Optimization Methodologies for DPF Substrate-catalyst Combinations

As the Diesel Particulate Filter (DPF) technology is nowadays established, research is currently focusing on meeting the emission and durability requirements by proper system design. This paper focuses on the optimum combination between the catalytic coating and substrate structural properties using experimental and simulation methodologies. The application of these methodologies will be illustrated for the case of SiC substrates coated with innovative sol-gel coatings. Coated samples are characterized versus their uncoated counterparts. Multi-dimensional DOC and DPF simulation models are used to study several effects parametrically and increase our understanding on the governing phenomena. The comparative analysis of DOC/DPF systems covers filtration – pressure drop characteristics, CO/HC/NO oxidation performance, effect of washcoat amount and catalyst dispersion on oxidation activity and finally passive regeneration performance. It is concluded that the optimum design of DPF substrate/catalyst can be substantially supported by combined testing - simulation methodologies reducing the development time towards cost-effective system solutions.