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A novel CFD simulation technique has been developed that unites realistic three-dimensional resolution of diesel particulate filter systems with computational efficiency. Three-dimensional resolution of the thermofluiddynamic behaviour during transient soot loading and regeneration is necessary for the optimization of the function, durability, weight and cost of DPF systems. Computational efficiency is required to allow its use as a standard development tool during all engineering phases and to allow the simulation of driving cycles. The detailed conclusions that can be drawn about soot distribution and thermal characteristics during the regeneration assist in ensuring the DPF function and avoiding DPF failures over the operational lifetime.

Meeting backpressure and flow uniformity requirements within severe packaging constraints presents a particular challenge in the layout of catalyst inlet cones. In these cases, a parameterized optimization of the potentially complex cone geometries is inefficient (and inappropriate). Even assuming that a parameterization of the complex surface forms is possible, the choice of parametric shapes invariably affects the achievable results. Additionally, the long computation time for solving the flow fields limits the number of shape parameters that can be considered. To overcome these restrictions, an optimization tool has been developed at EMCON Technologies that is based on the continuous adjoint method (augmented Lagrange method) of Othmer et al. The open source CFD toolbox OpenFOAM® is used as the platform for the implementation.