Metal Fibre Based DPF for Wide Range of Applications · • Composite of FECRALLOY® fibers with various size and porosity fully subject to design • Porosity: up to 93% Mono-layer

Metal Fibre Based DPF for Wide Range of Applications

Feng MEIN.V. Bekaert S.A.

6th ETH Conference 19-21/08 -2-

• Technical profile of Bekipor®• Flexibility of Bekipor® in DPF applications• Developing and Optimizing by Modeling• Field testing• Conclusion


Technical Profile - Material Structure

• Composite of FECRALLOY® fibers with various size and porosity fully subject to design

• Porosity: up to 93%MonoMono--layerlayer

cross section cross section A nonA non--woven sintered labyrinthwoven sintered labyrinth ThreeThree--layerlayer

cross sectioncross section

Microscope of Bekipor® mediaMicroscope of Bekipor® media


Technical Profile - Fluid-dynamic Property

• Air permeability of Bekipor® media heavily depends on the specific structure. A typical value ranges from 1.4x10-11 m2 to 2.0x10-10 m2 under clean air condition

Pressure drop at clean air condition as a function of face velocity

0

5

10

15

20

25

30

35

40

0 50 100 150 200 250

Face velocity ( cm/s )

Pre

ssu

re d

rop

( m

bar

) NPF0065NPF0201NPF0202

The air permeability of most Bekipor® media drops somewhere within these curves


Technical Profile - Thermophysical Properties

Density: 700 - 2800 kg/m3

Specific heat capacity: about 460 J/kgEmissivity: >= 0.7 Working temperature: up to 1000 °C Electrical resistivity* : 1.39 ohms.mm2/m

* FECRALLOY® at 20°C


Technical Profile - Ductilitys t ress - de fo rma t i on cha r t : N P F 0 0 6 5

0

2

4

6

8

1 0

1 2

1 4

0,0 0,5 1,0 1,5 2 , 0 2 , 5 3 , 0

% d e f o r m a t i o n

str

es

s

(N

/mm

wid

th)

material : NPF0065, Testing results:deformation at room temperature > 2%

Bekipor® can survive substantial deformation without being demaged

Tensile Tests (room temperature)

Tensile Tests (room temperature)

Break point

force - deformation

0

500

1000

1500

2000

2500

3000

3500

0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0

deformation (mm)

forc

e (N

)koud vorm B / NPF0075A/414

warm B/NPF0075A/417

Compressing testsCompressing testsRoom temperature

600 °C

Test Force


Data & Facts:

Destroying Testing in Vehicle Research Inst., Univ. of Applied Sciences Dresdenunder the following condition:

• 48 hours continuous operation• Loading to 900 mbar• Regenerating by adding additives

No damage identified on Bekipor® DPFNo damage identified on Bekipor® DPF


Technical Profile - Corrosion resistance

Intensive corrosion investigations have been done both internally (Bekaert Technology Center) and externally (Vehicle Research Inst. Univ. of Applied Sciences Dresden), which come up with the same conclusion:

The corrosion resistance of Bekipor®is high enough to be applied for

diesel exhaust aftertreatment

The corrosion resistance of Bekipor®is high enough to be applied for

diesel exhaust aftertreatment


Corrosion experiments conducted by Univ. of Applied Sciences Dresden:

No substantial mass loss has been found under the

specified corrosive environment

Data & Facts:


Flexibility in DPF applications

The material properties enable high flexibility of Bekipor® in DPM aftertreatment applications

– Flexible to apply various regeneration strategies

– Flexible to be shaped into various geometries– Flexible to customize filtration performance by

application – Flexible to the positioning of filter


Flexibility in DPF applications - Regeneration

Electrical heating: high sulfur fuel or low exhaust temperature applications

Catalyst coating

Hybrid strategy: Combining two or more techniques in one filtration system

Heating by External CombustionHeating by External Combustion

Adding additivesAdding additives

The stack to be regenerated is partially shut off when pressure reaches threshold

Filter stack 1

Filter stack 2

Data & Facts:


Flexibility in DPF applications - shaping


Flexibility in DPF applications –customizing filtration perfomance by applications

Filtration mechanisms, e.g., wall flowfiltration, deep-bed filtration or mix, can be customized according to user’s regeneration strategy and engine performance

6th ETH Conference 19-21/08 -15-CONFIDENTIAL INFORMATION

Flexibility in DPF applications - filter positioning

This indicates that despite its very porous structure, Bekipor® would also perform well when positioning very close to the engine, where PM sizes are generally smaller but temperature are quite higher.

Nanoparticle Measurement with SMPS (Scanning Mobility Particle Sizer)Engine: PSA DW12ATED/EUROIII, Trap: Bekaert PF-Round (0,6 m2)

0.E+00

1.E+07

2.E+07

3.E+07

4.E+07

5.E+07

6.E+07

7.E+07

17

19

22

26

30

35

40

46

53

62

71

82

95

109

126

146

168

195

225

259

300

346

400

461

533

Co

nc.

dW

/dlo

g(D

p) [

P/c

m³]

0.E+00

1.E+06

2.E+06

3.E+06

4.E+06

5.E+06

6.E+06

7.E+06

afte

r tr

ap C

on

c. d

W/d

log

(Dp

) [P

/cm

³]

before Trap

after TrapEmission before filter

AVG PM reduction : 95%

Emission after filter


0.E+00

1.E+07

2.E+07

3.E+07

4.E+07

5.E+07

6.E+07

7.E+07

17

19

22

26

30

35

40

46

53

62

71

82

95

109

126

146

168

195

225

259

300

346

400

461

533

Co

nc.

dW

/dlo

g(D

p) [

P/c

m³]

0.E+00

1.E+06

2.E+06

3.E+06

4.E+06

5.E+06

6.E+06

7.E+06

afte

r tr

ap C

on

c. d

W/d

log

(Dp

) [P

/cm

³]

before Trap

after Trap


0.E+00

1.E+07

2.E+07

3.E+07

4.E+07

5.E+07

6.E+07

7.E+07

17

19

22

26

30

35

40

46

53

62

71

82

95

109

126

146

168

195

225

259

300

346

400

461

533

Co

nc.

dW

/dlo

g(D

p) [

P/c

m³]

0.E+00

1.E+06

2.E+06

3.E+06

4.E+06

5.E+06

6.E+06

7.E+06

afte

r tr

ap C

on

c. d

W/d

log

(Dp

) [P

/cm

³]

before Trap

after TrapEmission before filter

AVG PM reduction : 95%

Emission after filter

The simulation shows that PM size distributions has no major impact to the filtration performance

Measurement at Univ. of Applied Sciences, Dresden


0

50

100

150

200

250

300

350

0 500 1000 1500Time (sec)

Pre

ss

ure

dro

p, D

P (

mb

ar)

experimentsimulation

Developing & Optimizing by Modeling

Modeling at Media Level

In cooperation with CERTH/CPERI, Greece Modeling at Filter level

Modeling at System Level

CFD and other modeling techniques are extensively applied at all levels to optimize and upgrade performances


Field Testing

Road grader (John Deere) :Road grader (John Deere) : Stationary Gensets :Stationary Gensets :Lombardini Lombardini CumminsCummins

Forklifts : Forklifts : Hyster Hyster with Perkins enginewith Perkins engine


• Material robustness: no damage found under

– Working temperature up to 1000°C;

– Heating/cooling rate ~100 °C/s

– 2-3 % deformation by tensile/compressive stress

• Filtration performance flexibility: subject to needs of customers

– 90% mean efficiency achievable at up to 240 cm/s face velocity and 27 mbar initial backpressure

– Bearable backpressure 900mbar

• Regeneration strategy flexibility: subject to needs of customers

– Active mode (electricity, external combustion)

– Passive mode (catalyst, additives)

– Mix (active + passive)

ConclusionInvestigations find Bekipor® filters robust and flexible

≥


Conclusion (cont’d)

• from very low to very high exhaust temperature;

• from very low to very high backpressure constraints;

• involved with severe mechanical vibration and/or thermal instability

• using high sulfur fuel

• of special needs in filter geometry

• demanding in easy reshaping or resizing

The robustness and flexibility make Bekipor® possible to be applied in wide range of DPF activities which are:

Documents

Metal Fibre Based DPF for Wide Range of Applications · • Composite of FECRALLOY® fibers with various size and porosity fully subject to design • Porosity: up to 93% Mono-layer