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Catalytic Solutions for Emission Controlof Natural Gas Vehicles
Dr. Toni Kinnunen*Osmo JahkolaSergio Del ReDr. Andreina MorenoDr. Kauko Kallinen
Ecocat Group
Ecocat is an international and fast growingclean air technology company headquarteredin Finland.
Substrates and coatings for exhaust gasaftertreatment
Global market share is close to 20% ofmetallic catalysts
Global presence
Ecocat cleans the air for the world
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2005 2006 2007
Projected Revenue (€million)
Introduction
Global Presence
China - JiangsuSouth Korea - Seoul
India - Faridabad
Turkey - Istanbul
Romania - Craiova
Czech Rep. - Prague
Finland - Vihtavuori (Headquarters)
Iran - Tehran
Italy - Genoa
Italy - TurinGermany - Undeheim
UK - Penwortham PrestonFinland - Oulu (R&D Centre)
USA - Chicago
Sales AgentsManufacuring Hubs
Sweden - Sandviken
Introduction
•Low back pressure•Size benefit•Flexibility in shape•Durability•Immediate catalytic performance
Formulas for several applications- Gasoline- Diesel- Natural Gas- VOC
•Fast and highly effectiveresponse to meet applicationrequirements•Easy integration into exhaustsystem
Metallic substrate Chemical know-how
Catalytic converter
•Ecocat has been active in the catalyst market since the early stages of the regulation of exhaustemission controls internationally and has over 20 years of know-how in all three processes
Coating process
Introduction
Natural Gas –Potential solution
Advantages
• Lower CO2 emissions compared to gasoline and diesel
• No particulate emissions
• Significantly lower NOx emissions
• Other benefits
Global natural gas sources
Lower noise level
Odourless exhaust gas
No need to refine it
Disandvantages
• Lack of distribution network
• Need for specific engine development
• Methane emissions specific CNG catalysts is needed
Introduction
Trough intensive research, Ecocat has developed an advance formulationdesigned to cope with the demanding conditions CNG catalysts must endure
Our range of products covers:CNG only applicationsBi-fuel applicationsLD & HD, Stationary
Particular emphasis has been put on:Increasing durabilityReducing light-offCost-efficiency (PGM)
Advanced Coating
Introduction
CH4 + 2O2 CO2 + 2H2O809 kJ
High loadingsaffect dispersion
negativelyTo avoid this effect
a promoter is needed
Promoter stabilizesthe surface
Enhancing activity
To tackle the high energy barrier is common to use high loaded catalysts
Slowing sintering
Extending durability
Introduction
Metallic Substrates
• 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
Metallic substrates enable reduced emissions
• Features groove system for substrate lockingand improved flow dynamics.
• 100 % stainless steel (1.4767/1.4725substrate, FeCrAl).
• Easy to integrate into the exhaust system.
• Brazed only when absolutely needed
• Maximum diameter in serial production 600mm
One of the metallic substrates - mechanically locked Ecocat®
EcoCat® substrates have been supplied to PCV, LCV, HCVand Industry for diesel, gasoline and CNG applications
Solution for CNG-only Applications
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Gas temperature Inlet Middle Outlet
Tem
pera
ture
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empe
ratu
re( °°
C)
C)
Time (sec)Time (sec)
10mm
10mm
SubstrateSubstrate
RA-H ageing temperature profile
Light-off Aged/ CNG applications
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THC CO Nox
tem
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atu
reat
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vers
ion
Previous generation product Gasoline chemistry New K5.7
New Washcoat for CNG-Only Applications
Conversion of methane starts at lower temperatures
CNG engine test0,
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THC CO Nox
emis
sion
sg/
km
Previous generation product gasoline chemistry New K5.7
56% less emissions
38% less emissions
64% less emissions
New Washcoat for CNG-Only Applications: K5.7
Results Correspond to Aged Samples
Cumulative THC Emisions During Engine Test
Results Correspond to Aged Samples- CNG Test
Lambda window for THC in laboratory tests
THC
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0,97 0,98 0,99 1 1,01 1,02 1,03Lambda
Co
nve
rsio
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)
K5.7 Methane K5.7 Gasoline
•After laboratory ageing (LS - 1030°C/20h)
Solution for Bi-fuel (gasoline and CNG) Applications
Light-off Aged/ Bi-fuel applications
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THC CO Nox
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atu
reat
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vers
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Previous generation product Gasoline chemistry New K5.8 for bi-fuel appl
New Washcoat for Bi-fuel Applications
High efficiency due to faster light-off!
Gasoline engine test
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THC CO Nox
emis
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m
Previous generation product Gasoline chemistry New K5.8 for bi-fuel appl
57% less emissions
58% less emissions
69% less emissions
New Washcoat for Bi-fuel Applications: K5.8
Results Correspond to Aged Samples
Cumulative NOx Emisions During Engine Test
Results Correspond to Aged Samples- Gasoline Test
Nanotechnology behind
Ce-ZrCe-Zr
Alumina
PGMnanoparticlestailored interactions
Ce-Zr
Constant need for enhanced activity without significant increase in cost Optimised usage of precious metals needs improvements in catalytic chemistry
Active sites in optimum usage
Effect of promoter on Activity/ CNG engine test
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THC CO Nox
Em
issi
on
sg
/km
K5.7 Without promoter K5.7 With promoter
Promoter Effect on Emissions: K5.7 for CNG only applications
Results Correspond to Aged Samples
Effect of promoter on activity / Gasoline engine test
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THC CO Nox
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/km
K5.8 Without promoter K5.8 With promoter
The promoter effect is particularly signifficant on NOx emissions from gasoline
Results Correspond to Aged Samples
Promoter Effect on Emissions: K5.8 for Bifuel applications
Addittion of promoter hinders the sintering of PGM
Fresh
Unpromoted Surface
PdO
Aged
PdO cluster
Fresh
Promoted Surface
PdO Promoter
Aged
PdO clusters around the promoter
Dispersion is kept at good levels
Aged Sample with promoter
Promoter stabilizes the surface
Low density of Pd clusters on the surface
Aged Sample without promoter
Addittion of promoter hinders the sintering of PGM
Less sintering after aging
High density of Pd clusters on the surface
Ustabilized surface
More sintering after aging
Ecocat technology = Optimised combination ofappropriate substrate and efficient chemistry
Competitive solutions for CNG and Bi-fuel√Low-Dp durable metallic substrate√Enhanced promotion effect√Fast light-off, high activity√Excellent thermal durability√Pd-rich = cost effective
SUMMARY