Diesel Exhaust Fluid, or DEF, is a nontoxic solution that’s vital for modern diesel engines. Its main purpose? To reduce nitrogen oxide (NOx) emissions. DEF is a key part of Selective Catalytic Reduction (SCR) systems, which are designed to make diesel engines cleaner.
More and more businesses are exploring the possibility of DEF making at their own facilities. Why? Because it gives them better control over quality, reduces costs, and improves the sustainability of their supply chains.
This article will walk you through everything you need to know about producing DEF in-house, from the materials and equipment required to the process itself, and the benefits you can expect to see.
What is Diesel Exhaust Fluid (DEF)?
Diesel Exhaust Fluid, or DEF, is a liquid used to reduce the amount of pollution created by diesel engines. Here’s what you need to know about it.
Defining DEF
DEF is a carefully measured mix of high-purity urea and deionized water. It’s usually 32.5% urea and 67.5% deionized water. You may also see it called DEF 32 for this reason. Other blends, like DEF 40 and DEF 50, are available, but they’re used in more specialized applications.
Diesel Exhaust Fluid is used in Selective Catalytic Reduction (SCR) systems, where it transforms NOx emissions into harmless nitrogen and water vapor.
Why standards matter
To make sure DEF is high quality and performs as expected, it’s important that it meets ISO 22241 standards.
When you use certified DEF, you can be sure the SCR systems in your vehicle are working correctly, and you can avoid any potential engine damage.
Why consider making your own DEF?
A lot of people who use DEF buy it from external suppliers. But there are some good reasons to consider making it yourself:
- Cost Savings: It can be cheaper to produce DEF in-house than to buy it.
- Quality Control: When you make your own DEF, you have more control over the quality. You can make sure it meets the standards you need.
- Supply Chain Resilience: Making your own DEF means you don’t have to rely as much on outside suppliers. This can protect you from supply disruptions.
- Scalability: You can increase or decrease your DEF production as needed.
- Sustainability: You can cut down on transportation emissions by making your own DEF.
What do you need to make DEF?
You only need two ingredients to make diesel exhaust fluid:
- High-Purity Urea: The urea you use to make DEF has to meet specific quality standards, or your SCR system could fail. Always buy from reliable suppliers.
- Deionized Water: Regular tap water contains minerals and other junk that can contaminate your DEF and make it unusable. The deionization process removes these impurities.
Essential Equipment for DEF Production
Producing DEF requires specialized equipment to ensure purity and quality. Here’s a look at some of the key components:
Water Purification System
Since DEF is mostly water, the water used needs to be extremely pure.
- Deionization Unit: This removes minerals and other impurities from the water, producing deionized water.
- Water Quality Monitoring: Regular testing is vital to confirm the water’s purity meets the strict standards for DEF production.
Urea Dissolving and Mixing System
This equipment mixes the urea with the deionized water to create the DEF solution.
- Mixing Tanks: These tanks are used to dissolve the urea in the deionized water.
- Agitation System: This system ensures the urea is thoroughly mixed and doesn’t settle at the bottom of the tank.
Quality Control and Testing Equipment
Quality control is crucial to ensure the DEF meets the required specifications.
- Refractometer: This measures the urea concentration to confirm it’s at the required 32.5%.
- Conductivity Meter: This monitors the conductivity of the DEF, which can indicate the presence of unwanted impurities.
Storage and Packaging Equipment
Proper storage and packaging are important to maintain the DEF’s quality.
- Storage Tanks: These tanks are specifically designed to store DEF, preserving its purity and preventing contamination.
- Filling and Packaging Equipment: This automates the process of filling containers with DEF for distribution.
How is DEF Made?
Making DEF is a pretty involved process, but here’s a breakdown of the steps:
- Get the goods: You’ll need high-purity urea and deionized water that meet ISO 22241 standards. Think of it like using the best ingredients for a recipe!
- Water Prep: Run the water through a deionization system. This makes sure it’s super pure.
- Mix it up: Carefully dissolve the urea in the deionized water in a special mixing tank. You need to stir it just right.
- Test, test, test: Use a refractometer and a conductivity meter to check the urea concentration and water purity. Quality control is key!
- Filter it out: Filter the solution to remove any tiny bits of stuff floating around.
- Pack it up: Put the DEF in airtight containers and label them clearly. You want to know what you’re dealing with!
How to ensure DEF quality
DEF has to be right. If you want to make sure your DEF is good stuff, you need to:
- Test it. You can’t just guess if your urea concentration and water purity are right. Test it regularly.
- Write it down. Keep detailed logs of all your testing results.
- Fix what’s wrong. If something goes wrong, you need a plan to fix it.
- Calibrate your tools. Make sure your testing equipment is accurate.
- Get certified. Certifications from groups like API and ISO can demonstrate to customers that you follow industry standards.
How to package and store DEF
DEF is very sensitive to contamination, so you need to be careful about how you package and store it.
- Containers: Use airtight containers designed for DEF storage.
- Labels: Label each container with the production date, batch number, and expiration date.
- Environment: Store DEF in a cool, dry place, out of direct sunlight and away from extreme temperatures.
- Contamination: Do not mix DEF with anything else.
How does DEF impact the environment?
Diesel Exhaust Fluid (DEF) can help reduce the environmental impact of diesel engines. Here’s how:
- Lower Greenhouse Gases: DEF reduces NOx emissions, which in turn lowers greenhouse gas emissions.
- Less Smog: By reducing NOx, DEF helps cut down on smog.
- Cleaner Air: DEF makes the air cleaner, which is better for public health.
- Sustainable: DEF is safe and doesn’t hurt the environment.
Closing Thoughts
Making your own DEF can save you money, help you control quality, and support sustainability efforts. But remember to follow best practices for DEF production, storage, and quality assurance.
By using DEF in your diesel engines, you’re helping to reduce harmful emissions and make the air cleaner for everyone.