Home Tech Talk Diesel, Fuel Injection & Turbo Tackling DPM issues

Tackling DPM issues

October 3, 2019

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FROM design and manufacture to installation of heavy-duty exhaust systems, Aletek specialises in tailor-made solutions for diesel engine applications for the underground mining sector.

The company is committed to tackling the issue of DPM (Diesel Particulate Matter) and exposure to harmful emissions for underground workers.

It offers a specialised range of DPF (Diesel Particular Filters) and Emission Control Solutions to directly address this problem.

Continual exposure to diesel emissions is hazardous and may result in long-term health problems and the risk of developing cancer.

DPM has been labelled as ‘the next asbestos’, and in 2012 diesel emissions were classified as a Class 1 carcinogen by the World Health Organisation.

Small particles, big problem

In response to addressing the issue of reducing diesel emissions, Aletek has developed a specialised range of emission control solutions.

As diesel engines have evolved to become the highly efficient machines that they are today, they have created a huge problem.

The issue is that engines now produce particulate matter well below one micron diameter, and these particles are now small enough to reach the alveoli of humans (the subtle respiratory membrane, a barrier that normally prevents particles from entering the bloodstream).

Nano particulates (50-1nm) are fine enough to translocate through the subtle respiratory membrane.

Trapping harmful DPM

Aletek Diesel Particulate Filters (DPFs) are designed to trap diesel particulate matter, opacity, carbon monoxide and hydrocarbons from exiting the engine.

A vehicle or engine fitted with an Aletek diesel particulate filter operates normally, using only the heat generated in the exhaust gas to continuously burn off particulates in a continuous matter.

This process is known as regeneration and takes place whilst the engine is running.

For continuous regeneration to occur, the equipment must be operated so that its duty cycle produces exhaust temperatures greater than the balance point of the DPF for greater than 30pc of the time.

The required operating conditions of the DPF is for the temperature to remain over 350°C for 30pc of its time.

This will ensure that the filter passively regenerates without creating additional back-pressure.

How a DPF works

The catalytically-coated ceramic monolith contains long narrow channels open at one end and blocked at the other.

The exhaust gas is forced to escape by passing through the filter walls, trapping particulate matter (soot) in the filter.

At high exhaust gas temperatures, the soot particles burn away and transform into harmless carbon dioxide.

The filter also destroys carbon monoxide (CO) and diesel hydrocarbons (HC).

Aletek tailor-made DPFs

Aletek’s Diesel Particulate Filter (DPF) product range has been specifically designed to combat the issue of DPM.

Its range of purpose-built DPFs includes wall flow DPFs, diesel oxidation catalysts and flow-through DPFs.

Aletek DPF product features include:

DPF housings are designed, engineered and manufactured in-house
Wall Flow (>99pc), Partial Flow (<66pc) and active regenerating configurations
Manufactured from 304 grade stainless steel
Heavy gauge 5mm and 8mm plate construction
DCL premium cordierite substrates utilised

Aletek Wall Flow DPFs

Aletek Wall Flow (>99pc) DPFs provide maximum effectiveness in trapping Diesel Particulate Matter (DPM) for a safer underground working environment.

An optional filter can be added to remove diesel nano particles which provide the highest human health risks.

These Wall Flow DPFs offer high diesel particulate reduction with minimal ongoing maintenance required.

Aletek Wall Flow DPF features include:

Filters need no regeneration or fuel additives
Retrofit in-line on the exhaust system or silencer muffler integration
Back-pressure and temperature logger to ensure peak performance
Tailor-made to suit Caterpillar, Epiroc, Jacon, Normet, Sandvik and Volvo underground mining vehicles

DPF data logging

It is critical that DPFs are fitted with data loggers.

The purpose of a data logger is to record the back-pressure, exhaust gas temperature and engine RPM.

This data is used to predict the lifecycle to schedule cleaning and analyse filter performance.

Aletek Data Logger features include:

Stainless Steel IP66 enclosure
‘Plug n Play’ wiring harness
Mil-Spec cable terminations with cannon fittings
Stainless braided Teflon hose
Dash-mounted data download
Harnesses protected with fire-rated sleeve

Aletek’s data logger system has evolved to become a robust heavy-duty system that utilises the latest technology.

This system can be upgraded to assist maintenance planners in their work by offering real-time and semi real-time data transfer.

A data transfer upgrade utilises a Bluetooth, Wi-Fi and mobile network transfer system.

Onsite emission testing

Aletek’s auditing and onsite services are further complemented by onsite emission testing.

This allows maintenance personnel to monitor, track and control the emissions performance of each machine in your fleet.

Aletek’s DPF condition monitoring service provides reporting data on machine back-pressure and thermal performance to assist with your maintenance scheduling.

This service includes: