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Functionalized ceramic membrane filter for highly efficient soot particle removal

Objective



Objectives and content
Recent findings correlating mortality rates in cities
with concentrations of fine particles smaller than
approximately 2.5 microns prompt for increasingly tighter
legislation in terms of reducing particulate burden on
the environment. Soot particles emitted from combustion
sources occupy a central position among the total amount
of emitted particles in the less than 2.5-micron size
range. Although combustion process modifications have
been actively pursued both for stationary and mobile
sources, it is commonly felt that meeting future
particulate emission standards will not be feasible
without aftertreatment devices. The present Industrial
Research project addresses the problem of developing
advanced ceramic filters for soot particle emissions
control with the following main objective:
To overcome problems of currently available ceramic
filter technology in terms of material reliability,
pressure drop, collection efficiency for fine particles
and ease of cleaning ("regeneration" by oxidation of
collected soot) at a lower cost than competing nonEuropean technology by integrating:
A silicon carbide (SiC)-based extruded monolithic
filter, with very high collection efficiency (>99%) for
nano-sized particles, low-pressure drop and high material
reliability. A two layer gradient filter structure (a
filter membrane with an overlaid highly porous "foamy"
layer) functions at the same time as a fine particle
separator and as a soot oxidation reactor, through a
catalytic coating dispersed into the entire ceramic
microstructure.
Advanced catalytic coatings for soot oxidation
incorporated into the filter microstructure. Two types
of novel catalytic coatings will be developed: Physical
Vapour Deposition (PVD)-based nanoscale catalysts and
Supported Liquid Phase (SLP) catalysts.
Adaptive control of flow direction in the ceramic
filter based on comprehensive computer modelling tools,
extended beyond the state-of-the-art for the design and
optimisation of soot particle filter systems.
The project is structured around four workpackages:
filter development, development of catalytic coatings,
testing and characterisation, and modelling and
simulation.
The main innovations of the present approach compared to
state-of-the-art practice include:
The development and use of a composite ceramic
filter/membrane-reactor microstructure with locally
varying properties to assure good contact of soot
particles with catalytic coatings produced and dispersed
into the structure with novel techniques.
Optimised autothermal regeneration of the ceramic
filter by adaptive flow direction control.
The formation of a strategic partnership for a new
generation of soot particle emission control technology
with no foreign (non-European) patent dominance,
combining SME's, manufacturers, suppliers and research
institutes,
Expected achievements of the project compared to current
USA/Japanese dominated soot filter technology include:
The considerable increase in system reliability and
avoidance of material failures, thereby increasing
substantially the cost effectiveness of the system
The higher removal efficiency of the new filter system
for nano-sized particles with appreciably lower pressure
drop and improved permeability.
The significant improvement in filter "regeneration"
temperature compared to the best available technology
with catalytic filters.
The consortium spanning the European continent (6
countries) consists of an industrial SME with significant
patented
R&D experience in ceramic filters and materials
manufacturing, an industrial SME with substantial
international presence in combustion technology and
aftertreatment, the materials division of a reputed
engine manufacturer, a large catalyst manufacturer and an
internationally acknowledged engineering software
industry. Non-industrial R&D performers include a wellknown research group in industrial catalysis, a particle
technology group from an established research institute,
and a specialised thin film and coatings technology
laboratory.
Brite Euram areas covered are: 2.1.6.M, 2.1.2.M, 2.1.2.S,
2.1.1.L.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

Notox International A/S
Address
10,Sandtoften 10
2820 Gentofte
Denmark

Participants (7)

AACHEN UNIVERSITY OF TECHNOLOGY
Germany
Address
8,Schinkelstrasse 8
52062 Aachen
AEA TECHNOLOGY PLC
United Kingdom
Address
329,Harwell 329
OX11 0QR Didcot,harwell,chilton
ARISTOTLE UNIVERSITY OF THESSALONIKI
Greece
Address
University Campus
54006 Thessaloniki
CENTRO RICERCHE FIAT S.C.P.A.
Italy
Address
Strada Torino 50
10043 Orbassano
FEV MOTORENTECHNIK GMBH
Germany
Address
Neuenhofstrasse 181
Aachen
JOHNSON MATTHEY PLC (TRADING AS SYNETIX)
United Kingdom
Address
Orchard Road
SG8 5HE Royston,herts
Technische Universiteit Delft
Netherlands
Address
136,Julianalaan
2628 BL Delft