Microwave-Regenerated Ceramic Diesel Particulate Filter Using a Catalyst-Coated Silicon Carbide Fiber Filter Substrate

The proposed research will demonstrate a diesel particulate matter (PM) exhaust aftertreatment technology that exceeds the performance of the catalyzed diesel particle filter (CDPF) technologies currently being tested by the U.S. Environmental Protection Agency (EPA). Using a unique microwave-sensitive silicon carbide fiber filter cartridge, Industrial Ceramic Solutions¿ microwave-regenerated particulate filter (Mw-CDPF) provides active filter cleaning at exhaust temperatures below the catalyst light-off temperatures. Catalyst coating of the fiber filter cartridge then allows the filter to passively destroy particulates, as does the CDPF, at exhaust temperatures above the catalyst reaction temperature (greater than 300¿C. The Mw-CDPF also can be used to restore the catalyst (due to sulfur poisoning) by raising the temperature of the particulate, NOx adsorber, and dissolved organic carbon (DOC) catalyst devices to 700¿C on demand. The fiber filter backpressure will be approximately one-fifth that of the current extruded ceramic wall-flow filter technology. This is considered to be a unique, high-risk technology by the diesel automotive industry. The objective of this research is to demonstrate durability and commercial feasibility to that industry. This demonstration will be accomplished by conducting a 12,000-mile road test on a 7.3-liter diesel vehicle. Federal test procedure cycle exhaust emissions testing will be conducted on a chassis dynamometer at 0, 2,000, 4,000, 8,000, and 10,000 miles to detect any degradation of the filter efficiency during Phase I. Phase I results will be used to solicit the participation of major diesel exhaust aftertreatment suppliers to include the Mw-CDPF in a total PM, NOx, and DOC system to be developed during Phase II. Success of the Phase I and Phase II research projects will lead to an exhaust aftertreatment technology that will be independent of engine exhaust temperatures and diesel fuel sulfur content. This will allow smaller diesel engines, both mobile and stationary, to comply with the EPA 2007 regulations for PM and NOx. It will provide near-term commercial sales to the mining and retrofit applications that do not have technology to meet current air quality standards. Future commercial sales will reach high volumes in the heavy-duty pickup and delivery truck markets. The 60 percent cost reduction over current technologies eventually will move sales into Class 8 large heavy-duty engines.