Industrialisation of Proof of Concept Wall-flow DOC + Filter System

Underground » Maintenance

Published: June 19Project Number: C26070

Get ReportAuthor: Nick Coplin | Orbital Australia

The need to protect workers from diesel particulate matter (DPM) had led the underground coal mining industry to install disposable filter systems on their vehicles.

This project has progressed the industrialisation of the wall-flow DPF system with additional site work, assessments of system robustness and the embedding of real-time, and near-real-time, technology to monitor the performance of diesel particulate filter system.

The first five parts of the project were completed under project C25073, with this one consisting of a further two main parts with specific sub-tasks under each:

  • Part 6 -
  • Industrialisation Design - DPF, pipework and monitoring,
  • On-Engine Validation and Durability Testing,
  • Field Trial Support and Monitoring System Software Refinement;
  • Part 7 -
  • Emissions Compliance Testing,
  • Safety System Testing.

The system outline for industrialisation proposed by the coal sector was as a retrofit installation that will be designed to meet the performance and safety standards required by the industry with a focus on minimising system cost.

The work scope for activities in this project included a mix of specific design and validation, as well as some application engineering. The project yielded what Orbital (and the automotive sector) call a P2 (second stage prototype) which has the form, function and performance of a production intent design but was not using production tooling/fixtures. It includes the industrialisation features, but not the commercialisation aspects which would also involve setup of tooling and manufacturing supply chain considerations.

In addition to the industrialisation activities, there were a number of additional technical investigations undertaken:

  • Characterisation of the absorption of NO2 in the wet exhaust scrubber as a means of investigating opportunities to reduce tailpipe noxious emissions;
  • Characterisation of DPM particle size / distribution characteristics from the DPF system; a point of interest with regard to occupational exposure;
  • Characterisation of DPF system performance and durability with Eromanga fuel (the 100ppmS fuel used in some mines);
  • The addition of NOx and DPM exhaust sensors post-DPF to monitor DPF system performance; and potentially demonstrate ongoing system compliance;
  • Realtime broadcasting of DPF monitor status for in-service machine monitoring and system performance management; and
  • Verification of the applicability of the C25073 proof-of-concept wall-flow DPF to legacy Mechanical Injection engines; which are still prevalent in operations.

The addendum investigations provided additional technical insights into the performance of the DPF and /or LHD emission control and monitoring systems.

Despite some regulatory questions requiring clarification, the wall-flow DPF system industrialised under this project makes for a compelling solution to diesel particulate management in underground coal mining operations.


Health and safety, productivity and environment initiatives.

Recently Completed Projects

C26059Proof Of Concept Of The Electronic Spark Test Apparatus On Existing Known Power Supplies

This project continued a long running research program into an elect...

C26070Industrialisation Of Proof Of Concept Wall-Flow DOC + Filter System

The need to protect workers from diesel particulate matter (DPM) had...

C25001Ventilation And Gas Management - Underground Coal Mines

This planning guideline has been prepared to assist mine operators t...


Open Cut

Safety, productivity and the right to operate are priorities for open cut mine research.

Recently Completed Projects

C26034Coking Properties Deterioration In Small Samples

Accurate evaluation of coking coal parameters at the exploration sta...

C23029Alternative And Sustainable Explosive Formulations To Eliminate Nitrogen Oxide Emissions

This technical report describes the technology of a novel mining exp...

C25005Site Based Trials Of Alternative Explosive Formulations To Eliminate Nitrogen Oxide Emissions

This report documents the outcomes of Phase 3 of this project and b...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C26009Improved Precision Of Determining Coal In Urban Dust

Dust samples collected in coastal locations using High Volume Air Sa...

C26015Novel Characterisation Of Coal Petrography For Improving The Dewatering Of Fine Coals Using Chemicals

This project aimed to develop alternatives to existing mechanical de...

C26014Low Cost Online Measurement Of Particle Size And Density For Diagnostics Across The Fine Coal Circuit

This project has developed a novel prototype optical system for prof...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C26045Mineralogy Effects On The 3D Porosity Evolution Of Coke And Coke Reactivity

CRI/CSR CO2 combustion data are key metrics of coke quality and perf...

C25049Fusibility Of Coal Blends And Minerals In Coking

The CSIRO optical reflected light imaging CGA (Coal Grain Analysis) ...

C25045Stage Two - Assessment Of In Situ High-Temperature Strength Of Cokes

Stage I of this project established a reliable and repeatable proces...

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C27058Technological Assessment Of A Recycle Reactor For VAM Abatement

Underground coal mining emits high volumes of methane, diluted in ve...

C27008Selective Absorption Of Methane By Ionic Liquids

The connection of a ventilation air methane (VAM) abatement plant di...

C24061Proof-Of-Concept Photocatalytic Destruction Of Methane For Coal Mining Fugitive Emissions Abatement

Australia's fugitive emissions in 2015 were 41 Mt CO2-e (representin...

Mine Site Greenhouse Gas Mitigation

Low Emission Coal Use

Step-change technologies aimed at reducing greenhouse gas emissions.

Recently Completed Projects

C17060BGasification Of Australian Coals

Four Australian coals were trialled in the Siemens 5 MWth pilot scale ga...

C17060AOxyfuel Technology For Carbon Capture And Storage Critical Clean Coal Technology - Interim Support

The status of oxy-fuel technology for first-generation plant is indicate...

C18007Review Of Underground Coal Gasification

This report consists of a broad review of underground coal gasification,...

Low Emission Coal Use

Mining And The Community

The relationship between mines and the local community.

Recently Completed Projects

C16027Assessing Housing And Labour Market Impacts Of Mining Developments In Bowen Basin Communities

The focus of this ACARP-funded project has been to identify a number...

C22029Understanding And Managing Cumulative Impacts Of Coal Mining And Other Land Uses In Regions With Diversified Economies

The coal industry operates in the context of competing land-uses that sh...

C23016Approval And Planning Assessment Of Black Coal Mines In NSW And Qld: A Review Of Economic Assessment Techniques

This reports on issues surrounding economic assessment and analysis ...

Mining And The Community


National Energy Research,Development & Demonstration Council (NERDDC) reports - pre 1992.

Recently Completed Projects

1609-C1609Self Heating of Spoil Piles from Open Cut Coal Mines

Self Heating of Spoil Piles from Open Cut Coal Mines

1301-C1301Stress Control Methods for Optimised Development...

Stress Control Methods for Optimised Development and Extraction Operations

0033-C1356Commissioned Report: Australian Thermal Coals...

Commissioned Report: Australian Thermal Coals - An Industry Handbook