Diesel particulate lters (DPFs) are essential tools for controlling pollution emissions. However, some DPFs may encounter failures during operation, thereby posing risks to both the diesel vehicle engine and emission control. Low-quality diesel fuel, due to its higher sulfur content, raises the risk of DPF becoming inactive. This paper examines the reliability of DPFs from a leading national vehicle manufacturer, utilizing after-sales maintenance data. Statistical analysis has been conducted on 10,833 vehicles over the years 2018 to 2022. In addition, the records of failures, the root causes of malfunctions, and the factors in uencing the failures of these lters have also been investigated. The results indicate that the highest percentage of failures is associated with urban buses, and the least reliable are mini-buses. In such a way that, it can be stated that the DPFs of all mini-buses malfunction at least once after 17,000 kilometers, which is signi cantly lower than the de ned threshold of 100,000 kilometers. The main causes of damage to the DPF substrate are leaks in the fuel and lubrication systems. Additionally, laboratory analysis of a silicon carbide DPF sample, using scanning electron microscopy (SEM) and Xray diffraction (XRD), revealed corrosion within the DPF substrate. The chemical compounds obtained from laboratory studies indicate a high percentage of sulfur (2.28% by weight) in diesel fuel and oil leakage into the DPF. Chemical compounds obtained from laboratory studies indicate a high percentage of sulfur (2.28% by weight) in diesel fuel and oil leakage to the DPF. This study accurately demonstrates the alignment of results obtained from simulation, reliability assessment, failure root cause analysis, and laboratory analysis.

Abstract Particulate filters are state-of-the-art and are used in internal combustion engines worldwide to eliminate carcinogenic nanoparticles. Health studies estimate that this prevents about one million premature deaths annually. What is less known and often neglected is their equally powerful effect on mitigating global warming. This is because these ultrafine particles form stable aerosols in the atmosphere, absorb sunlight, and heat the atmosphere due to their jet-black color. In addition, once deposited on the ground, they reduce albedo especially when deposited on ice or snow. They also thin clouds and reduce their reflectivity. In this paper, we estimate for the first time the cumulative effect of more than 300 million particulate filters currently installed globally on vehicles, showing that, while they reduce ~ 0.5 Mt of soot per year, their effect on slowing global warming is equivalent to reducing 1 Bt of CO2 per year or about one-third of the CO2 emissions of all European Union Member States combined. Despite its strong potential, this highly efficient, proven, and low-cost technology is not yet regarded as a priority in curbing global warming, even though it is possibly the easiest and quickest to implement. If used in retrofitting more diesel and petrol engines worldwide, it could triple the aforementioned effect. While modern internal combustion engines are on track to be replaced with zero-emission vehicles, it is also crucial, and we strongly suggest that, in the interim, all remaining internal fossil fuel combusting engines be fitted with particulate filters. Evidence is presented in this paper that the potential benefits of such retrofit on climate and human health will be impactful and lasting.

To precisely control a vehicle powertrain to minimize emissions, accurate and detailed models are needed to capture the spatio-temporal variability of the variables of interest. The aim of this work is to analyze flow and temperature fields in a geometrically realistic — and thus complex — exhaust gas aftertreatment system under transient conditions. The spatio-temporal response of these fields to upstream step changes is predicted using three-dimensional unsteady Reynolds-averaged Navier-Stokes (URANS) kappa - omega simulations where the catalytic converter is described as a porous medium. A catalytic converter geometry with a 90^{circ }-bend and a partially dead volume is used to demonstrate the effects of time-resolved flow maldistribution on the profiles of velocity and temperature. Two sets of transient simulations in terms of step changes in velocity and temperature are performed. Uniformity indices are used to characterize the distribution and variability of the different catalyst channels under transient conditions. The evolution of the uniformity indices as functions of time and axial distance into the catalyst are calculated at different cross-sectional planes. The results show that the evolution of the temperature uniformity is rate controlling, continuously modulating the otherwise much faster flow uniformity response via the fluid properties. The temperature uniformity time scale is determined by the balance of flow, thermal inertia, and the heat losses from the system. The interplay between pressure drop and heat losses governs the transition to the new steady state in uniformity. These types of transient simulations and analyses can contribute essential information when developing reduced-order engineering models to represent the spatio-temporal variability in exhaust aftertreatment systems, in particular during rapid events such as cold start.

Selective catalytic reduction (SCR), based on the injection of urea-water-solution (UWS), is one of the prevailing and more effective approaches to reduce NOx emissions in diesel engines. To improve the performance and durability of the system, it is crucial to develop reliable simulation tools able to correctly describe not only the urea conversion into ammonia and the mixing with exhaust gases but also the possible formation of solid deposits along with the engine’s exhaust line.In the present paper, two different exhaust systems for off-road applications are analyzed, both of them consisting of a diesel oxidation catalyst (DOC) followed by a diesel particulate filter (DPF), a UWS injection and a mixing device, and an SCR catalyst. Two alternative UWS mixing subsystems are evaluated, including a newly developed design. A 3D-CFD numerical analysis is carried out to assess the performance of both systems in terms of pressure drop, UWS spray, and liquid film development, in addition to flow velocities and species concentration uniformities at SCR catalyst inlet. A detailed analysis of droplet impingement on walls and liquid film development is enabled, thanks to a conjugate heat transfer (CHT) approach. Moreover, a deposit risk index is used to identify the areas of the systems where urea deposit formation is expected.Eventually, numerical results are compared with experiments on one operating condition chosen as the most challenging in terms of exhaust temperature and flow rate, both in terms of systems NOx conversion efficiency and deposit formation, showing a satisfactory agreement, thus paving the way to use the proposed synergetic numerical and experimental approach to further optimize the design and the system’s performance.

Two copper-exchanged zeolites, Cu/SSZ-13 and Cu/BEA, were studied as catalysts for the selective reduction of NOx by NH3 (NH3-SCR). Their activities for standard SCR (NOx = NO) and fast SCR (NOx = 50% NO + 50% NO2) were measured before and after sulfur poisoning at 250 °C. The effect of 30 ppm SO2 and a mixture of 24 ppm SO3 + 6 ppm SO2 was evaluated. The repetition of subsequent activity measurements served as regeneration method in SCR conditions. SO2 deactivated Cu/SSZ-13 whereas Cu/BEA was only moderately affected. SO3 led to stronger deactivation of both catalysts than SO2. However, also for this case, the Cu/BEA was significantly less affected than Cu/SSZ-13, even though Cu/BEA contained larger amount of stored sulfur. One possible reason for this could be the large pores of Cu/BEA, where the sulfur species possibly resulted in less sterical hindrance than in the small pore SSZ-13 structure. NH3 temperature-programmed desorption (NH3-TPD) showed no loss of storage sites upon sulfur treatment and subsequent regeneration. Partial activity recovery was observed after a period in SCR conditions at 400 °C and 500 °C. Temperature at 300 °C was insufficient to regenerate the catalysts. Diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) of NO adsorption suggested that SO2 interacts with the ZCuOH sites on Cu/SSZ-13, causing the strong poisoning.

Synthetic fuels and fuel blends like OMEs can contribute to tank-to-wheel CO2 emission savings. At the same time, it is known that these fuels have a lower exhaust temperature compared to conventional diesel. This effect has major impact on the exhaust after-treatment system, particularly in cold start conditions. This paper investigates the light-off behavior of exhaust gases containing OMEs by temperature-programmed oxidation experiments using a state-of-the-art oxidation catalyst. The main side product of catalytic oxidation of OMEs between 100 °C and the oxidation temperature T50, which was around 160 °C, was shown to be formaldehyde. While alkane oxidation, in this case heptane, was little influenced by OME oxidation, the oxidation temperature T50 of CO increases by more than 10 °C by OME addition. Nitrogen monoxide impeded the oxidation of OME in a similar way to the other components investigated. Due to the amount of FA produced and its toxicity, it could be concluded that it is necessary to heat up exhaust after-treatment systems of OME diesel engines even faster than conventional diesel exhaust after-treatment systems. The relatively high reactivity of OME on oxidation catalyst can be used by active thermal management approaches.