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Transportation & Fuel Source Technology

New Hybrid Diesel Particulate Filter Cuts NO2 by 96% and Soot by 93%

Environment Canada's test results on a new Rypos diesel engine filter show that this filter not only reduces soot by 93%, but also cuts nitrogen dioxide or NO2 by 96% while scrubbing particulates from the exhaust.

Since NO2 is a reactive gas associated with health problems, the California Air Resources Board (CARB) is striving to minimize it in the environment. Competing diesel engine particulate filters actually increase NO2 during the process of removing soot from emissions. California Air Resources Board has now limited that increase to 20% and, in the coming months, will withdraw its verification from filters that do not meet this standard.

"Rypos technology has shown that the diesel industry can reduce particulates without contributing NO2 to the environment - in fact, our sintered metal filters substantially reduce harmful nitrogen dioxide gas," says Hans Wenghoefer, Ph.D., Research Scientist and R&D Manager at Rypos. Rypos, based in Holliston, MA has submitted Environment Canada's findings to CARB for Level III Verification, which is expected within eight weeks.

Environment Canada tested the new Rypos HDPF/C filter at its Emission Research and Measurement Division in Ottawa. Following a break-in or "aging" period, the Rypos HDPF/C achieved the following reductions with virtually no increase in fuel consumption:
  • Total Particulate Matter (TPM): 93% reduction
  • Nitrogen Dioxide NO2: 96% reduction
  • Carbon Monoxide CO: 94% reduction
  • Total Hydrocarbons THC: 75% reduction
The development of Rypos' technology and earlier testing was funded, in part, by a grant from The Texas Environmental Research Consortium (TERC) as part of an effort to reduce NOx and particulates from diesel fueled vehicles and equipment in Texas.

How it works

Rypos filters trap soot in a sintered metal mesh resembling compressed steel wool. The filter elements are cleaned by application of an electric current that heats the metal much like a resistance heater. Competing diesel particulate filters that rely on catalysts oxidize nitric oxide (NO) converting it to NO2 by adding an oxygen atom. While NO totals remain constant, there is a potential health and environmental risk associated with increasing NO2 -- a more reactive and toxic gas than NO. CARB's limits on NO2 will become increasingly stringent, with January 1, 2009 being the deadline for meeting its 20% threshold

Sud Chemie manufactures the diesel oxidation catalyst in the Rypos system. A Caterpillar Model 3306B genset was used for the Environment Canada tests.

Environment Canada's Emission Research and Measurement Division works with industry to support the development of new technologies and fuels that could potentially reduce emissions and conserve energy in vehicles, aircraft, and ships.

CARB, the bellwether for US clean air standards, has been striving to reduce particulates from diesel exhausts since 1998 through regulation of new engines and vehicles and by retrofitting older engines with advanced filtration. The advent of ultra-low sulfur diesel fuel has aided in meeting tougher nitrogen oxide and carbon monoxide emission standards.

Rypos has enhanced clean diesel technology with filters that automatically regenerate - reducing pollution, fuel consumption and maintenance costs. Rypos designed its newest product, the HDPF/C for OEM manufacture and to retrofit 100 kW to 2 MW engines. In addition to making diesel engines run cleaner, Rypos makes it easier to manage diesel engine operations with Blue Tooth technology to remotely gather emissions data and transmit instructions.

Rypos products also include the CARB-Verified Rypos ADPF designed for older diesel engines operating on high-sulfur fuel and Rypos ADPF/C which is configured with a diesel oxidation catalyst (DOC) to further reduce the soluble organic fraction, hydrocarbons, and carbon monoxide.

"Applications for Rypos technology are diverse, including US Navy marine engines, TEREX 70 earth moving equipment and a two Mega-Watt diesel power plant in South Korea. Strict clean air standards together with the efficiency and simplicity of diesel engines are fueling market opportunities for our products -- both in North America and Worldwide," says Klaus Peter, Rypos president.

The mining industry is evaluating Rypos filters for underground applications where clean air requirements are extraordinary.

Rypos' clean diesel technology is suitable for new and existing engines produced from 1996-2007 by manufacturers such as Caterpillar, Detroit Diesel Corporation, Deutz AG, Daimler/Chrysler, Motoren Fabrik HATZ GMBH, Generac, Komatsu, Navistar, Iveco, Deere, Perkins, MTU, MITF, Volvo Penta, Cummins, Daewoo, Hino, Case, GMC, VMMI, JCB, Yanmar, Nissan Diesel, Mitsubishi, Isuzu, Kubota, Lombardini Motori, Case, Scania AB, KUKJ, CNH Engine Corp, Power Systems, MITF, and International Trucks.

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