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NxtGen Emission Controls Inc. and Sud-Chemie on May 7 announced a lower cost, high-efficiency diesel particulate filter (DPF) optimized for low-temperature regeneration that is attainable by using the proprietary technologies of both companies. The collaborative development effort generated up to 40 percent savings as a result of optimizing the filter with up to 60 percent less precious metal. The announcement was made by Jeremy Holt, president and chief executive officer of NxtGen and Martin Morrill, general manager of Sud-Chemie.
With growing concern over health issues caused by diesel exhaust and regulations on diesel engines, there has been substantial demand for cost-effective, advanced diesel exhaust aftertreatment technology that can operate under a wide range of conditions. In urban environments, many applications require aftertreatment systems. The systems function under lightly loaded vehicle conditions at low-exhaust temperatures, which have lower regeneration temperatures than passive systems and hydrocarbon dosing systems.
According to Holt, preliminary results indicate the NxtGen syngas generator and proprietary control algorithm, coupled with Sud-Chemie's proprietary particulate filter technology, offers a potential solution that is functional even during low-temperature operation of the engine, including idle conditions.
"Sud-Chemie's technology resulted in a diesel particulate filter that utilizes up to 60 percent less precious metal than a standard filter and is more efficient during regeneration and across a broader range of engine exhaust conditions and temperatures. Depending on the current cost of precious metals, a savings of several hundred dollars per filter can be achieved," Morrill said.
Together with Sud-Chemie's proprietary wash coat and catalyst technology, the NxtGen syngas technology provides an opportunity to further develop and apply diesel engine emissions controls on urban vehicles, which operate at low-exhaust temperatures.
The Sud-Chemie Group is headquartered in Munich, Germany. The Sud-Chemie Needham, Mass., facility contains a fully outfitted engine catalyst facility, research and development, manufacturing, analysis labs, warehouse, as well as sales and administrative functions. From the Boston-area facility, the company provides a rapid response to technical and production needs.
Sud-Chemie Needham manufactures catalyzed DPF and diesel oxidation catalysts, as well as three-way catalysts and oxidation catalysts for natural gas engines and gas turbines. These catalysts are used for reducing the exhaust emissions from engine-powered generator sets, gas compressors, and construction, agricultural and mobile equipment.
NxtGen's syngas technology addresses the emissions challenges of diesel engines through aftertreatment, but also has applications in combustion enhancement and for other fuels addressing emissions and CO2 regulations or targets. Syngas creation has been successfully scaled for use in light- to heavy-duty vehicles and upcoming product applications include an active syngas DPF system for urban trucks that solves particulate filter regeneration problems caused by low temperature, stop / start city driving and syngas lean NOx trap for NOx control to avoid the cost and complexity of urea selective catalytic reduction systems.