Abstract Signifcant progress towards reducing diesel engine fuel consumption and emissions is possible through the simultaneous Waste Heat Recovery (WHR) and Particulate Matter (PM) fltration in a novel device described here as a Diesel Particulate Filter Heat Exchanger (DPFHX). This original device concept is based on the shell-and-tube heat exchanger geometry, where enlarged tubes contain DPF cores, allowing waste heat recovery from engine exhaust and allowing further energy capture from the exothermic PM regeneration event. The heat transferred to the working fuid on the shell side of the DPFHX becomes available for use in a secondary power cycle, which is an increasingly attractive method of boosting powertrain effciency due to fuel savings of around 10 to 15%. Moreover, these fuel savings are proportional to the associated emissions reduction after a short warm-up period, with startup emissions relatively unchanged when implementing a WHR system. Due to the absence of prior DPFHX research and the unique heat transfer process present, this effort describes construction of a prototype DPFHX and subsequent WHR experiments in a single cylinder diesel engine test cell with a comparison between heat exchanger performance with and without DPF cores installed. Furthermore, the paper discusses the implications of installing the DPFHX within a diesel engine exhaust stream, including the effects on engine performance and the sequencing of aftertreatment devices, as well as several other practical considerations. Finally, this paper discusses alternative DPFHX designs from the perspectives of performance and manufacturing. Introduction Over the past few decades, periods of high fuel costs along with concerns over imported oil have gone alongside the emphasis to lower hazardous engine emissions including greenhouse gases. As a result, the reduction of fuel consumption and emissions have emerged as the two main avenues to advance engine technology. Conventional approaches to improve thermal effciency include Variable Valve Timing (VVT), intake charge boosting, and direct injection technology for spark ignition engines [1]. Moreover, signifcant research is underway in the area of advanced combustion regimes such as Homogeneous Charge Compression Ignition (HCCI) and Pre-mixed Charge Compression Ignition (PCI) that have the potential for high thermal effciencies. These techniques require increasingly complex engine designs and control architectures where further decreases in fuel consumption are burdened by signifcant hardware costs. Furthermore, the Low Temperature Combustion (LTC) regimes of HCCI and PCI can only be employed at lower loads because of the signifcant pressure rise that occurs [2]. In addition, incremental lowering of emission levels are causing engine manufacturers to limit combustion temperatures and pressures, decreasing potential effciency gains. Among the exhaust species subject to Environmental Protection Agency (EPA) regulations under the Clean Air Act are particulate matter (PM), hydrocarbons (HC), carbon monoxide (CO), and nitrogen oxides (NO x ) [3], with future legislation targeting carbon dioxide (CO 2 ) on the horizon. To meet these standards, Compression Ignition (CI) engine manufacturers are utilizing signifcant levels of cooled Exhaust Gas Recirculation (EGR) along with multiple in-cylinder fuel injection events in order to decrease combustion temperatures since NO x increases exponentially with temperature through the thermal NO mechanism [4]. This method subsequently diminishes the effciency of CI engines because of the reduced work available due to lower combustion pressures along with a reduced heat release rate through a longer combustion event. Combining a Diesel Particulate Filter and Heat Exchanger for Waste Heat Recovery and Particulate Matter Reduction 2014-01-0673 Published 04/01/2014 Charles Sprouse III Benedictine College; University of Kansas Christopher Depcik University of Kansas CITATION: Sprouse III, C. and Depcik, C., "Combining a Diesel Particulate Filter and Heat Exchanger for Waste Heat Recovery and Particulate Matter Reduction," SAE Technical Paper 2014-01-0673, 2014, doi:10.4271/2014-01-0673. Copyright © 2014 SAE International Downloaded from SAE International by Christopher Depcik, Friday, March 21, 2014 10:45:24 AM