How DPFs Work
Diesel engine aftertreatment systems are extremely effective at controlling the output of dangerous and harmful emissions by trapping diesel particulate (PM) matter in the diesel particulate filter (DPF) and allowing it to be broken down into carbon dioxide. The PM is mainly soot, but may also contain oil, ash, sulfur oxides and hydrocarbons. In properly working DPFs, visible soot is virtually eliminated from exhaust helping to drastically reduce your equipment's carbon footprint. A properly functioning DPF will allow you to save on fuel costs and reduce repair intervals which makes aftertreatment system maintenance a necessity.
Understanding Aftertreatment System Regeneration
The Diesel Oxidation Catalyst (DOC) is the first device in the after-treatment system. It is a flow-through filter that contains precious metals to start the oxidation of hydrocarbons, carbon monoxide, and unburned fuel and oil. Both the DOC and the Diesel Particulate Filter (DPF) are
honeycomb ceramic filters. However, unlike the DOC, the DPF is a wall-flow filter that traps any remaining soot that the DOC couldn’t oxidize.
The soot remains in the DPF until it is regenerated either passively or actively. Passive regeneration occurs when the vehicle’s normal operating
temperatures and the DPF will oxidize the particulates anywhere between 275-360⁰ Celsius. Active regeneration is instigated when sensors
detect an excessive build-up of particulates within the DPF.
Raw fuel is injected into the exhaust stream to trigger temperatures over 600⁰ Celsius is required to oxidize the build-up of soot. Backpressure
usually returns to normal after the soot is gone, however, don’t forget about the ash!
Ash builds up inside the DPF and does not burn or oxidize like soot and will remain until removed. Ash is made of minerals, metals, and other
trace elements from the breakdown of lubricants, additives, and engine wear. Ash builds up at a much slower rate than soot but if ignored will
eventually cause increased back pressure, fuel consumption, and sometimes DPF failure.
As ash builds inside the DPF the number of active regenerations increases causing poor fuel economy, extremely high temperatures, and more
constant back pressure that can be detrimental to the turbocharger. The longer the ash is left inside the DPF the greater the chance of it
hardening into a plug which closes off a portion of the filter.
Service Cost: DPF $150 / DOC $50 / SCR $250
Our pneumatic cleaning process can remove up to 90% of the existing ash, through a "Dual Force" technology that focuses on each cell. In turn, you receive a filter that will perform longer between cleaning cycles simply because the filter is cleaned thoroughly.
Service Cost: DPF $250 / DOC $100 / SCR $350
During the thermal cleaning process your filter(s) are heated to temperatures exceeding one thousand degrees fahrenheit and are monitored for uncontrolled regeneration or damage to the filter. Our ovens are equipped with multiple filter specifications considered to ensure a proper regeneration process for your specific need.
Service Cost: DPF $350 / DOC $150 / SCR $400
The aqueous cleaning process cleans contaminant soaked filters while clearing out residual soot and ash dust not removed during the pneumatic cleaning stage. This stage adds an additional layer of cleaning that has proven to increase the lifespan of the filter.
Service Cost: DPF $350 / DOC $250 / SCR $450
The ultrasonic cleaning process is used to create sound waves that agitate the water the filter is soaking in, causing cavitation (the implosion of tiny air bubbles with the liquid). The ultrasonic induced cavitation increases the effectiveness of the aqueous solution improving the efficiency of the cleaning process further.