Experience with 7000 Particle Filter Retrofits onroad and offroad in

Switzerland

Andreas Mayer / TTM

PM- Emissionen onroad und offroad

0.0%10.0%20.0%30.0%40.0%50.0%60.0%

Liefer

wagen

Schwere

Nutz

fahrz.

Busse

Person

enwag

enOnro

ad to

tal RailNav

igatio

n

Constr

uctio

n mac

hines

Agricu

lture

& Forestr

yInd

ustry

Military

Offroad

total

Swiss DPF Regulations

• 1990 (EJPD): Retrofit only permitted under conditions:- no additional Noise Emission- no Formation of secondary toxic Air Contaminants

• 1994: SUVA: Diesel-Emissions DME carcinogenic• 1998: LRV: Diesel-Soot carcinogenic• 1998: Limit for Stationary Engines < 5 mg/m3• 2000: SUVA: PFS mandatory underground• 2002: BUWAL-BauRLL: PFS mandatory

for construction (B-type construction sites)• 2003: only VERT approved PFS for onroad vehicles

Quality Control Instruments VERT-Standards

Homologation Procedureand Field Control

Not all Filters are good Filters

VERT specifications for particle trap systems

New

> 95%

2000 hrs

> 95%

> 90%

0.12 m-1

85%

< 0.12 m-1

No increaseof limited emissions CO, HC, NOx and PM

No relevant increaseof secondary toxic emissions

Filtration efficiency number countNumber concentration“ of solid particlesin the size range 20-300 nm

Filtration efficiency EC massEC mass concentration

Opacity during free acceleration

VERT Filter Suitability Test

• VFT1: PFS new• VSET: Secondary Emissions Test

(PAH, Nitro-PAH, PCDD/F and …total > 150)

• VFT2: 2000 Operation Hours Field Test• VFT3: Repetition of VFT1 after Field Test

VERT-Approval → BUWAL FilterlistVERT-Approval is lost at a Failure Level > 5 % pa

VERT- tested PFS Status 8/2003

Active Regeneration Passive Regeneration Filtration-Efficiency

DEUTZ Full Flow Burner 98 old data

ECS-UNIKAT Electr.Heating Catalyt.Coating 99.99

HJS CRT, FBC (Additives) 99.40

JOHNSON MATTHEY Electr.Heating CRT, FBC 99.50

HUSS Electr.HeatingStandstill-Burner

99.99

DCL Electr.Heating Intake Throttling

FBC, Catalyt.Coating

99.99

ARVINMERITOR Full Flow Burner 99.84

ENGELHARD CSF 99.60

HUG Full Flow Burner Catalyt.Coating 98.60

INTECO FBC 99.24

EHC Exchangable 96.70

TSH Electr.Heating Catalyt.Coating 98.90

Possible Drawbacks:CostNoise

BackpressureInfluence on Fuel Economy

Risks for the Engine and Vehicle

Cost at low and high production volume

• Retrofit Cost at low volume today25 kW :125 Fr/kW - 20 % of vehicle cost

100 kW: 100 Fr/kW - 8 % of vehicle cost> 250 kW: 80 Fr/kW - 5 % of vehicle costCost Reduction expected - Manufacturing Cost by 1/3 within 2 YearsCost of high volume DPF production - LDV: 2 % of vehicle cost- HDV: 2 % of vehicle cost

COST-EFFECTIVENESS 1:4 (10)

Influence of Backpressure on Engine Performance limit 200 mbar

Impact on Noise

Possible Failures

Common Failuresand Measures/Methodsfor Quality-Improvement

as introduced in Switzerland

Spectacular Filter DamageRing-off-Cracks

and Melting of the Cordierite Material source Johnson Matthey

Reasons for Failures: Local Temperature Peaks during Regenerations (source IBIDEN)

0

200

400

600

800

1000

1200

0 2 4 6 8 10 12 14Time(min)

Tem

pera

ture

( ℃)

Soot load : 123.1 g (30.0 g/L)Max.temp. :951 ℃Max.temp.grad. :84.5 ℃/cmRegeneration rate : 94.5 %

Ash Plugging of Filter Cells (source SHELL)

Reliability-History of PFS in Switzerland

• 1990: 230 Filters installed in Buses (DB/M&H-System)1998: still 200 in Operation

• 2000: 2400 PFS in Operation, > 6% Failures pa→ too many Failures urgent measures

• 2003: > 6500 PFS in Operation- Failures < 2-3 % per year - PFS > 750‘000 km with Trucks and Buses- PFS > 10‘000 Bh with Construction Machines- PFS > 30‘000 Bh on a Ferry Boat

• 2005: Construction Directive > 15‘000 PFS expectedFailure Target: < 1% pa

Character of Failures (1)

Most Failures immediately after Retrofit

• Canning Failures of the Ceramic Monolith• Material Failures of the Filter Media• Cementing Failures with segmented Filters • Mechanical Shock: during Transport or Installation • Installation: often insufficient Vibration Decoupling• Operation: wrong Fuel – Sulfur Content too high• Application: wrong System selected• High Lubrication Oil Consumption

Character of Failures (2)

Failures rare after long Operation:

• Backpressure-Alarms not respected• Ash-Cleaning unprofessional• Engine Maintenance careless

Experience proves that VERT-Filters show no aging effects – Filtration Quality remains constant

Measures to improve Qualityintroduced in 2000

• One Filter Family lost VERT-Approval • Introduction of the 2000-hrs Operation Test (VFT2)• Electronic On-board-Control • Access upstream of PFS for emission diagnosis• --------------------------------------------• Use of active Filter-Systems in critical applications• Engine Maintenance and Instruction !!!• Periodic Emission Control by User • Systematic PFS-Selection (CD available)• Use low-S fuels and LASP lubrication oils

VERT- Datalogger

Maintenance Sticker Emission Sticker

AKPF-Q-Labelfor PFS with outstanding Filtration Quality

1

1112

0203 04 05

06

07

Proper Filter Selection: BUWAL Interactive CD

Duty Cycle Analysis: 5 CH Bus-Fleets “EFO”

Planning for Switzerland

Retrofits• Construction 25‘000 (total 55‘000) today: 5‘800• Agriculture 30‘000 (total 110‘000)• Trucks 20‘000 (total 65‘000)• Buses 3‘500 (total 5‘500) today: 1‘200

Incentives for new Vehicles• LD-Vehicles Reduction of Import Tax (4%)• HD-Vehicles Reduction of Road Tax LSVA

Quality Criterion• Ultrafine Particle Number Concentration

Summary and Conclusions (1)

• PFS have excellent emission reduction potential >99%very careful homologation and selection is needed

• PFS have long life and filtration does not deteriorate• PFS are available for all applications • PFS-cost is acceptable – compared to health cost

will soon be further reduced (increasing production and competition)

Summary and Conclusions (2)

• PFS-reliability is acceptable now if carefully controlledcan be further improved ( 3% 1 % failure pa)

• Engine maintenance and periodic checks are very important

• no risk for the engine is backpressure is < 200 mbar • Use of proper fuel and lube oil is important• Applications can and will now be extended in

Switzerland to HDV onroad, Agriculture Tractors and LDV

Thank You for your kind Attention

We are ready for Questions now or later

ttm.a.mayer@bluewin.ch