged.
Addressing Challenge 3: Monitoring, Data Logging, and Compliance Reporting
Advanced Local Monitoring & Logging System
The solution includes an integrated local monitoring and data management system featuring:
Intuitive Touchscreen HMI (Human-Machine Interface)
Displays real-time critical parameters such as:
Exhaust temperatures
System backpressure
NOx levels
System operating status and alarms
Onboard Data Logger
Securely records all key operational and emissions-related data
Enables easy data extraction for audit trails and compliance reporting
Operates independently, without requiring cloud connectivity, ensuring data availability even in restricted or remote environments
This provides the customer with full transparency, traceability, and confidence during regulatory inspections and environmental reporting processes.
