The science of a Diesel Particulate Filter (DPF)
Diesel engines power around 75% of our heavy construction equipment and it’s projected that the construction industry will grow by 85% before 2030. This highlights the prevalence of diesel engines in machinery worldwide. As of 2013, all plant machinery comes equipped with emission systems in place. Let’s take a closer look at one of these systems – the Diesel Particulate Filter (DPF).
What it does
A DPF consists of a honeycomb filter encased in a metal shell. It works to reduce emissions by capturing diesel particulates and preventing them from releasing into the atmosphere. As the gases run through the exhaust system, the filter traps the excess of carbon (soot) and stores it for release at a later time.
After a certain amount of use, the filter will reach its full capacity and need to be emptied. There are sensors before and after the filter that measure the pressure of gases running through. It’s when they sense too much pressure – a result of the filter being too full – that you get the dreaded warning lights.
To empty the filter, the machine must go through a process of regeneration. In a car, this occurs naturally after a certain speed or engine temperature is reached. In plant machinery, you perform this process actively. It burns off any stored carbon and begins the whole process all over again.
How it can go wrong
In theory, a DPF system makes a lot of sense. In reality, they can be a lot of hassle.
Regeneration in diesel machines takes about thirty minutes. And it requires your machine to be idle for the whole duration. It means you can experience some hefty periods of downtime. It costs you time and money, with staff unable to operate the machine still getting paid. And this is the best-case scenario.
Chances are you won’t want to wait around for half an hour while the filter regenerates. This can be a problem in the rental market in particular, as customers will see the warning pop up, ignore it, and carry on with their work. Though this might not be a problem exclusive to the rental market – ask any construction or demolition company. Then you’re looking at a blocked filter, something that probably won’t be reversible. And to replace a DPF? You’re looking at £3-4,000. Not ideal.
You can’t deny that DPFs have the best intentions, but in practice, they make for extremely temperamental equipment. You end up wasting time or risking potentially needing thousands of pounds worth of repairs. You want to keep your fleet at its best. And you still can.
At DPF Doctor, we understand DPF systems aren’t always all they’re cracked up to be. That’s why we offer kits to bypass both DPF and AdBlue systems. You’re only two plugs away from saying goodbye to blocked filters. If you have any questions or want to inquire about a specific kit, get in touch on +44 (0) 1234 567890.
