Level 3 key for Sud-Chemie: CARB Level 3 verification for company's EnviCat-DPF opens door to wider diesel engine markets

Diesel Progress North American Edition, Feb, 2007 by Dawn M. Geske

Sud-Chemie Inc. has received Level 3 verification by the California Air Resources Board (CARB) for its catalyzed EnviCat-DPF diesel particulate filter (DPF). The filter is Level 3 verified to at least 85% reduction of particulate matter (PM), as required by CARB, for use in stationary applications such as prime power and emergency generators and pump sets.

The verification comes following an 18-month period of analysis where the University of California-Riverside, performed emissions and durability testing. The required testing included 1000 hours of durability trials, including 144 cold-starts on a Caterpillar 3406 gen set and an additional 500 test hours on a diesel-fueled pump set. These tests allow the EnviCat-DPF to be classified for use with diesel-fueled stationary prime and emergency generator sets and diesel pump sets as part of the Level 3 verification.

"For a manufacturer like Sud-Chemie, achieving CARB verification opens the door to a larger market for its engine exhaust products," said Michael Pope, marketing manager, Air Purification Catalysts at the Needham, Mass.-based Sud-Chemie. In addition, Pope said the verification makes it more hassle-free for owners, particularly those in situations where an engine is operated in California and some other states. Pope added that an increasing number of states are following the lead set by CARB by requiring that Level 3-verified devices be used with stationary engine applications.

With the Level 3 verification, Sud-Chemie's EnviCat-DPF is classified for use with 1996 to 2006 model year engines with a PM output of 0.2 g/bhp-hr or less and do not employ exhaust gas recirculation (EGR). The EPA Tier 1, 2 or 3 compliant engines may be turbocharged or naturally aspirated, mechanically or electronically controlled, and must incorporate a Dwyer 3000 series AN 14 (or equivalent) backpressure monitor. Engines equipped with the EnviCat-DPF are specified to utilize low sulfur diesel (LSD) under 500 ppm, ultra-low sulfur diesel (ULSD) or up to a B20 biodiesel fuel.

Construction of the Sud-Chemie EnviCat-DPF incorporates a Coming wall-flow cordierite honeycomb substrate and a Sud-Chemie patented washcoat with precious metal formulation. During the oxidation process, PM, carbon monoxide (CO) and hydrocarbons (HC) are reduced from the engine exhaust as it passes through the substrate. According to Sud-Chemie, the EnviCat-DPF can be sized and configured to a number of footprints to fit any application and is listed by CARB as meeting the 2007 N[O.sub.2] requirement based on the minimal increase during the oxidation process.

To date, Martin Morrill, Sud-Chemie general manager, Air Purification Catalysts, said 30% of Sud-Chemie's business is composed of its engine exhaust products and he anticipates that number to rise to 50% in the future. "The biggest growth market is diesel exhaust," said Morrill. "We are now a part of that."

Sud-Chemie also produces exhaust catalysts for various volatile organic compounds (VOC) applications, such as automobile paint booths, wood stoves, printing presses and plywood/panel manufacturing.

The Sud-Chemie engine exhaust product line is also made up of a range of oxidation catalysts to reduce CO and HC for diesel and lean-burn natural gas engines and gas turbines, as well as three-way catalysts to reduce nitrogen oxides (N[O.sub.x]), CO and HC in rich-burn natural gas and gasoline engines.

Sud-Chemie began production of the EnviCat-DPF in 2005. The company is part of the Air Purification division of Sud-Chemie AG headquartered in Munich, Germany, and founded 150 years ago. Its engine exhaust products are manufactured in Needham. Sud-Chemie's 40,000 sq.ft, facility houses its R&D and catalyst analysis labs and a new $1.3 million engine emissions test lab that incorporates Horiba PM emissions test equipment and an AVL SPC Smart Sampler, as well as multiple engine dynamometers.