Sintered metal filter

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Sintered metal filters have an incredibly diverse range of possible uses (chemical industry, process engineering, measurement technology, safety technology). The limitation as here in the article to an exhaust filter for exhaust gases from diesel engines is only a very small part of it.
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Sintered metal particle filter from HJS Emission Technology GmbH & Co KG in Menden / Sauerland.

A sintered metal filter (SMF) is a closed diesel soot particle filter (DPF) that is used to filter exhaust gases from a diesel engine. It reduces soot and fine dust particles . In combination with an upstream diesel oxidation catalyst (DOC), the sintered metal filter not only reduces soot and fine dust emissions, but also the gaseous pollutants carbon monoxide (CO) and hydrocarbons (HC). As an “open system”, the sintered metal filter has particle reduction rates of up to 70 percent. As a "closed system", it reduces particle emissions by more than 99 percent. The filter consists largely of extremely durable types of steel . The special properties of this material enable a robust design with high heat resistance and a long service life. This means that the filter has ideal conditions for use in different diesel engines - both as original equipment and as retrofitting.

Material sintered metal

Production of a sintered metal particle filter at the company HJS Emission Technology in Menden / Sauerland.

The advantages of the sintered metal filter result from the special construction and the use of the sintered metal material . Chrome-nickel steel is used both as a carrier material and as a metal powder. This makes the filter easy to shape in production and particularly durable in use. Due to the flexible design, both the filter structure and the filter size can be easily adapted to the requirements of the respective application.

advantages

Compared to conventional ceramic filters, the sintered metal filter offers numerous advantages. Due to the pocket design, for example, clogging is not possible as with conventional ceramic filters with a honeycomb structure. In addition, the filter pockets that can flow freely from the outside reduce the exhaust back pressure. The additional fuel consumption and the associated CO 2 emissions in the SMF are therefore optimized. The storage volume for non-regenerable particles such as engine oil ash is three to four times as high as that of conventional ceramic filter systems. While these have to be cleaned after a short running time, the SMF can be operated for several years before maintenance - even for older vehicles and machines with high oil consumption. Due to the special design and the use of sintered metal, filter cleaning is also easier. Ceramic filters require elaborate cleaning devices, the sintered metal filter, on the other hand, can be freed from residues with a conventional high-pressure cleaner. After all, the SMF is 100 percent recyclable because it consists exclusively of stainless steel. No complex separation of materials is necessary. In addition, recycling does not cause any secondary carcinogenic emissions, such as the fibrous storage mats used in ceramic filters.

functionality

Diesel particle filter made of sintered metal loaded with soot.

The hot engine exhaust gas with the soot particles first reaches the filter housing. It then flows through a porous metal foil, the gaseous components of the exhaust gas flow through the microscopically fine pores of the filter material. The soot particles including the finest particles are retained on the surface and are deposited. The cleaned exhaust gas flows out on the back of the filter medium, the pores of the filter hold back almost all particles in the exhaust gas up to the detection limit. There are various options for breaking down the soot that has accumulated in the filter:

  • Continuous regeneration (passive process): The so-called CRT effect ( English Continuously Regenerating Technology ) is used to break down the soot that has accumulated in the SMF . CRT combines a highly efficient, upstream diesel oxidation catalyst (DOC) with an SMF. The DOC converts the nitrogen monoxide (NO) present in the exhaust gases into nitrogen dioxide (NO 2 ). This enables the soot residues in the filter to be burned continuously in a temperature range of 200 to 450 degrees Celsius (soot oxidation). The SMF can also be catalytically coated to support the CRT effect in applications in the low temperature range - for example construction machinery or vehicles that are mainly operated in inner-city areas. This coating enables the soot ignition temperature to drop to values ​​that allow the diesel particulate filter to be operated as a completely passive system without further aids.
  • Discontinuous regeneration (active process): Active filter systems are used when the required exhaust gas temperature for the passive regeneration process is not reached, such as in inner-city stop-and-go or with mobile machines. This is where active regeneration processes, such as burner-supported systems or the SMF-AR system, come into play. SMF-AR stands for sintered metal filter with self-sufficient thermoelectric regeneration. The soot is collected in the filter until an optimal amount for regeneration has been deposited. Only then is the soot burn-off initiated by means of heating elements arranged in a circle around the filter medium. The soot is actively ignited by the radiation energy. This means that discontinuously operating systems can free the filter from the accumulated soot in almost every engine operating state, regardless of the exhaust gas temperature.

Areas of application

Sintered metal particle filter from HJS Emission Technology in a ready-to-install version for commercial vehicles from Twintec, Koenigswinter (as ″ Canner ″).

Due to their modular structure, sintered metal filters can be used in different systems and variants: Vehicle manufacturers can install the filter concept in the original equipment. Currently (up to and including 2015) there is not a single automobile manufacturer that uses a sintered metal particle filter as original equipment. However, there are numerous vehicles (cars and trucks) and machines that are retrofitted with sintered metal particle filters - usually with the city filter. Areas of application are all diesel engines, for example in cars, light to heavy commercial vehicles, buses, construction machinery, agricultural machinery and industrial trucks, but also in stationary equipment such as power generators or combined heat and power plants.

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