Innovative coating material to reduce soot in diesel particulate filters

The challenge facing the automobile industry

Following the introduction of Euro 5 standards for passenger cars at the beginning of September 2009, almost every new diesel vehicle is now equipped with a diesel particulate filter. The majority of the filter units are catalytically coated in order to reduce the requisite burn-off temperature and improve regeneration.

The solution

In developing solutions aimed at soot reduction in diesel vehicles, we have focused on the catalytic coating used in DPF systems for the purpose of regenerating the filter. Working in close cooperation with a partner, the company has developed a pioneering coating material based on an alkali silicate substance. Initially licensed worldwide and exclusively to ElringKlinger for automotive applications by the partner company specializing in coating technology, the material was subsequently assessed in engine test stands, before being refined and optimized for use as a coating material in diesel particulate filter units.

Laboratory test runs have shown that this coating, which is free from heavy and precious metals, is highly catalytic and significantly improves soot burn-off within the diesel particulate filter. When deploying this innovative coating, therefore, both the regeneration temperatures and the regeneration times relating to DPF operation can be scaled back, which translates into lower fuel consumption and CO₂ emissions. Furthermore, the potential cost advantages compared to conventional systems that rely mainly on the use of precious metals are an attractive proposition in favor of this new technology.

In view of the impending EURO VI legislation governing commercial vehicle emissions – scheduled for 2012 –, we believe that this technology will also be of considerable interest to truck manufacturers.