Effects of Sintered Metal Diesel Particulate Filter System on Diesel Aerosols and Nitric Oxides in Mine Air

By Aleksandar Bugarski, George H. Schnakenberg, & Emanuele Cauda

12th U.S./North American MVS, Reno, Nevada, June 9-11, 2008

Introduction

Diesel particulate matter (DPM) and generally nanometer and ultra fine aerosols are shown to have acute and chronic health effects:

DPM declared by NIOSH [1988] as a potential carcinogen; Long-term exposure to combustion-related fine particulate air pollution is an important environmental risk factor for cardiopulmonary and lung cancer mortality [Pope et al. 2002].

MSHA regulations (2001):

30 CFR Part 57.5060 - Diesel Particulate Matter Exposure of Underground Metal and Nonmetal Miners; 30 CFR Part 72 - Diesel Particulate Matter Exposure of Underground Coal Miners.

Industry is working on identifying technically and economically feasible control technologies to reduce exposure of underground miners and other workers to diesel particulate matter (DPM) and gases.
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Introduction

NIOSH is assisting industry and MSHA by conducting research related to establishing potential of various control technologies and strategies to control exposure of underground miners to nano and ultrafine aerosols and regulated and unregulated gases emitted by diesel engines and by facilitating the application of current and evolving diesel emission control technologies into underground mines: diesel particulate filter (DPF) systems, filtration systems with high temperature disposable filter elements (DFEs), diesel catalytic converters (DOCs), biodiesel

Diesel Emissions

Diesel particulate matter is complex mixture of nano and ultrafine aerosols present in liquid and solid phase. Regulated gases: CO, CO2, NO, and NO2 Unregulated gases: PAH

Methodology

Characterization of DPM in occupational setting:

NIOSH Mobile Engine Emissions Laboratory (MEEL) at Lake Lynn Laboratory (LLL) Avoid laboratory uncertainties introduced with various simulations of processes Bridge gap between inherently inaccurate field and unrealistic laboratory experiments

LLL offers unique environment for field testing with laboratory accuracy.

NIOSH Lake Lynn Laboratory (LLL) Portal

E Drift
Ventilation Shaft

D Drift
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NIOSH Diesel Laboratory at LLL

Engine/Dynamometer Systems: 150 kW Dynamometer Coupled to Isuzu C240 Engine

Instrumentation Downstream Sampling and Measurement Station

SMPS

TEOM

ELPI

Instrumentation Downstream and Tailpipe Sampling and Measurement Stations

CLD & NDIR

NDIR
10

Ventilation Measurement and Control

11

Sintered Metal DPF System

12

Diesel Particulate Filters Sintered Metal Filters

Electro conductive High porosity Low back pressure Withstands high temperatures Heats up fast (low thermal mass)

13

Other Evaluated DPF Systems

Cordierite DPF

SiC DPFs

14

High-Temperature Disposable Filter Elements (DFE) Integrated in the Filtration System with Dry Heat Exchanger
DFE in the canister

15

Diesel Oxidation Catalytic Converter and Muffler

DOC

Muffler

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Test Modes

Mode

Description

Engine Speed rpm

Torque

Power

Nm 55.6

kW 17.2

R50

Rated speed 50% load Rated speed 100% load Intermediate speed 50% load Intermediate speed 100% load

2950

R100
I50 I100

2950
2100 2100

111.2
69.1 136.9

34.3
14.9 30.6

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Results

Effects of the system on size distribution of diesel aerosols in mine air Effects of the system on total aerosol number and mass concentrations Effects of the system on NOx concentrations

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Size Distributions Measured with SMPSs at Downstream and Upstream Stations During Sintered Metal DPF System Evaluation
1.00E+07
Muffler R50 Muffler R100 Muffler I50 Muffler I100 M-H R50 1 M-H R50 2 M-H R100 M-H I50 M-H I100 BCG M-H R50 1 BCG M-H R50 2 BCG M-H R100

1.00E+06

dN/dlog(D_p) [#/cm^3]

1.00E+05

1.00E+04

1.00E+03

BCG M-H I50 BCG M-H I100 BCG Muffler R50

1.00E+02

BCG Muffler R100 BCG Muffler I50 BCG Muffler I100

1.00E+01 10 100 D_p [nm] 1000

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Size Distributions Measured with SMPSs at Downstream and Upstream Stations During Sintered Metal DPF System Evaluation
3.00E+06
Muffler R50 Muffler R100 Muffler I50 Muffler I100 M-H R50 1 M-H R50 2 M-H R100 M-H I50 M-H I100 BCG M-H R50 1 BCG M-H R50 2 BCG M-H R100

2.50E+06

dN/dlog(D_p) [#/cm^3]

2.00E+06

1.50E+06

1.00E+06

BCG M-H I50 BCG M-H I100 BCG Muffler R50

5.00E+05

BCG Muffler R100 BCG Muffler I50 BCG Muffler I100

0.00E+00 10 100 D_p [nm]

20

1000

Size Distributions Measured with SMPSs at Upstream Stations During Sintered Metal DPF System Tests
2.00E+04

Background

R50 R100

1.50E+04

dN/dlog(D_p) [#/cm^3]

I50 I100
1.00E+04

5.00E+03

0.00E+00 10 100 1000

D_p [nm]

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Size Distributions Measured with SMPSs at Downstream Stations

1.00E+07 Muffler R50 1.00E+06 Muffler R100 Muffler I50 1.00E+05 Muffler I100 1.00E+04 M-H R50 1 M-H R50 2 1.00E+03 M-H R100 M-H I50 M-H I100 1.00E+01 10 100 D_p [nm] 1000
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dN/dlog(D_p) [#/cm^3]

1.00E+02

Effects of the System on Total Aerosol Number and Mass Concentrations:

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Effect of Sintered DPF System on NOx Concentrations

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Effect of Sintered DPF System on Percentage of NO2 in total NOx

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Size Distribution of Aerosols Measured at Downstream Station: R50

1.00E+07

R50
1.00E+06

dN/dlog(D_p) [#/cm^3]

1.00E+05

Muffler
1.00E+04

DOC Cordierite DPF SiC DPF Sintered Metal DPF

1.00E+03

DFE #1 LDFE #1 DFE #2

1.00E+02 1 10 100 1000

D_p [nm]

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Size Distribution of Aerosols Measured at Downstream Station: I50

1.00E+07

I50
1.00E+06

dN/dlog(D_p) [#/cm^3]

1.00E+05

Muffler
1.00E+04

DOC Cordierite DPF SiC DPF Sintered Metal DPF

1.00E+03

DFE #1 LDFE #1 DFE #2

1.00E+02 1 10 100 1000

D_p [nm]

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Size Distribution of Aerosols Measured at Downstream Station: R100

1.00E+07

R100
1.00E+06

dN/dlog(D_p) [#/cm^3]

1.00E+05

Muffler
1.00E+04

DOC Cordierite DPF SiC DPF Sintered Metal DPF

1.00E+03

DFE #1 LDFE #1 DFE #2

1.00E+02 1 10 100 1000

D_p [nm]

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Size Distribution of Aerosols at Downstream Station: I100

1.00E+07

I100
1.00E+06

dN/dlog(D_p) [#/cm^3]

1.00E+05

Muffler
1.00E+04

DOC Cordierite DPF SiC DPF Sintered Metal DPF

1.00E+03

DFE #1 LDFE #1 DFE #2

1.00E+02 1 10 100 1000

D_p [nm]

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Results Indicate Strong Relationship between Size Distributions and Exhaust Temperatures

DPFs, DOC, Muffler

DFEs

Mode

Exhaust Temperature at Inlet of Device

Temperature at Outlet from Device

Exhaust Temperature at Inlet of Device

Temperature at Outlet from Device

C R50 R100 I50 I100 306 529 254 485

C 258 436 216 402

C 200 329 160 313

C 154 242 125 234

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Size Distribution of Aerosols at Downstream Station: R50

1.00E+07

R50
1.00E+06

dN/dlog(D_p) [#/cm^3]

1.00E+05

Muffler
1.00E+04

DOC Cordierite DPF SiC DPF Sintered Metal DPF

1.00E+03

DFE #1 LDFE #1 DFE #2

1.00E+02 1 10 100 1000

D_p [nm]

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Size Distribution of Aerosols at Downstream Station: I50

1.00E+07

I50
1.00E+06

dN/dlog(D_p) [#/cm^3]

1.00E+05

Muffler
1.00E+04

DOC Cordierite DPF SiC DPF Sintered Metal DPF

1.00E+03

DFE #1 LDFE #1 DFE #2

1.00E+02 1 10 100 1000

D_p [nm]

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Size Distribution of Aerosols at Downstream Station: R100

1.00E+07

R100
1.00E+06

dN/dlog(D_p) [#/cm^3]

1.00E+05

Muffler
1.00E+04

DOC Cordierite DPF SiC DPF Sintered Metal DPF

1.00E+03

DFE #1 LDFE #1 DFE #2

1.00E+02 1 10 100 1000

D_p [nm]

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Size Distribution of Aerosols at Downstream Station: I100

1.00E+07

I100
1.00E+06

dN/dlog(D_p) [#/cm^3]

1.00E+05

Muffler
1.00E+04

DOC Cordierite DPF SiC DPF Sintered Metal DPF

1.00E+03

DFE #1 LDFE #1 DFE #2

1.00E+02 1 10 100 1000

D_p [nm]

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Effects of Control Technologies on Total Aerosol Number and Mass Concentrations:

R50
100

R50
Total Concentration Change [%]
80

60

40

20

-20

Cordierite DOC 8.6 -19.9 34.93

Cordierite DPF 81.3 74.1 97.31

SiC DPF 20.6 12.9 90.19

Sintered Metal DPF 95.4 90.0 91.52

DFE #1 99.6 96.6 88.38

LDFE 97.8 94.2 99.38

DFE #2 96.3 91.7 80.36

SMPS ELPI TEOM

Engine Operating Mode

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Effects of Control Technologies on Total Aerosol Number and Mass Concentrations:

I50
100

I50
Total Concentration Change [%]
80 60 40 20 0 -20 -40

Cordierite DOC 8.2 -13.3 -31.15

Cordierite DPF 88.5 86.1 87.20

SiC DPF 94.6 93.8 91.67

Sintered Metal DPF 94.5 90.8 97.11

DFE #1 93.3 84.0

LDFE 98.3 95.6 97.75

DFE #2 99.2 98.5 100.00

SMPS ELPI TEOM

Engine Operating Mode

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Effects of Control Technologies on Total Aerosol Number and Mass Concentrations:

R100
100

R100
Total Concentration Change [%]
80

60

40

20

-20

Cordierite DOC 9.3 33.4 11.7

Cordierite DPF 95.3 95.2 97.4

SiC DPF 62.2 77.1 97.8

Sintered Metal DPF -16.7 19.5 96.6

DFE #1 75.0 69.8 98.4

LDFE 65.6 56.3 95.1

DFE #2 68.8 61.9 100.0

SMPS ELPI TEOM

Engine Operating Mode

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Effects of Control Technologies on Total Aerosol Number and Mass Concentrations:

I100
100 90

I100

Total Concentration Change [%]

80 70 60 50 40 30 20 10 0
Cordierite DOC 21.6 43.2 41.7 Cordierite DPF 94.0 96.3 99.5 Sintered Metal DPF 58.6 86.0 99.7

SiC DPF 83.3 92.3 99.0

DFE #1 76.6 81.4 99.2

LDFE 96.1 95.8 98.9

DFE #2 94.0 94.8 99.4

SMPS ELPI TEOM

Engine Operating Mode

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Conclusion

The effects of the SM DPF system on number and mass concentrations were found to be engine operating mode dependent. A 10-fold reductions in total mass concentrations as measured by TEOM were observed for the two low-power R50 and I50 modes. The corresponding reductions were more than 20-fold at R100 and then more than 100-fold for I100 conditions. In the R50 and I50 mode cases total mass reductions were accompanied with approximately 20-fold reductions in total number concentrations. I the cases of R100 and R100 high concentrations of nucleation particles resulted in significantly lower reductions or even an increase in total particle number.
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Conclusion

The SM DPF system and muffler were found to have comparable effects on NOx concentrations for all four modes. The percentages of NO2 in total NOX are found to be strongly dependent on engine operation mode / exhaust temperature.

The system consistently produced lower NO2 fractions them muffler for all four modes.

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Thank you for your attention!!!

The findings and conclusion of this publication have not been formally disseminated by the National Institute for Occupational Safety and Health and should not be constituted to represent any agency determination or policy. Mention of any company or product does not constitute endorsement by NIOSH.

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