Diesel Particulate Filters (DPF)

Foley Environmental

Foley Environmental manufactures a complete line of SXS diesel particulate filters (DPF) for off-road diesel fueled engines operating in underground mining, tunneling, construction, materials handling and power generation equipment. The SXS diesel particulate filter effectively reduces particulate matter (PM) , diesel odors (HCHO) and gaseous pollutants (CO and HC) from the exhaust gas flow of diesel engines. Mobile mining equipment diesel engines operate in very difficult working conditions. Exposure to diesel particulate matter and gaseous pollutants by mobile mining equipment operators and other mine personnel is of great concern since ventilation air is sometimes inadequate and/or poorly distributed. Exposure to diesel exhaust is a contributing factor in heart disease, lung disease and has been linked to various forms of cancers. Exposure to diesel exhaust can decrease productivity and increase employee sick time. SXS diesel particulate filters are designed to meet MSHA standards for particulate matter reduction in diesel fueled engines used in underground mining. Foley also offers a variety of retrofit emissions control products designed for mining including SX series diesel oxidation catalysts (DOC) and SXS diesel particulate filters (DPF). The correct use of these products for mining equipment fleets will minimize downtown and costs while achieving the mine’s diesel emission reduction objectives. SXS diesel particulate filters work best on diesel engines manufactured after 1996 (minimum Tier 1) or newer diesel engines. Contact Foley Environmental to determine the feasibility of a SXS diesel particulate filters for older diesel engine applications.

PM Filtering Process of SXS diesel particulate filters:

The SXS diesel particulate filter is a “wall flow” filter which is made up of a large number of small channels which are alternately open or plugged at the inlet / outlet ends of the DPF substrate. The engine exhaust gases and PM are forced to flow through the internal porous channel walls of the filter substrate core due to the alternating inlet / outlet plugs. The PM is trapped within the internal porous walls of the substrate core due to the sieving action of the internal pores and the agglomeration action of PM. Changes in the porosity of the substrate channel walls, the substrate channel cell density, substrate volume and other variables can be altered to increase PM trapping efficiency and reduce exhaust gas back pressure restriction.

Available Substrate Materials for SXS diesel particulate filters:

The SXS diesel particulate filter substrate cores are available in Cordierite Ceramic or Silicon Carbide material compositions. Each substrate core material composition has inherent advantages and disadvantages. Silicon Carbide substrate cores have a higher resistance to thermal stress in comparison to Cordierite Ceramic substrate cores. Therefore a Silicon Carbide substrate core has a higher capacity per liter of filter volume in terms of PM mass in comparison to a Cordierite Ceramic substrate core. Silicon Carbide substrate cores are more expensive in comparison to Cordierite Ceramic substrate cores. Silicon Carbide substrate cores are heavier in comparison to ceramic substrate cores and require a different canning process.

Substrate Coatings for SXS diesel particulate filters:

We offer a variety of exhaust emissions control products for underground mining equipment applications such as SX diesel oxidation catalysts (DOC) and SXS diesel particulate filters (DPF). The correct application of these products will minimize downtown and costs while meeting the mine diesel emission reduction targets. SXS diesel particulate filters are available in 4 coating formats which are described as follows:

1) SXS uncoated diesel particulate filter

The SXS diesel particulate filter is a uncoated DPF which has no base metal or precious metal coating. The SXS diesel particulate filter is best suited for 1990 and newer light to heavy duty engine/equipment applications where continuous engine operation does not exceed 8 to 12 hours. Oversized configurations are available where continuous engine operation may exceed 24 to 36+ hours. The SXS uncoated DPF is not passive in operation and must be manually or electrically regenerated at the appropriate time. The SXS diesel particulate filter can be regenerated manually by baking the filter at 600+ ºC degrees (for 2 - 4 hours in a kiln) or by blowing accumulated PM out of the DPF with compressed air. The SXS diesel particulate filter can be regenerated electrically by attaching our SXS-E electrical regeneration unit to the DPF inlet cone at the appropriate time. Initial cost of the SXS DPF is relatively low however the costs associated with DPF regeneration can be quite high in terms of capital and labor expense.

The SXS diesel particulate filter can be used with diesel fuel additives which will allow the uncoated DPF to regenerate at temperatures as low as 350+ ºC . The diesel fuel additives can be manually mixed into the equipment diesel fuel tank or a main supply tank by the equipment operator. Alternately the diesel fuel additives can be automatically mixed by an optional fuel dosing system.

2) SXS-CX platinum coated diesel particulate filter

The SXS-CX diesel particulate filter is a platinum coated DPF which is best suited for 1996 and newer light to heavy duty engine/equipment applications. The SXS-CX diesel particulate filter is a passively regenerating diesel particulate filter coated with a low load platinum metal catalytic coating. The low load platinum metal catalytic coating allows for the reduction of PM, HC and CO while minimizing NO2 production. Exhaust enters the filter inlet where particulate is “trapped” by the porous filter walls. When higher exhaust gas temperatures are reached the particulate is oxidized or “burned”. The

SXS-CX DPF will initiate regeneration when engine exhaust gas temperatures exceed 290 ºC to 350 ºC for 20% of engine daily operating time. Initial cost of the SXS-CX DPF is relatively high however the costs associated with DPF regeneration can be quite low in terms of capital expense and labor.

3) SXS-C platinum coated diesel particulate filter

The SXS-C diesel particulate filter is a platinum coated DPF which is best suited for 1996 and newer medium to heavy duty engine/equipment applications. The SXS-C diesel particulate filter is a passively regenerating diesel particulate filter coated with a specially formulated high load platinum/base metal catalytic coating. The high load platinum/base metal catalytic coating allows for the reduction of PM, HC and CO. NO2 is not produced by the SXS-C DPF however we recommend a careful pre-evaluation of engine duty cycle and exhaust temperatures to determine if this DPF filter option is feasible . Exhaust enters the filter inlet where particulate is “trapped” by the porous filter walls. When higher exhaust gas temperatures are reached the particulate is oxidized or “burned”. The SXS-C DPF will initiate regeneration when engine exhaust gas temperatures exceed 320 ºC to 390 ºC for 20% of engine daily operating time. Initial cost of the SXS-C DPF is relatively high however the costs associated with DPF regeneration can be quite low in terms of capital expense and labor.

4) SXS-B base metal coated diesel particulate filter

The SXS-B diesel particulate filter is a base metal coated DPF which is best suited for 1996 and newer medium to heavy duty engine/equipment applications. The SXS-B diesel particulate filter is a passively regenerating diesel particulate filter coated with a base metal catalytic coating. The base metal catalytic coating allows for the reduction of PM and will not produce NO2. HC and CO are usually not reduced when using the SXS-B DPF. Exhaust enters the filter inlet where particulate is “trapped” by the porous filter walls. When higher exhaust gas temperatures are reached the particulate is oxidized or “burned”. The SXS-B DPF will initiate regeneration when engine exhaust gas temperatures exceed 370 ºC to 420 ºC for 20% of engine daily operating time. Initial cost of the SXS-B DPF is generally lower in comparison to precious metal coated DPF and the labor/capitol costs associated with DPF regeneration are higher.

Special Features of SXS diesel particulate filters:

1. Quick-Release V-Band Clamps

Quick-release clamps V-band clamps in combination with unique modular designs allow the SXS DPF increased installation flexibility and ease of service.

2. Heavy Duty Construction

SXS DPF are heavily constructed and designed to resist the effects of stress due to high heat, vibration, corrosion and impact typically found in underground mobile mining equipment applications.

3. Custom Connections

Virtually any type of SXS DPF inlet/outlet connection is, metric tube, imperial tube and. available including NPT pipe ANSI flanges

4. Custom Engineered Designs

Foley manufactures custom SXS DPF canning designs which duplicate OEM mufflers and OEM exhaust components to provide a proper fitment for crowded engine compartments.

 

 

Noise Attenuation Performance for SXS diesel particulate filters:

The SXS DPF provides a typical noise level insertion attenuation of approximately 10 to 14 dB(A). The actual insertion loss may vary per engine application. Generally we recommend that the SXS DPF replace the OEM muffler in order to minimize engine exhaust gas flow restriction.

For higher noise level insertion attenuation requirements, we can offer our line of SS add-on mufflers which are designed to attach directly to the SXS DPF. Additional noise level insertion attenuation of 6 to 10 dB(A) is available by using the SS add-on muffler. The SS add-on muffler will provide low engine exhaust gas backpressure restriction and low weight in a compact package designed to suit the tight space constraints of typical vehicle engine compartments.

Additional SXS diesel particulate filter configurations:

The SXS series DPF manufactured by Foley Environmental are available in numerous configurations to fit into the tight confines of the various vehicle engine compartments. Numerous custom SXS series DPF configurations are available upon request. SXS series DPF can be installed in vertical or horizontal orientations. The combination of quick release V-band clamps and v section flanges allow the inlet and outlet cones of the SXS DPF to be completely rotated in order to maximize installation flexibility. The quick release V-band clamps and v section flanges also allow the inlet/outlet cones to be quickly removed for ease of inspection and periodic non–combustible ash removal maintenance. We recommend that the non-combustible ash which accumulates within the DPF core be removed after approximately 1000 hours of engine use. The ash removal maintenance interval is widely dependent upon engine duty cycle, engine operating conditions, fuel type and lubrication oil used.

 

SXS diesel particulate filter options:

SS DPF add-on mufflers

Exhaust gas back pressure gauge systems with alarm triggers

Inlet pipe flex connectors

Inlet pipe heat insulation blankets

SXS DPF heat insulation blankets

SXS DPF electrical regeneration system

 

Comparison Chart of SXS-C/SXS-CX versus SXS-B DPF Performance

SXS-C/SXS-CX Performance


SXS-B DPF Performance

 

General Warranty Policy

Diesel Particulate Filter manufactured by Foley Environmental are warrantied for one year or 4000 engine hours, whichever occurs first, against failure due to emissions reduction performance, material or labor defect. The time period is effective from the date of shipment. The sole obligation of Foley will be repair or replaced in part or in whole any complete Diesel Particulate Filter unit or components thereof. The complete Diesel Particulate Filter or components thereof must be returned to Foley within the warranty time period at the end users expense. The warranty is null and void in the case of improper handling, improper storage, improper transportation, improper fuel grade, improper lubrication oil grade, inadequate engine load/speed, inadequate engine exhaust temperature, improper engine operation, improper engine condition, improper engine usage etc… Foley will make the final determination as to the cause of the Diesel Particulate Filter failure. Except as expressly state herein, any other warranty either expressed or implied, intended or otherwise given are hereby excluded and are null and void.

If you have any questions please call us toll free at 1 800 233 6539, or simply e-mail your inquiry to info@foleyengines.com.

Foley Environmental is different: we are a three-generation, ninety year old family firm that wants to help.

Sincerely,

 

The Foley Engine Team