Characterizing Diesel Particulate Filter Failure During Commercial Fleet Use due to Pinholes, Melting, Cracking, and Fouling

Abstract

Diesel particulate filters (DPFs) are essential particulate matter emission control devices. Some diesel particulate filters have been observed to fail during industrial-fleet vehicle use. DPFs that fail during vehicle use compromise particulate matter emission capture. Herein, failures in cordierite DPF substrates observed during commercial fleet use were characterized as pinhole failure, melt failure, crack failure, and fouling failure. The observed failures were correlated to particulate matter chemical composition and physical changes in the cordierite substrate of the exhausted DPFs. The physical-chemical characteristics of pinhole failure, melt failure, crack failure, and fouling failure were determined by applying scanning electron microscopy-energy dispersive spectrometry (SEM-EDS), X-ray photoelectron spectroscopy (XPS), and X-ray diffraction (XRD). Results indicate that the chemical composition and crystalline structures of cordierite DPF substrate changed according to the failure characterization. The specific changes to the cordierite substrate during failure can contribute towards understanding fundamental DPF failure mechanisms.

Review on Post-Treatment Emission Control Technique by Application of Diesel Oxidation Catalysis and Diesel Particulate Filtration

“…The results of simulation showed that the combustion of soot causes a high temperature rise in the filter which would affect the durability of DPF. Uncontrolled combustion during Fuel based regeneration will result in failure of DPF by formation of cracks, melts and pinholes [1].…”

“…Diesel engines are considered as second leading anthropogenic source of particulate matter (PM2.5 and PM10) which is formed due to combustion of fuel and lubricating oil [1]. The exhaust emission from diesel engine includes carbon monoxide, nitrates, hydrocarbons and particulate matter [2].…”

Using CFD Simulation as a Tool to Identify Optimal Operating Conditions for Regeneration of a Catalytic Diesel Particulate Filter

“…x Oxygen (Equations (2) and (3)) is the oxygen mole fraction in the gas phase, m total (Equation (2)) is the local concentration of soot (all the soot present in the system), and m catalyzed (Equation 3) is the local concentration of soot in contact with the catalyst. The values of the kinetic parameters for Equations (2) and 3are given in Table 1. Table 1.…”

“…Catalytic (i.e., catalyst-coated) diesel particulate filters (DPFs) have been proposed to allow regeneration (i.e., oxidation of soot) at low temperatures [1], thus overcoming the drawbacks of the thermal process, including the formation of excessively hot regions that may cause irreversible damage to the filter [2].…”

Experimental study of lubricant-derived ash effects on diesel particulate filter performance

“…The DPF peak temperature and the maximum temperature gradient during active regeneration are vital for the DPF, because both of them should be controlled within the safety limits of the DPF substrate material to avoid melting or cracking of the DPF. 27 In this study, the DPF temperature field during active regeneration was measured. Theoretically, the circumferential temperature distribution should be uniform if the flow uniformity of the aftertreatment system has been well optimized.…”