The project described in this report seeks to promote effective diesel particulate filter technology with minimum fuel penalty by enhancing fundamental understanding of filtration mechanisms through targeted experiments and computer simulations. The overall backpressure of a filtration system depends upon complex interactions of particulate matter and ash with the microscopic pores in filter media. Better characterization of these phenomena is essential for exhaust system optimization. The acicular mullite (ACM) diesel particulate filter substrate is under continuing development by Dow Automotive. ACM is made up of long mullite crystals which intersect to form filter wall framework and protrude from the wall surface into the DPF channels. ACM filters have been demonstrated to effectively remove diesel exhaust particles while maintaining relatively low backpressure. Modeling approaches developed for more conventional ceramic filter materials, such as silicon carbide and cordierite, have been difficult to apply to ACM because of properties arising from its unique microstructure. Penetration of soot into the high-porosity region of projecting crystal structures leads to a somewhat extended depth filtration mode, but with less dramatic increases in pressure drop than are normally observed during depth filtration in cordierite or silicon carbide filters. Another consequence is greater contact between the soot and solid surfaces, which may enhance the action of some catalyst coatings in filter regeneration. The projecting crystals appear to provide a two-fold benefit for maintaining low backpressures during filter loading: they help prevent soot from being forced into the throats of pores in the lower porosity region of the filter wall, and they also tend to support the forming filter cake, resulting in lower average cake density and higher permeability. Other simulations suggest that soot deposits may also tend to form at the tips of projecting crystals due to the axial velocity component of exhaust moving down the filter inlet channel. Soot mass collected in this way would have a smaller impact on backpressure than soot forced into the flow restrictions deeper in the porous wall structure. This project has focused on the development of computational, analytical, and experimental techniques that are generally applicable to a wide variety of exhaust aftertreatment technologies. By helping to develop improved fundamental understanding pore-scale phenomena affecting filtration, soot oxidation, and NOX abatement, this cooperative research and development agreement (CRADA) has also assisted Dow Automotive in continuing development and commercialization of the ACM filter substrate. Over the course of this research project, ACM filters were successfully deployed on the Audi R10 TDI racecar which won the 24 Hours of LeMans endurance race in 2006, 2007, and 2008
and the 12 Hours of Sebring endurance race in 2006 and 2007. It would not have been possible for the R10 to compete in these traditionally gasoline-dominated events without reliable and effective exhaust particulate filtration. These successes demonstrated not only the performance of automotive diesel engines, but the efficacy of DPF technology as it was being deployed around the world to meet new emissions standards on consumer vehicles. During the course of this CRADA project, Dow Automotive commercialized their ACM DPF technology under the AERIFYTM DPF brand.