DIESEL PARTICULATE FILTERS (DPFs)

WHAT ARE THEY AND HOW DO THEY WORK? WHAT ARE THEY MADE FROM?
• The Diesel Particulate Filter (DPF) is the part of the exhaust system which removes particulate matter (soot) from the • Cordierite DPFs look very similar to Catalytic Converters and are mostly used in additive systems in conjunction with
exhaust gasses; it captures, contains and converts these soot particulates into carbon dioxide via Regeneration Diesel Oxidisation Catalysts. Often used in aftermarket products
• Exhaust gasses containing soot enter the DPF channels, which are closed off at alternating ends • Silicon Carbide (SiC) DPFs are constructed from small sections cemented together. More commonly used in O.E. and
• The channel walls are porous; allowing exhaust gasses to pass through, but retaining (trapping) the soot particles inside the DPF Catalysing DPFs; classed as a Premium product
• Clean exhaust gasses exit the DPF. Trapped soot particles are eliminated during Regeneration cycles to prevent blockages and its
function therefore from being affected
DPF TECHNOLOGIES
Holes are blocked Cell walls are porous enabling To aid the Regeneration process, several methods have evolved over several euro emissions regulations.
at alternate ends clean gasses to exit

• Fuel Additive Systems - Diesel engines using a fuel additive system to aid the Regeneration process do not
need to reach as high temperatures as other engines. The additive reduces the effective temperature at which soot
Exhaust gasses in Clean gasses out combustion takes place to approximately 400 0C. Favoured by French Manufacturers

• Coated DPFs - Also known as Catalysing DPFs; the precious metal coating on the DPF catalyses as well as filters,
The Engine Management System (ECU) constantly therefore lowering the temperature at which Regeneration takes place to approximately 400 0C. The vehicle does not
monitors the filter and will carry out a regeneration
Particulate matter is deposited against the cell walls
to stop it blocking. necessarily need a separate Cat. Favoured by German Manufacturers
and trapped inside the filter

• Thermal (Close-coupled) - DPFs positioned close to the engine benefit from the readily available high
temperatures, meaning the unit reaches the optimum Passive Regeneration temperature quickly
Soot is the product of incomplete combustion of diesel fuel. The desired conditions for complete combustion are difficult to
maintain; an efficient fuel delivery system and an exact supply of air and heat.

REGENERATION
There are 3 different types of Regeneration – Passive, Active and Forced. Regeneration “burns off” (oxidises)
NO DPF NO MOT
the particulates that have accumulated in the DPF: If a vehicle has had its DPF removed
• Passive Regeneration - a process of soot reduction via natural conversion. Occurs when ideal driving conditions
apply (60mph for 15 minutes – e.g. motorway driving). The DPF becomes hot enough to burn off some of the it will fail its MOT
trapped particulates naturally between 350 and 500 0C – organic conversion. The carbon soot particles are converted
into carbon dioxide by a reaction with nitrogen oxide using the platinum coating, which works as a catalyst
• Active Regeneration - occurs when the optimum exhaust gas temperatures can no longer be maintained
meaning Passive Regeneration can no longer take place. Therefore, active regeneration is an ECU led process that
WHY ARE SiC DPFs A PREMIUM PRODUCT?
increases the EGT (exhaust gas temperature) to 500-800 0C. When the carbon soot deposits in the filter reach a • 3 Year Warranty
certain level, the engine management system initiates the regeneration process; lasting around 10 minutes
• 99% Filtration Efficiency
• Forced Regeneration - Involves very high temperatures and is carried out by garages with diagnostics equipment
• Higher Melting Point - 2700 0C
Warning! The very high temperatures applied during Active and Forced Regeneration can lead to an accumulation of ash;
ageing. The build-up of ash is treated by physical intervention; chemical cleaning, ultrasonic cleaning or replacement of the DPF. • Higher thermal conductivity
• More resistant against Monolith fractures
• Corrosive resistant

DPF MAINTENANCE
AND REPAIR
PREVENTION OF DPF BLOCKAGE
• Correct and regular use of quality fuel additives
• Correct use of oils and lubricants
• Use of quality fuels
• Correct driving technique and operating
environment – i.e. short journeys will cause
the DPF to block due to lack of time for
successful regeneration to take place
• Full, regular servicing of the vehicle is essential
• Use of high quality replacement parts
• Always use new gaskets and fittings and replace
sensors where possible
• The inappropriate use of sealing paste can
damage substrates and lead to local hot spots
• Follow manufacturer’s guidelines when
resetting the ECU
DPF RECOVERY BLOCKED DPF? DIAGNOSING THE FAULT DPF REPLACEMENT
When a DPF can no longer regenerate itself, a DPF When a DPF becomes blocked, the cause is The following components are used in the A DPF will find it impossible to convert soot
warning light will illuminate on the dashboard. very unlikely to be the DPF itself; soot problems control of soot combustion, and therefore into carbon dioxide once it has been impaired
A garage would then look to perform a Forced begin long before they reach the DPF. The two mechanical defects in any of the below can by; excessive regeneration cycles, ageing (ash
Regeneration, dependent on the level of blockage. main reasons for a blocked DPF are: result in the DPF becoming blocked. Ensure the accumulation) or due to inappropriate cleaning
following components are operating correctly methods that have damaged the coating. In
• Regeneration should NOT be attempted on an 1. Unsuitable driving styles before assuming a replacement DPF is required: such cases, replace with a high quality DPF.
adversely blocked DPF system without the
prior removal and cleaning of components to • Air Mass Meter • Lambda Sensor
2. Mechanical defects in other components Some vehicle manufacturers recommend that
reduce blockage within the engine the DPF is replaced from 60,000 miles.
• EGR Valve • Exhaust Gas Sensor
• Recovery additives (chemical treatments) aid
Replacing a blocked DPF without correct • Heater plugs • DPF Pressure Sensor
conversion by loading the DPF with products
that help increase temperatures sufficient to diagnosis of the genuine fault will only cause • Swirl flaps • Oxidation Cat
oxidise soot. These “washing” methods the new DPF to also become blocked!
require product knowledge and training if • Injectors • Turbo
critical damage is to be avoided
• Water-based cleaning can deteriorate DPF
efficiency by 25-30% as it can remove the
precious metal coating

Reed Mill, Sheepbridge Lane, Tel: +44 (0) 1623 663800

Mansfield, Nottinghamshire, Email: enquiries@bmcatalysts.com
NG18 5DL, United Kingdom Web: www.bmcatalysts.com
Manufacturer
of the Year
WINNER
Achievement in
International Business
WINNER
Business
of the year
WINNER

TECHNICAL HELPLINE: +44 (0) 1623 663802