Catalytic Solutions for Emission Control of Natural Gas Vehicles Dr. Toni Kinnunen Osmo Jahkola Sergio Del Re Dr. Andreina Moreno Toni Kinnunen, Osmo Jahkola, Sergio Del Re Ecocat Oy
Introduction Ecocat Group Ecocat is an international and fast growing clean air technology company headquartered in Finland. Ecocat develops and manufactures catalytic converters, in other words mechanical substrates with chemical coatings for automotive industry, small engines and industrial applications. Ecocat s global market share is close to 20% of metallic substrates and 3% of all substrates. Projected Revenue ( million) 100 93 90 80,9 80 70 60 52,2 50 40 30 20 10 0 2005 2006 2007 The company has manufacturing plants in Finland, India, Italy, Middle-East and the U.S. Ecocat cleans the air for the world
Introduction Global Presence Sweden - Sandviken Italy - Turin Germany - Undeheim UK - Penwortham Preston Czech Rep. - Prague Finland - Vihtavuori (Headquarters) Finland - Oulu (R&D Centre) Romania - Craiova South Korea - Seoul China - Jiangsu USA - Chicago Italy - Genoa Turkey - Istanbul Iran - Tehran India - Faridabad Manufacuring Hubs Sales Agents
Introduction Catalytic converter Fast and highly effective response to meet application requirements Easy integration into exhaust system Coating process Metallic substrate Low back pressure Size benefit Flexibility in shape Durability Immediate catalytic performance Chemical know-how Formulas for several applications - Gasoline - Diesel - Natural Gas - VOC Ecocat has been active in the catalyst market since the early stages of the regulation of exhaust emission controls internationally and has over 20 years of know-how in all three processes
Introduction CNG: Compressed Natural Gas Composition: 95-98% Methane (CH 4 ) CNG is a very economic fuel since there is no need to refine it There are around 6.182 trillion ft 3 proven reserves of natural gas in the world when compared to 1.317 billion barrels of oil CNG is gaining territory as a fuel of choice for mobile and stationary combustion engines: By 2020 there will be around 25 million cars running on CNG in Europe alone!! Ecocat has both the technical and logistical ability to provide substrate, coating and canning as an integrated one-piece solution Hence Ecocat s strategy of focusing on CNG
Introduction 809 kj CH 4 + 2O 2 CO 2 + 2H 2 O To tackle the high energy barrier is common to use high loaded catalysts To avoid this effect a promoter is needed High loadings affect dispersion negatively Extending durability Promoter stabilizes the surface Slowing sintering Enhancing activity
Introduction Trough intensive research, Ecocat has developed an advance formulation designed to cope with the demanding conditions CNG catalysts must endure Our range of products covers: CNG only applications Bi-fuel applications LD & HD, Stationary Particular emphasis has been put on: Increasing durability Reducing light-off Advanced Coating
Introduction Metal substrates enable reduced emissions Thinner walls mean: Lower pressure drop More geometric surface area Higher CPSI possible Higher thermal conductivity and lower heat capacity mean: Faster, more uniform heat up No hot spots Air gap between substrate and canning means: Air insulation Higher operating temperatures Speed bumps improves mass and heat transfer
Introduction Features groove system for substrate locking and improved flow dynamics. 100 % stainless steel (1.4767/1.4725 substrate, FeCrAl). Easy to integrate into the exhaust system. Improved heat and mass transfer rate, low thermal inertia. High resistance against thermal and mechanical shocks.
Introduction Brazed Ecocat 500 cpsi Lower bumps, decreased back pressure Excellent mechanical durability by brazing
Solution for CNG Applications
New Washcoat for CNG-Only Applications Light-off Aged/ CNG applications 350 temperature at 50% conversion 315 300 287 298 278 273 256 254 257 254 250 200 150 100 50 0 THC CO Previous generation product Gasoline chemistry Nox New K5.7 Conversion of methane starts at lower temperatures
New Washcoat for CNG-Only Applications: K5.7 Results Correspond to Aged Samples 0,665 CNG engine test 0,7 38% less emissions 0,410 56% less emissions 0,4 0 THC CO Previous generation product gasoline chemistry Nox New K5.7 0,040 0,1 0,039 0,113 0,122 0,2 64% less emissions 0,152 0,3 0,279 emissions g/km 0,5 0,440 0,6
Cumulative THC Emisions During Engine Test Results Correspond to Aged Samples- CNG Test
Solution for Bi-fuel (gasoline and CNG) Applications
New Washcoat for Bi-fuel Applications Light-off Aged/ Bi-fuel applications 350 Temperature at 50% conversion 315 300 287 298 267 278 273 256 250 244 200 150 100 50 0 THC CO Previous generation product Gasoline chemistry Nox New K5.8 for bi-fuel appl High efficiency due to lower light-off! 265
New Washcoat for Bi-fuel Applications: K5.8 Results Correspond to Aged Samples Gasoline engine test 0,477 0,6 58% less emissions 0 THC Previous generation product CO Gasoline chemistry Nox New K5.8 for bi-fuel appl 0,050 0,055 0,041 0,1 0,053 0,2 69% less emissions 0,16 57% less emissions 0,200 0,3 0,258 0,4 0,096 emissions g/km 0,5
Cumulative NOx Emisions During Engine Test Results Correspond to Aged Samples- Gasoline Test
Nanotechnology behind
Active sites in optimum usage PGM nanoparticles tailored interactions Ce-Zr Ce-Zr Ce-Zr Alumina Constant need for enhanced activity without significant increase in cost Optimised usage of precious metals needs improvements in catalytic chemistry
Promoter Effect on Emissions: K5.7 for CNG only applications Results Correspond to Aged Samples Effect of promoter on Activity/ CNG engine test 0,600 0,533 0,500 Emissions g/km 0,410 0,400 0,300 0,200 0,138 0,122 0,100 0,057 0,040 0,000 THC CO K5.7 Without promoter Nox K5.7 With promoter
Promoter Effect on Emissions: K5.8 for Bifuel applications Results Correspond to Aged Samples Effect of promoter on activity / Gasoline engine test 0,35 0,312 0,3 Emissions g/km 0,25 0,200 0,2 0,15 0,097 0,1 0,05 0,05 0,050 0,041 0 THC CO K5.8 Without promoter Nox K5.8 With promoter The promoter effect is particularly signifficant on NOx emissions from gasoline
Addittion of promoter hinders the sintering of PGM Unpromoted Surface Promoted Surface PdO PdO Promoter Fresh Fresh PdO clusters around the promoter PdO cluster Aged Aged Dispersion is kept at good levels
Addittion of promoter hinders the sintering of PGM Aged Sample with promoter Aged Sample without promoter Low density of Pd clusters on the surface High density of Pd clusters on the surface Promoter stabilizes the surface Less sintering after aging Ustabilized surface More sintering after aging
SUMMARY Ecocat technology = Optimised combination of appropriate substrate and efficient chemistry Ecocat is unique in the world by providing the whole product for catalytic aftertreatment Competitive solutions for CNG and Bi-fuel Low-Dp durable metallic substrate Enhanced promotion effect Low light-off, high activity Excellent thermal durability Pd-rich = cost effective