Diesel Particulate Filter Catalysts

Micro Fresh Filters diesel exhuast filters and diesel catalytic converter / diesel particulate catalysts are among the many industrial, mining and diesel filtration products our company supply and manufacture for mining, underground coalmine and confined space applications.

These diesel particulate filtration products and systems have been assisting to protect the health of underground coal miners for well over a decade now. Micro Fresh high efficiency disposable exhaust filters are found on most Australian OEM’s equipment and used in some capacity by most major coal groups including BHP Billiton Illawarra coal who have made their use mandatory on all filter appropriate vehicles. New legislation and emission level guidelines are seeing this technology become an industry standard across the coal industry.

Micro Fresh Particulate Catalysts can be fitted to any equipment including large loaders. Even Open Cut operations can find their use beneficial on Haul Trucks where emissions can be problematic at pit bottom.

Micro Fresh has now developed high temperature (catalytic) exhaust filtration technology for Australia’s metalliferous and non-coal mines. The 100% stainless steel filters will reduce CO by up to 99%, hydrocarbons by 90%, NOx by 30% and most importantly carcinogenic Diesel Particulate by 80%. The MSHA approved technology developed with assistance of the Canadian mining industry overcomes the shortcomings of older catalytic exhaust filters.

A ceramic particulate filter will cost on average ten times what a Micro Fresh particulate catalyst costs. The cost of a Micro Fresh catalyst is in fact not much more than a standard muffler. Even if mine sites are within emission level guidelines, the improvement in working conditions and associated productivity improvements would far outweigh any cost when installing Micro Fresh Catalysts.

The very fragile ceramic core in a traditional particulate filter is susceptible to cracking due to vibration and/or temperature variance, which is a major problem in the mining industry. Micro Fresh Particulate Catalysts are made of 100% stainless steel and are built to withstand the most extreme working conditions.

A ceramic particulate filter must be installed immediately after the manifold due to temperature requirements. In many cases there isn’t enough space in the engine compartment to install this type of product without costly modifications. Micro Fresh particulate reducing catalysts can be installed at various points along the exhaust system in about 30 minutes. Remote placements can also be achieved through the use of heat retaining Kevlar / steel mesh blankets as shown in picture.

A ceramic particulate filter has a backpressure rating that is generally in excess of 20 inches of water. Micro Fresh S/S catalysts have a maximum rating of 3.9 inches across the catalyst element. This allows engines to run better, with more power and eliminates risk of engine damage due to excessive backpressure. Ceramic particulate filters are also far more susceptible to clogging. When purchasing a ceramic based particulate filter, companies must routinely purchase two in order to have a spare one available while the original filter is removed and sent off-site for cleaning. This procedure results in frequent additional costs and downtime. Micro Fresh Catalysts are designed to be maintenance free when a minimal exhaust temperature is present and will last for 4-5 years.

New S/S catalysts (left) are a fraction the size of standard mufflers (right) and can easily be tucked up under chassis rather than requiring costly alterations and fitment to outside of vehicle where they can be knocked off.

Micro Fresh particulate catalysts are currently being used by a variety of major mining operators including Xstrata at Australia’s largest underground mine, Mt Isa. Here catalysts are being evaluated on Toyota Landcruisers which, like most metalliferous mines around the world, are used as underground man transporters. Micro Fresh have a custom made catalyst ideally suited to the 4.2 Litre turbocharged Toyota diesel engine. In North America, Toyota installs this exact filter directly on to Landcruisers destined for underground markets in order to meet with EPA requirements.

Catalytic exhaust filters can also be used in a wide variety of above ground applications where emissions pose a health risk to personnel or contamination risk of some kind. A West Australian ore port recently installed a Micro Fresh IC-12-500 particulate filter on to their Cat 980G loader. Here gaseous and particulate diesel emissions can potentially pose a major health risk to personnel in the sheds. Ventilation in such installations can be minimal compared to that found in underground mines and is compounded by ever stringent EPA guidelines limiting any fugitive dust emissions.

Furthermore dust filtration systems in such sheds can quickly become contaminated by diesel particulate rendering them ineffective. Whilst ore dusts are readily removed from the surface of such filters with compressed air, diesel particulate sticks deep within the dust filter fibres and quickly blocks them resulting in a very costly changeout. Micro Fresh Particulate catalysts oxidize Diesel Particulate into CO2 and water, protecting both staff and the expensive dust filters.

Micro Fresh are presently looking for mine sites wishing to trial this catalytic converter diesel particulate filter catalyst technology on their fleet(s) of light and/or heavy vehicles. Micro Fresh engineers can make technical assistance and training presentations countrywide by appointment.

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