New Design of a Ceramic Filter for Diesel Emission Control Applications

Diesel particulate filters (DPF) made from an advanced ceramic material (ACM) based on mullite have demonstrated high filtration efficiency, low‐pressure drop, high‐temperature handling capability, and excellent mechanical integrity at a porosity of 60% or higher. Due to the ability to control microstructure, total porosity, and particle size distribution, Dow's acicular mullite can be tailored to meet requirements for deep bed filtration and fine particles emission control. In addition, the ACM DPF is suitable for catalyzed applications and it can retain its performance with a broad range of catalysts and over a wide range of catalyst loadings. This study describes a material selected for a DPF design that meets current diesel particulate emission control requirements as well as a four‐way NOx control system.