12th U.S./North American MVS, Reno, Nevada, June 9-11, 2008 Effects of Sintered Metal Diesel...

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

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

2

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.

3

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 …

4

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…

5

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.

6

NIOSH Lake Lynn Laboratory (LLL)

D Drift

E Drift

VentilationShaft

Portal

7

NIOSH Diesel Laboratory at LLL

8

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

9

InstrumentationDownstream Sampling and Measurement Station

SMPS

ELPI

TEOM

10

InstrumentationDownstream and Tailpipe Sampling and Measurement

Stations

CLD & NDIR NDIR

11

Ventilation Measurement and Control

12

Sintered Metal DPF System

13

Diesel Particulate FiltersSintered Metal Filters

Electro conductive High porosity Low back pressure Withstands high

temperatures Heats up fast (low

thermal mass)

14

Other Evaluated DPF Systems

Cordierite DPF SiC DPFs

15

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

DFE in the canister

16

Diesel Oxidation Catalytic Converter and Muffler

DOC Muffler

17

Test Modes

Mode Description

Engine Speed

Torque Power

rpm Nm kW

R50Rated speed

50% load2950 55.6 17.2

R100Rated speed

100% load2950 111.2 34.3

I50Intermediate speed

50% load2100 69.1 14.9

I100Intermediate speed

100% load2100 136.9 30.6

18

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

19

Size Distributions Measured with SMPSs at Downstream and Upstream Stations During Sintered Metal DPF System

Evaluation

1.00E+01

1.00E+02

1.00E+03

1.00E+04

1.00E+05

1.00E+06

1.00E+07

10 100 1000

D_p [nm]

dN

/dlo

g(D

_p)

[#/c

m^

3]

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

BCG M-H I50

BCG M-H I100

BCG Muffler R50

BCG Muffler R100

BCG Muffler I50

BCG Muffler I100

20

Size Distributions Measured with SMPSs at Downstream and Upstream Stations During Sintered Metal DPF System

Evaluation

0.00E+00

5.00E+05

1.00E+06

1.50E+06

2.00E+06

2.50E+06

3.00E+06

10 100 1000

D_p [nm]

dN

/dlo

g(D

_p)

[#/c

m^

3]

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

BCG M-H I50

BCG M-H I100

BCG Muffler R50

BCG Muffler R100

BCG Muffler I50

BCG Muffler I100

21

Size Distributions Measured with SMPSs at Upstream Stations During Sintered Metal DPF

System Tests

0.00E+00

5.00E+03

1.00E+04

1.50E+04

2.00E+04

10 100 1000

D_p [nm]

dN

/dlo

g(D

_p)

[#/c

m^

3]

R50

R100

I50

I100

Background

22

Size Distributions Measured with SMPSs at Downstream Stations

1.00E+01

1.00E+02

1.00E+03

1.00E+04

1.00E+05

1.00E+06

1.00E+07

10 100 1000

D_p [nm]

dN

/dlo

g(D

_p)

[#/c

m^

3]

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

23

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

24

Effect of Sintered DPF System on NOx Concentrations

25

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

26

Size Distribution of Aerosols Measured at Downstream Station: R50

1.00E+02

1.00E+03

1.00E+04

1.00E+05

1.00E+06

1.00E+07

1 10 100 1000

D_p [nm]

dN

/dlo

g(D

_p)

[#/c

m^

3]

Muffler

DOC

Cordierite DPF

SiC DPF

Sintered Metal DPF

DFE #1

LDFE #1

DFE #2

R50

27

Size Distribution of Aerosols Measured at Downstream Station: I50

1.00E+02

1.00E+03

1.00E+04

1.00E+05

1.00E+06

1.00E+07

1 10 100 1000

D_p [nm]

dN

/dlo

g(D

_p)

[#/c

m^

3]

Muffler

DOC

Cordierite DPF

SiC DPF

Sintered Metal DPF

DFE #1

LDFE #1

DFE #2

I50

28

Size Distribution of Aerosols Measured at Downstream Station: R100

1.00E+02

1.00E+03

1.00E+04

1.00E+05

1.00E+06

1.00E+07

1 10 100 1000

D_p [nm]

dN

/dlo

g(D

_p)

[#/c

m^

3]

Muffler

DOC

Cordierite DPF

SiC DPF

Sintered Metal DPF

DFE #1

LDFE #1

DFE #2

R100

29

Size Distribution of Aerosols at Downstream Station: I100

1.00E+02

1.00E+03

1.00E+04

1.00E+05

1.00E+06

1.00E+07

1 10 100 1000

D_p [nm]

dN

/dlo

g(D

_p)

[#/c

m^

3]

Muffler

DOC

Cordierite DPF

SiC DPF

Sintered Metal DPF

DFE #1

LDFE #1

DFE #2

I100

30

Results Indicate Strong Relationship between Size Distributions and Exhaust Temperatures

Mode

DPFs, DOC, Muffler DFEs

Exhaust Temperature

at Inlet of Device

Temperature at Outlet from

Device

Exhaust Temperature

at Inlet of Device

Temperature at Outlet from

Device

ºC ºC ºC ºC

R50 306 258 200 154

R100 529 436 329 242

I50 254 216 160 125

I100 485 402 313 234

31

Size Distribution of Aerosols at Downstream Station: R50

1.00E+02

1.00E+03

1.00E+04

1.00E+05

1.00E+06

1.00E+07

1 10 100 1000

D_p [nm]

dN

/dlo

g(D

_p)

[#/c

m^

3]

Muffler

DOC

Cordierite DPF

SiC DPF

Sintered Metal DPF

DFE #1

LDFE #1

DFE #2

R50

32


1.00E+02

1.00E+03

1.00E+04

1.00E+05

1.00E+06

1.00E+07

1 10 100 1000

D_p [nm]

dN

/dlo

g(D

_p)

[#/c

m^

3]

Muffler

DOC

Cordierite DPF

SiC DPF

Sintered Metal DPF

DFE #1

LDFE #1

DFE #2

I50

33

Size Distribution of Aerosols at Downstream Station: R100

1.00E+02

1.00E+03

1.00E+04

1.00E+05

1.00E+06

1.00E+07

1 10 100 1000

D_p [nm]

dN

/dlo

g(D

_p)

[#/c

m^

3]

Muffler

DOC

Cordierite DPF

SiC DPF

Sintered Metal DPF

DFE #1

LDFE #1

DFE #2

R100

34


1.00E+02

1.00E+03

1.00E+04

1.00E+05

1.00E+06

1.00E+07

1 10 100 1000

D_p [nm]

dN

/dlo

g(D

_p)

[#/c

m^

3]

Muffler

DOC

Cordierite DPF

SiC DPF

Sintered Metal DPF

DFE #1

LDFE #1

DFE #2

I100

35

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

R50

-20

0

20

40

60

80

100

Engine Operating Mode

To

tal C

on

cen

trat

ion

Ch

ang

e [%

]

SMPS 8.6 81.3 20.6 95.4 99.6 97.8 96.3

ELPI -19.9 74.1 12.9 90.0 96.6 94.2 91.7

TEOM 34.93 97.31 90.19 91.52 88.38 99.38 80.36

Cordierite DOC

Cordierite DPF

SiC DPFSintered

Metal DPFDFE #1 LDFE DFE #2

R50

36


I50

-40

-20

0

20

40

60

80

100


To

tal C

on

cen

trat

ion

Ch

ang

e [%

]

SMPS 8.2 88.5 94.6 94.5 93.3 98.3 99.2

ELPI -13.3 86.1 93.8 90.8 84.0 95.6 98.5

TEOM -31.15 87.20 91.67 97.11 97.75 100.00

Cordierite DOC

Cordierite DPF

SiC DPFSintered


I50

37


R100

-20

0

20

40

60

80

100


To

tal C

on

cen

trat

ion

Ch

ang

e [%

]

SMPS 9.3 95.3 62.2 -16.7 75.0 65.6 68.8

ELPI 33.4 95.2 77.1 19.5 69.8 56.3 61.9

TEOM 11.7 97.4 97.8 96.6 98.4 95.1 100.0

Cordierite DOC

Cordierite DPF

SiC DPFSintered


R100

38


I100

0

10

20

30

40

50

60

70

80

90

100


To

tal C

on

cen

trat

ion

Ch

ang

e [%

]

SMPS 21.6 94.0 83.3 58.6 76.6 96.1 94.0

ELPI 43.2 96.3 92.3 86.0 81.4 95.8 94.8

TEOM 41.7 99.5 99.0 99.7 99.2 98.9 99.4

Cordierite DOC

Cordierite DPF

SiC DPFSintered


I100

39

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.

40

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.

41

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.

Thank you for your attention!!!

12th U.S./North American MVS, Reno, Nevada, June 9-11, 2008 Effects of Sintered Metal Diesel...

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Transcript of 12th U.S./North American MVS, Reno, Nevada, June 9-11, 2008 Effects of Sintered Metal Diesel...