Virtually all industries are continuing to face the challenge of mitigating increasing operating costs, whilst at the same time seeking to reduce their environmental impact on the path towards achieving net zero emissions. This is particularly relevant for sectors such as transport, construction and agriculture, which rely on diesel-powered heavy plant and equipment. Minimising fuel consumption and unscheduled maintenance are key priorities, alongside the need to ensure compliance with emissions regulations, including Euro VI for HGVs and Stage V for off-road machinery and powered equipment.
To prevent noxious particulate matter, such as soot and ash, from entering the atmosphere, diesel particulate filters (DPFs) are fitted as part of the engine’s exhaust after treatment system (EATS). Soot deposits are largely removed automatically by a continuous, ‘passive’ regeneration process, which occurs during normal operation. High temperature in the DPF causes soot particles to oxidise, converting them into CO2 and water vapour.
Where a diesel engine has a less demanding duty cycle in applications such as highway maintenance or lightly loaded construction equipment, for instance telehandlers, passive regeneration is likely to be insufficient due to faster accumulation of soot deposits in the DPF. Instead, ‘active’ regeneration is initiated. This process involves raising the temperature of the exhaust gases to facilitate the burning of soot particles and is achieved through less efficient, energy-consuming measures such as increasing engine load, injecting fuel into the exhaust system, or using electric heaters.
Besides soot, non-combustible ash also accumulates in the DPF over time. This needs to be removed from the filter off-vehicle at regular intervals, depending on the specific duty cycle of the engine. Ceramex, the UK’s leading scalable provider of DPF cleaning and remanufacturing, offers specialist cleaning processes to remove soot and ash deposits, which restores the filter’s performance. These include the company’s patented Xpurge® system for standard DPFs, typically found in HGV or on-road applications Flexpurge® for ‘closed-end’ or sealed units, which are typically installed in Stage V equipment employed in a wide of range of industrial, agricultural or construction-related activities.
A saturated DPF quickly loses its effectiveness and immediately causes a reduction in engine performance. Detailed research by Ceramex has found that a unit in this condition is likely to result in a minimum 2% increase in fuel consumption, compared to a clean filter.
When the volume of soot and ash inside a DPF increases, the back pressure rises, which produces a higher load on the engine, required to force the exhaust gas through the DPF. Consequently, this consumes more fuel and can also cause excessive stress to the engine and emissions system, which in turn increases the risk of breakdown, subsequent downtime and the need for expensive component replacement. Should 20% of a filter become blocked, for example, the remaining 80% of its capacity works harder to remove noxious contaminants, thereby putting greater pressure on the unit and heightening the chances of failure.
Processing typically more than 2,000 DPFs per week from its 67,000 square-foot facility in Reading, Ceramex operates a number of tailored service packages, where batches of saturated DPFs are collected from customers, both in the UK and in Europe. Using a fast turnaround, contract-based approach, minimises downtime for operators and delivers cost efficiencies through economies of scale and a planned approach to DPF cleaning. From an environmental perspective, the process ensures a vehicle or machine operates efficiently, in accordance to its duty cycle.
Ceramex’s Xpurge® cleaning process, which uses an innovative combination of de-ionised water and compressed air, removes accumulated soot and ash deposits within the DPF. Xpurge® collects the particulate matter in aqueous suspension, which eliminates any risk of noxious particulates entering the atmosphere. This process is unique to Ceramex globally. After cleaning, Ceramex’s patented Veritex® technology provides a detailed internal inspection of the DPF and quality assurance relating to the filter’s condition when returned to service.
Taking an environmentally responsible approach to waste disposal, Ceramex is the only UK DPF cleaning provider that operates an onsite treatment plant. This facility removes all the particulate matter from the water used for cleaning through a continuously monitored filtration system. The water is then returned to the grid in a cleaner state than its source and the solid matter is safely disposed of by a government licensed third party, in accordance with environmental regulations.
