What causes Regen Cycles, How to Reduce Them and Benefits To Be Had
The Diesel Particulate Filter (DPF) is an assist in emissions-control included within diesel exhaust systems, to catch the remaining particulates left within the combustion cycle of the diesel engine. Each combustion cycle includes un-burnt components of diesel fuel, carbon and particulates that accumulate into a visible smoke from the exhaust stacks. Among other components along the way, the DPF captures many of these particulates, helping eliminate the ‘dirty-exhaust’ emanating into the air.
As an exhaust component continually clogging from the perpetual operation of a diesel truck, this filter is built into a system where it essentially cleans itself of the buildup. In doing so the filter can more efficiently capture exhaust artifacts, and more easily pass through the airflow from intake to output, causing less stress on the engine itself.
“A regeneration cycle occurs by essentially ‘cooking’ the filter clean again,” says Kyle Nace of Response Equipment Specialists (Kalispell, MT). “The DPF Regen contains the heat of the exhaust, adding up to temperatures exceeding 1000 degrees Fahrenheit, so that the filter is depleted of its buildup and returns to proper functioning capabilities.”
DPF Regeneration Cycles:
An active regen cycle is a normal process that takes place as the truck is going down the road. A computer sensor monitors the DPF and a dashboard indicator light notifies the driver that the regen is taking place, or the DPF is now cleaning. “You’ll notice a reduction in power during a regen,” notes Nace. “You can sometimes hear a ‘hissing’ type noise, or a different sound from the engine.” First time diesel owners often think there is something wrong with their trucks, but the DPF regen is a normal, often recurring, requirement included with diesel ownership.
A forced regeneration cycle is a manual process that takes place at the diesel shop with a certified technician initiating the cleaning of the DPF. “We force the truck’s computer to initiate the process prior to the parameter requests that happen with the active regen,” says Nace. “These circumstances happen when the owner/technician recommends a regen prior to the automated process. If something happens that indicates a necessity, or to simply avoid the process while driving, we can override the system to regen.”
Indicators of Pending DPF Regen:
Depending on the manufacturer and the gauges installed in the truck, the driver may notice an increase in exhaust back-pressure, and/or simply a lack of performance.
“When the engine is being choked down with a clogged filter, the driver may recognize just a lack in performance, throttle response, and power,” says Kyle. “The diesel engine is essentially a compressor in the airflow. With the efficiency of drawing that air into the truck for the combustion and then releasing it through the exhaust, it’s imperative that the least amount of restriction exists for enhanced performance of the motor.”
If the DPF regen cycle is not taking place, or not completing a full cycle, a ‘check engine’ light might illuminate on your dash. In doing so the many sensors in the system will calculate the particulates prior to the DPF and post, recognizing a lack in operation of the DPF. “With the accuracy in modern computerization, and the rigs that control that whole system, it’s something you want to pay attention to and address relatively soon, before you enter ‘limp mode’ or ‘De-rate’ where the truck will not operate over 20 to 30 mph in some cases.”
If the EGR system is failing, with improper recirculation of the exhaust, the truck runs with a lot more particulate and a lot more soot, therefore also clogging the DPF even more. “The entire system relies on the engine running well and doing everything possible to avoid repair or replacement of the DPF,” says Kyle. “An exhaust system is incredibly expensive and susceptible to abuse just like anything else. And with the fragile condition of the DPF itself, the less regens required, the better.”
How Often Does a DPF Regen Cycle Take Place?
Unfortunately, there is no predefined number of regens to be expected. Depending on the maintenance and upkeep of the truck, there may be less regens required with proper maintenance and attention to your truck, or if the engine is underperforming and a continually ‘dirty-exhaust,’ many regens may be required. Multiple regen cycles can happen per day if a truck is in heavy operations. And with multiple regens come mounting costs and interruptions in daily use.
“It depends on each individual truck,” says Kyle. “It all comes down to how efficiently that truck is running. From the quality of the fuel it’s burning to the additives that are being added to preserve the quality of the injectors, to improving the cetane in the fuel system, to changing the filters; These all affect the cleanliness of the fuel burn, therefore the cleanliness in the combustion, which determines the quality and the quantity of the exhaust being produced, which then may or may not clog the DPF.” Clean exhaust obviously is a by product of the care that goes into the fuel tank and the treatment of that fuel, from pump to exhaust stack. Nace says “the dirtier and more rich exhaust you produce, the faster it’s going to clog your DPF, therefore requiring another regen cycle.“
Proper Additives Help Reduce DPF Regens
Stiction is the sticky friction caused by byproducts of burnt oil. High pressure builds heat in tight-tolerance applications. Extreme heat causes the oil to burn, oxidize and create layers of sludge and deposits. Fuel injectors, pistons, rings, and a variety of other engine components, are continually susceptible to this stiction buildup. All of which are the enemy of any clean and efficient mechanical system. When oxidization, layers of sludge, carbon and deposits form throughout the engine, additives are an imperative need to clean the parts. The proper additives clean the gum, varnish and stiction while also lubricating everything the oil touches in your engine. But the proper additives also do so with no harsh solvents that potentially harm engine components. Specific to the DPF, the correct additives properly clean the engine parts and reduce the amount of particulates clogging the DPF, thereby reducing multiple regen cycles.
The proper additives also help restore dynamic compression with increased ring seal. The tighter seals provide improved combustion efficiency, thereby translating to not only better fuel economy, power and a better running engine, but also the efficiency required in the combustion cycle to prevent blow-by and added particulates flowing through the exhaust system. The proper combination of additives can provide not only a better running truck, but an extremely helpful deterrent to unexpected repairs and replacements in the future.
Specific to diesel engines, the proper additives also restore the lubricity that has been refined out of the ultra low sulphur diesel fuel purchased at the fuel pumps. With the proper lubricity returned to the fuel system however, mechanical parts are then more fluid in their operations with less friction. With less friction the amount of wear and tear is reduced, better maintaining the tolerances of machined parts for a cleaner burn and more complete combustion cycle.
Most diesel engines operate more efficiently with a fuel that has a cetane rating of 48 to 50. Fuels with higher cetane burn more efficiently and completely than those with lower cetane ratings. The proper additives contain a cetane improvement to reduce hydrocarbons and particulate matter in your exhaust. The cetane booster in Hot Shot’s Secret Diesel Extreme for example, promotes more complete combustion, fewer emissions and therefore fewer DPF regens. Diesel Extreme has been shown to have 83% less DPF regens.
“We see a lot of Cummins motors in our area for maintenance, in addition to heavy trucks. We rely heavily on the the Diesel Duo from Hot Shot’s Secret. It contains two 64oz bottles of Stiction Eliminator and Diesel Extreme, which provide an incredible solution to helping our customers with a variety of diesel issues,” says Nace. “We’ve saved several customers injector jobs, and/or had customers come to us that have already spent thousands of dollars on replacements or servicing their DPF system, their injectors, their EGRs and trying to figure out why they are constantly going into a regen cycle. We’ve used these additives and within 1000 miles we see complete resolve in many of these issues. It’s really been incredible for us.”
DPF Regen Case Studies:
Hot Shot’s Secret is working to continually provide the best additives on the market. With scientific testing in the lab, in conjunction with real world testing in the field, many of the top diesel experts monitor, learn and save from HSS testing results. In a past field study, Hot Shot’s Secret helped save the city of Columbus, OH thousands of dollars, annually, in fuel, labor and costs directly related to regen cycles. With an additives investment of $200 in two city test trucks, regen cycles were reduced from 36 annually, to 6.
See more information about Savings on DPF Regen Cycles.
“We have a customer that offers a delivery service for rental equipment,” states Kyle. “They were experiencing DPF regen cycles almost daily. They had sent their main truck to another shop and had the whole system replaced, to the tune of nearly $8000. It didn’t fix the problem at all. When they came to us for an oil change, we added our Hot Shot’s Secret additives and within about a week, they saw reductions in their regen cycles and within a month, they had no more issue at all.
We also had a mobile home mover which had their injectors replaced about a year previous, and it was just pumping white smoke out the exhaust and missing like it needed injectors again. Same thing; we ran both the Stiction Eliminator and the Diesel Extreme additives from Hot Shot’s Secret, and within a couple weeks, our customer was loading his truck again and noticed the miss and smoke were gone. That’s been probably eight months ago and he hasn’t been back. When we don’t hear back, we consider that ‘no news is good news’. Or when they do report back that its running better, and we don’t see them back in the shop for repairs, we chalk that up as a success.”
“There are a million (additives) products out there and we’ve tried almost all of them. When I found out about Hot Shot’s Secret at a Diesel event a couple years ago, I soon realized that Hot Shot’s has a claim just like everyone else. And when I look into new products, I try and test these claims and use these products myself, before I ever represent them for my customers. So my shop foreman, lead fabricator and I used these additives in our own trucks. Within a week we all noticed a significant improvement and have ever since then, felt comfortable attaching our name to these products and representing something that IS real, and something that DOES work. We continue to have great results.”
Response Equipment Specialists, LLC