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, CO
2
, NO, and NO
2


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
Ventilation
Shaft
Portal
7
NIOSH Diesel Laboratory at LLL
8
Engine/Dynamometer Systems:
150 kW Dynamometer Coupled to Isuzu C240 Engine
9
Instrumentation
Downstream Sampling and Measurement Station
SMPS
ELPI
TEOM
10
Instrumentation
Downstream and Tailpipe Sampling and Measurement Stations
CLD & NDIR NDIR
11
Ventilation Measurement and Control
12
Sintered Metal DPF System
13
Diesel Particulate Filters
Sintered 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
R50
Rated speed
50% load
2950 55.6 17.2
R100
Rated speed
100% load
2950 111.2 34.3
I50
Intermediate speed
50% load
2100 69.1 14.9
I100
Intermediate speed
100% load
2100 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 NO
x
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]
d
N
/
d
l
o
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]
d
N
/
d
l
o
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]
d
N
/
d
l
o
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]
d
N
/
d
l
o
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 NO
x
Concentrations
25
Effect of Sintered DPF System on Percentage of NO
2
in total
NO
x

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]
d
N
/
d
l
o
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]
d
N
/
d
l
o
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]
d
N
/
d
l
o
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]
d
N
/
d
l
o
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
C C C C
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]
d
N
/
d
l
o
g
(
D
_
p
)

[
#
/
c
m
^
3
]
Muffler
DOC
Cordierite DPF
SiC DPF
Sintered Metal DPF
DFE #1
LDFE #1
DFE #2
R50
32
Size Distribution of Aerosols 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]
d
N
/
d
l
o
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]
d
N
/
d
l
o
g
(
D
_
p
)

[
#
/
c
m
^
3
]
Muffler
DOC
Cordierite DPF
SiC DPF
Sintered Metal DPF
DFE #1
LDFE #1
DFE #2
R100
34
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]
d
N
/
d
l
o
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
T
o
t
a
l

C
o
n
c
e
n
t
r
a
t
i
o
n

C
h
a
n
g
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 DPF
Sintered
Metal DPF
DFE #1 LDFE DFE #2
R50
36
Effects of Control Technologies on Total Aerosol Number and Mass
Concentrations:
I50
-40
-20
0
20
40
60
80
100
Engine Operating Mode
T
o
t
a
l

C
o
n
c
e
n
t
r
a
t
i
o
n

C
h
a
n
g
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 DPF
Sintered
Metal DPF
DFE #1 LDFE DFE #2
I50
37
Effects of Control Technologies on Total Aerosol Number and Mass
Concentrations:
R100
-20
0
20
40
60
80
100
Engine Operating Mode
T
o
t
a
l

C
o
n
c
e
n
t
r
a
t
i
o
n

C
h
a
n
g
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 DPF
Sintered
Metal DPF
DFE #1 LDFE DFE #2
R100
38
Effects of Control Technologies on Total Aerosol Number and Mass
Concentrations:
I100
0
10
20
30
40
50
60
70
80
90
100
Engine Operating Mode
T
o
t
a
l

C
o
n
c
e
n
t
r
a
t
i
o
n

C
h
a
n
g
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 DPF
Sintered
Metal DPF
DFE #1 LDFE DFE #2
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 NO
x
concentrations for all four modes.

The percentages of NO
2
in total NO
X
are found to be strongly
dependent on engine operation mode / exhaust temperature.

The system consistently produced lower NO
2
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!!!