1. 1© Confidential Orbital Corporation Ltd
September 2017
ACARP
Wall-Flow DPF Project
27th Mechanical Engineers Safety Seminar

2. 2© Confidential Orbital Corporation Ltd
Today’s presentation
• Review some key findings from the ACARP
project(s) to develop wall-flow DPF tech
• Share particulate and emission results
Best approach to underground air quality is
point source control; ventilation is only a remedy
Today Tomorrow The Future

3. 3© Confidential Orbital Corporation Ltd
Australian Coal Industry Challenges
Underground coal mining has largely electrified many operations, but diesel
engines are still used for load-haul-dump (LHD) vehicles and man transporters.
<150oC
• Tailpipe exhaust
• All surfaces
Ambient CH4
• Comply at elevated levels
• Shutdown at excessive levels
Pollutants
• Particulate
• Ultra-fines
• Gaseous
Explosion Proof
• Certification

4. 4© Confidential Orbital Corporation Ltd
About ACARP…
ACARP – Australian Coal Industry’s Research Program;
formerly Australian Coal Association Research Program
Fundamental research projects
Applied research projects
Commissioned projects
A$0.05 per tonne
collected from all
black coal
produced in
Australia
Access to
R&D
taxation
rebates and
generated
research
Nominal
ACR budget
~$18m/year;
100% industry
funded
ACARP &
Industry Monitors
• Bevan Kathage
• Shayne Gillett
• Steve Coffee
• Dr Bharath Belle
• Andy Withers

5. 5© Confidential Orbital Corporation Ltd
About Orbital…
• Over 30 years of experience in:
• Mechanical design and prototype
• Engine testing and development
• Electronic design and production
• Control system design
• Engine systems manufacture
• A track record of supporting
global customers
• ISO9001 quality assurance

6. 6© Confidential Orbital Corporation Ltd
Project Outline
ACARP project C25073 was proposed by industry
stakeholders seeking an exhaust aftertreatment solution that:
• Enhances worker health through improved underground
air quality; and
• Reduces operational costs associated with currently
implemented diesel particulate emissions systems.
2017 will see the industrialisation
of the system for commercial trials,
including a DPF monitoring system
▲ Typical Load-Haul-Dump (LHD) vehicle used in underground coal

7. 7© Confidential Orbital Corporation Ltd
What is a Wall-Flow DPF?
Images © Johnson Matthey Catalysts Inc.
2HC + O2 2CO2 +H2O
2CO + O2 2CO2
2NO + O2 2NO2
Oxidation
Chemistry
Wall-Flow Filter Technology

8. 8© Confidential Orbital Corporation Ltd
Removal of Soot via CCRT Regeneration
Images © Johnson Matthey Catalysts Inc.
1
2C + O2 2CO2 ~600°C
2NO + O2 2NO2 With coated filters
2
C + 2NO2 CO2 + 2NO 250-300°C
3

9. 9© Confidential Orbital Corporation Ltd
Approach to Development
• Given explosion risks for product innovation in a
working coal mine an alternate approach to
development was adopted
• Characterisation of LHD operations in a working
mine were used to develop a series of real world
engine cycles for use during development
• Development was then undertaken off-line using a
state-of-the-art engine test facility, with hardware
transferred to the mine for confirmation testing
150oC

10. 10© Confidential Orbital Corporation Ltd
Developed Test Cycles
▲ Comparison of Regulatory and Fleet
Based profile of LHD engine operation
(Steady State engine testing points)
▼ Transient cycle representing a variety of
LHD operations in underground coal
mining composited into a single cycle
15%
15%
15%
10%
10%
10%
10%
15%
50%
7 Mode
9%
4% 3%
13%
15%
6%
53%
8 Mode
9% 13% 12% 5%
3%
2%
3%
-100
100
300
500
700
900
1100
1300
500 700 900 1100 1300 1500 1700 1900 2100 2300 2500
EngineTorque(Nm)
Engine Speed (rpm)
NRSC (ISO 8178 C1, Regulatory Cycle MDG43)
Custom 7 Mode Steady Cycle (fleet survey)
Custom 8 Mode Steady Cycle (fleet survey)
EngineTorque(Nm)
Engine Speed (rpm)
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
0
500
1000
1500
2000
2500
0 200 400 600 800 1000 1200 1400 1600 1800
EngineTorque(Nm)
EngineSpeed(rpm)
Cycle Time (s)
Engine Speed (rpm)
Engine Torque (Nm)
Laying
Cable
Lightly loaded
bucket
up incline
Raising heavily
loaded bucket
Dragging
road leveller
up incline
Unloaded
up incline
Unloaded
down decline
Cycle Time (s)
EngineSpeed(rpm)
EngineTorque(Nm)

11. 11© Confidential Orbital Corporation Ltd
Heavy Duty Engine Development Facility
Data acquisition
(temp and press)
Exhaust
Extaction
Exhaust Flow
by Horiba PTFM
Gravimetric PM,
Partial Dilution
4x Samples
AC Dyno
for Transients
Water Brake Dyno
for Steady State
Floating testing
bed for vibration
dampening
Fire Suppression
System
Intake Air,
with optional LFE
Data acquisition
(custom and
high-speed)
Onosokki
Fuel Flow Meter
Horiba gaseous
emissions
(next room)
Underfloor
coolant control
Precision
Torque Flange
Underfloor
coolant control
Intake
intercooling
(also underfloor)
Intake
intercooling
(also underfloor)
Fuel Conditioning
LNG Flow Meter

12. 12© Confidential Orbital Corporation Ltd
PM reductions in excess of 95% over both
regulated and real world cycles with the selected DPF.
Results – Particulate Mass (PM2.5)
NRSC NRTC

13. 13© Confidential Orbital Corporation Ltd
▲ Conventional wet scrubber and
disposable filter system
▲ Proposed layout of the wall-flow filter system
meeting underground coal regulations
System Changes
Diesel
Engine
Wet
Exhaust
Scrubber
Combination of water
cooling and insulation to
control surfaces below
150oC
T
u
r
b
o
DOC
DPF
Particle filtered
exhaust, and
below 150oC
Insulating jacket on
DOC/DPF module to
control surface
below 150oC
Combination of
water cooling
and insulation to
control surfaces
below 150oC
Diesel
Engine
Wet
Exhaust
Scrubber
Filter
Basket
Optional
oxidation
catalyst
T u r b o
Particle filtered
exhaust, and
below 150oC
Water jacket on
exhaust to control
surface below
150oC

14. 14© Confidential Orbital Corporation Ltd
System Surface Temperature
▲ Comparison of Proof-of-Concept CCRT DPF
with Insulated Surface Temperatures
▲ FLIR thermal images for 9.5”
Insulated DPF at 1200rpm Full-Load
(the highest EGT point; images
shown from Entry to Exit)
1 2
43

15. 15© Confidential Orbital Corporation Ltd
Project Milestones – Completed C25073
Project Activity
Phase 1 Part 1 - Onsite Duty Cycle Analysis and development of
custom test cycles
Part 2 - Engine Setup/Baseline and Correlation to Real
World
Part 3a - Hot System DOC+Filter
Phase 2 Part 3b - Preliminary (Aboveground)
Site Trial (hot system)
Part 4 - P1 Design Engineering - Cold exo-surface
DOC/Filter System
Part 5 - P1 Cold System PoC/Development
P1 is first level prototype; where proof-of-concept is demonstrated.

16. 16© Confidential Orbital Corporation Ltd
Next Project Milestones – C26070
Project Activity
Phase 1 Part 6a - Industrialisation Design - DPF, pipework
and basic monitoring
Part 6b - On-Engine Validation and Durability Testing
of P2* system
Part 6c - Field Trial of P2* system incl. Support and
Monitoring System Software Refinement
Phase 2 Part 7a - Emissions Certification Testing
Part 7b - Safety Certification Testing
* System level P2 is second level prototype; which will have the form, function and performance of
a production intent design but will not be made off production tooling/fixtures.

17. 17© Confidential Orbital Corporation Ltd
Newstan Surface Trial – July 2017

18. 18© Confidential Orbital Corporation Ltd
Summary
• ACARP C25070 has successfully demonstrated
that a wall-flow DPF system can be engineered to
meet the requirements of underground coal.
C26070 is continuing the work
• Characterisation of LHD operations in a working
mine were used to develop a series of real world
engine cycles for use during development
• Development was then undertaken off-line using a
state-of-the-art engine test facility, with hardware
transferred to the mine for confirmation testing
150oC

19. 19© Confidential Orbital Corporation Ltd
Acknowledgements:
ACARP and Industry Monitors
Contact Info
Website: www.orbitalcorp.com.au
Nick Coplin ncoplin@orbitalcorp.com.au
+61-8-9441-2379

20. 20© Confidential Orbital Corporation Ltd
www.orbitalcorp.com.au
+61-8-9441-2311
▲ CAD – Design Engineering ▲ CFD / FEA / Analysis
▲ Prototyping and Supply
▲ Fuel System Testing▲ Alternative Fuels – NG, Bio▲ Engine Test – 3hp to 800hp
▲ Vehicle Fitout & Modification▲ Failure Analysis&Metrology
▲ Embedded Electronics