Background The diesel particulate filter (DPF) is a cylinder assembled on the exhaust pipe of diesel engines just after the catalytic converter. It weighs 3.3 kg and is 16 cm long. The purpose of this piece of equipment is to retain the carbon particles produced by a diesel engine. As a consequence, it also captures particles such as Ce, Ca, Fe, Z, P, Ni and S, and after 80 000 km the efficiency of the device is reduced and it must be replaced. Objectives The aim of this pilot project was to set up a unit to remove the particles from used diesel particulate filters (DPF) and remanufacture these filters for further use. The daily treatment capacity was to be 200 filters per day. The main objectives were: - To eliminate the particles stored in the DPFs, in particular the carbon and cerium oxides, in an environmentally friendly way. - To assemble these components in keeping with exchange standards for the sales network of the manufacturers. - To multiply the number of treatment units within the Peugeot SA network and within other automobile groups (e.g. Fiat, Ford, Volkswagen, BMW, Mercedes). - To remanufacture 60 000 particles filters in 2004 and consequently reduce some 198 tonnes of waste. Results The project has been successful in that the manufacturing unit functions and has achieved the production targets. During the course of the project 9204 DPFs were treated and 83% of them were successfully remanufactured for reuse. The remanufacturing has enabled the recycling of 30 tonnes of ceramic and 30 tonnes of metal. Performance tests, validated by the manufacturer Peugeot SA (PSA), were carried out on the remanufactured DPFs; the average efficiency was 95%. 17% of the used DPFs were rejected for remanufacture for various reasons, including envelope corrosion (4%), ceramic cracks (10%), or deficient washing of the filter (3%). In the final report, the beneficiary indicated that 1800 DPFs per month were being processed for PSA, i.e. 21 600 per year. In 2004, 9600 DPFs were remanufactured and the production target for 2005 was 40000. Constructive contacts were established with one other car manufacturer: Daimler Chrysler placed an order for the remanufacture of 40 filters. The beneficiary has indicated that 150 to 300 DPFs could be remanufactured for DC from 2008. Other companies decided not to pursue the project, however they may decide to get involved at a later stage when the demonstration unit is well established. Contacts were also established with the company UMICORE to remanufacture DPFs for lorries. The first tests were to take place in September 2004. Water and air pollution, produced during the regeneration of the filters, was controlled and in conformity with legislation. Measurements were carried out to evaluate the level of emissions of several compounds, namely VOCs (volatile organic compounds), oxygen, carbon monoxide, carbon dioxide, and nitrogen oxides. The results were lower than the maximum limits. Wastewater treatment enabled 80% of the water to be recycled. The remaining 20% was released into the environment and complied with current standards. One key environmental advantage of the project is that it will considerably reduce the dumping of motor components which must be replaced once or twice during the life of the vehicle. In economic terms, the remanufactured part is interesting from the consumers point of view; it is 50 % less expensive than a new part. The beneficiary was planning to build a second demonstration unit in 2005 and a third one in 2010.