ingas 30 months meeting / ecocat

INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”

INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain

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INGAS 30 months meeting

Oulu - Finland

25 - 26 May 2011

InGas 30 months meeting / Ecocat

AVL, DAI, Delphi, Ecocat, ICSC-PAS, ICVT, Katcon, PoliMi



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WPB2.1Requirements /

Boundary Conditions

WPB2.2Advanced Catalyst

Development

WPB2.3Exhaust Heating/

Catalyst Concepts

WPB2.4Engine Testing/

EAT System Management

WPB2.5EAT System

Integration/Optimiz.

B2: Aftertreatment for Passenger Car CNG Engine

B0 A1 – A2 – A3 A2

Fuel Requirements/specifications

Exhaust boundaries

Engine/injection systemControl management

Engine for EATimplementation

Engine with EAT forfinal validation

Boundary conditionsReference catalyst

Catalyst samples

Coated heat exchanger

CH4/NOx operation strategy

EAT operation strategy 1

EAT operation strategy 2



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SPB2: Technologies and Approach

Development of specific active methane oxidation catalysts (WPB2.2) Catalyst preparation (precious metal and metal oxide technologies) Test of powdered catalysts, structured catalysts, substrates (metal and ceramics) Characterization studies

Development of a dedicated thermal management system (WPB2.3) Design and set-up of an integrated exhaust gas heating device (catalytic coated HEX) Modelling of heating device and catalytic combustion, simulation of behaviour Manufacturing, testing and optimisation of HEX

Development of operation strategies on engine test bench (WPB2.4) Identification of engine measures for faster light-off Testing of catalyst materials and HEX Optimization of operation strategies for improved CH4-Conversion

Demonstration of an exhaust gas aftertreatment system for Euro 6 (WPB2.5) Set-up of CNG engine with the exhaust aftertreatment system (transient bench) Optimization of the catalyst heating including cold-start Demonstration of the system performance (Euro 6 legislation) in NEDC on engine test bench Validation of the catalyst activity in a vehicle configuration for Euro 6 compliance (SPA2)



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InGas: SPB2/WPB2.2

6%-Pd/CeO2-Al2O3 material/powder made in Ecocat

(vs. made by POLIMI)

At the first stage 100 g ready powder ( 6% Pd) was madeaccording to the recipe achieved from POLIMI

Calcined alumina powder by Ecocat

Calcined alumina powder by POLIMI

Ce-Al powder by Ecocat

Ce-Al powder by POLIMI

SSA, m2/g 120 117 82 70

Pore volume, cm3/g 0,5 0,44 0,29 0,3

Pd % in ready powder: 6,1 wt-% for POLIMI and 6,15 wt-% for Ecocat made powder



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InGas: SPB2/WPB2.2

Catalyst sample made from the Ecocat 6%-Pd/CeO2-Al2O3 material/powder

• Good coating abilitiesfound on the metal surface • Combarable adhesion compared to the reference

Rolled sample for the tests

6%-Pd/CeO2-Al2O3

+ Bindercoated on themetal foil



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InGas: SPB2/WPB2.2

• Quite similar light off curves for COfor all the samples after HT-ageing

• After HT-ageing, THC light off for thenew samples is clearly better

Light off tests at lean (HT-700°C/20h aged)

CO Conversion in Light-off performance

0

20

40

60

80

100

100 150 200 250 300 350 400 450 500 550 600

Temperature before catalyst, °C

Co

nv

ers

ion

, %

1090 6Pd/CeO2-Al2O3 by Ecocat

640 REF (Pd)

896 6Pd/CeO2-Al2O3 by POLIMI

THC Conversion in Light-off performance

0

20

40

60

80

100

100 150 200 250 300 350 400 450 500 550 600Temperature before catalyst, °C

Co

nve

rsio

n, %


640 REF (Pd)




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InGas: SPB2/WPB2.2

• At λ=1 tests as LS-aged the new samplesshow better light off performance, especially for THC

Light off tests at λ=1 (LS-1030°C/20h aged)

CO Conversion in Light-off performance

0

20

40

60

80

100


Co

nv

ers

ion

, %


ref. 640 REF (Pd)


THC Conversion in Light-off performance

0

20

40

60

80

100


Co

nv

ers

ion

, %


ref. 640 REF (Pd)


NOx Conversion in Light-off performance

0

20

40

60

80

100


Co

nv

ers

ion

, %


ref. 640 REF (Pd)




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InGas: SPB2/WPB2.2

• After LS-ageing at λ=1 tests the new samples has better lambda for THC; for CO and NOx the window is very similar

Lambda tests at λ=1 (LS-1030°C/20h aged)

500°C CO Conversion in Lambda performance

0

20

40

60

80

100

0,97 0,98 0,99 1,00 1,01Lambda value

Co

nv

ers

ion

, %


ref. 640 REF (Pd)


500°C THC Conversion in Lambda performance

0

20

40

60

80

100

0,97 0,98 0,99 1,00 1,01

Lambda value

Co

nv

ers

ion

, %


ref. 640 REF (Pd)


500°C NOx Conversion in Lambda performance

0

20

40

60

80

100

0,97 0,98 0,99 1,00 1,01

Lambda value

Co

nv

ers

ion

, %


ref. 640 REF (Pd)




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InGas: SPB2/WPB2.2

Conclusions for the tests made for the 6%-Pd/CeO2-Al2O3 based samples:

At lean conditions the new samples has better light off peformance comparedto the reference, especially for THC, both as fresh and after ageing

At stoichiometric conditions after ageing the new samples has little better light off performance as well as better lambda window for THC; as freshthe sample made by Ecocat powder seems to have little better performance

The POLIMI powder was succesfully prepared by Ecocat

The catalyst based on the 6 wt-% containing Pd-CeO2-Al2O3 powdercould be a good candidate for a methane catalyst in In-Gas project

Scale up to 1 kg of the powder is in progress in order to make proto scalesamples for the engine tests



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Influence of certain (design) parameters on accumulated amount of CH4

Material thickness of corrugated spacer structures

L tot

Lc

Varied parameters

Optimized parameters

2 degrees of freedom for optimizer:•Lc

•Flap switch time

Varied parameters (const. in each optimization run:•sspacer

•Ltot

Development work TB2.3.2: Optimization of cold start operation strategies / design

12/25



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Fins

• Design modifications from Gen 1 to gen 2:– Increase number of fins– by decreasing the fin pitch from 1.8mm to 0.8mm

– Reduce the material thickness – to reduce the thermal inertia

• Risk assessment?– High risk of erosion of the material during the brazing – Gas leakage

– A new time/temperature profile of the brazing and the quantity of the brazing filler metal have been modified.

Design modifications



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MK2 hex generation

Flap 1

Flap 2

Flap 3

TWC coating

Exhaust in

Exhaust outFlap 1

Flap 2

Flap 3Flap 4 (optional, for complete decoupling of hex)

Lab-scale prototype (already at USTUTT): Bench-scale prototype:

Reduction of spacer structure wall thickness (0.15 mm 0.075 mm)

Hex turned by 180° to use hot exhaust more efficiently during heat up Additional flow configuration for heat up (see upcoming slides) EMICAT electric heater as cold start support for low exhaust temperatures

(only lab scale!)

Increase of cross sectional surface (0.0025 m2 0.0042 m2 (only lab-scale) High cell density (30 fpi ≈ 250 cpsi) for complete hex, coating length 10 cm



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Ltot = 0.3 m Atot = const. = 0.01618 m2

Development work TB2.3.2: Optimization of cold start operation strategies / design

MK 1 Proto

MK 2 Proto

MK 1 Proto

MK 2 Proto

MK 1 Proto

MK 2 Proto



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SPB2 WPB2.4

Comparison of exhaust gas composition at Lambda 1, using different operation strategiesThe diagram below shows the exhaust gas composition range with different operation strategies. With the used

configurations (MPI balanced / unbalanced) for TWC characterization the exhaust gas composition is in the same range as it is with direct injection. So the results done with MPI are valid also for DI

THC

MPI or DI operation / Variation of composition due to unbalancing

DI operation / Variation of composition due to homogenization (injection timing)

MPI operation / balanced (as used for catalyst characterization step 2 / balanced)

MPI operation / unbalanced (as used for catalyst characterization step 2 / unbalanced)

CH4 CO O2NOx

5000 5%

3000

2000

4000

1000

0

4%

3%

2%

1%

0

CO

, O

2 [

%]

TH

C,

CH

4,

NO

x [p

pm]



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1600rpm 3,4bar / catalyst #1Comparison between balanced and unbalanced operation

0

20

40

60

80

100

120

140

160

180

200

0,90 0,95 1,00 1,05 1,10 1,15

Lambda [-]

Te

mp

.Ra

ise

in c

ata

lys

t [K

]M

eth

an

e c

on

ve

rsio

n [

%]

Traise in cat

Methane conversion

TRaise in cat / unbalanced

Methane conversion / unbalanced

SPB2 WPB2.4

This example of the comparison between balanced an unbalanced cylinders shows the significant increase in conversion efficiency. Also the Lambda range with high conversion is much wider than with balanced cylinders

Catalyst Characterization

Significantly more exothermic reaction due to CO increase



191919

Hex testing engine operation points @ AVL

LFNR N PME MD P_Eff GHSV (λ = 1) V_dot (λ = 1)

- 1/min bar Nm kW 1/h Nm3/h

2 1200 0.77 10.95 1.38 ~ 8100 15.8

3 1600 2.03 29.05 4.87 ~ 14700 28.2

4 1600 3.41 48.68 8.16 ~ 19300 37.2

5 1600 4.74 67.77 11.36 ~ 23500 45.2

6 1800 3.41 49 9 ~ 21000 41.8

7 1800 6 86 16 ~ 30000 59.5

1 750 0.7 10.8 0.85 ~ 5300 10.0

For every load point measuring CO, CH4, NOX, NO, O2, lambda emissions upstream, at U-turn and downstream of hex.

Preliminary stationary results at this operating point will be presented



2020

Lambda Sweep 0.97->1.02 , 1600 rpm/2 bar

0.94 0.95 0.96 0.97 0.98 0.99 1.00 1.01 1.02 1.03 1.04LAVS_41

LAV

S_C

[1]

0.92

0.96

1.00

1.04LAVS_C1LAVS_C2LAVS_C3LAVS_C4

CO

_EO

[ppm

]

0

5000

10000

15000

CO_EO

Con

v_ra

te_C

H4

[ppm

]

40

60

80

100Conv_rate_CH4_EO_TP

Tem

pera

ture

hex

bric

k [°

C]

350

400

450

500

550

600

650

700

M_SP11M_SP17M_SP18

M_SP20M_SP25M_SP27

M_SP30

T_31

Tem

pera

ture

hex

pip

ing

[°C

]

50

100

150

200

250

300

350

400

450

500

M_SP21

M_SP23

M_SP24

M_SP26

M_SP29

T_31

M_SP28M_SP40

CH

4_E

O [p

pm]

0

1000

2000

3000

2011_03_08.001 D[1,7]2011_03_08.001 D[1,8]

N_avg 1/min 1600Name bar 2.01

C_SP26_avg - 1C_SP27_avg - 0

Catalyst operating temperature significantly increased due to amplification of hex!

Tin



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SPB2: Road Map Catalyst / HEX testing

Catalysts:Pd/Rh 170 g/ft3Pd/Rh 200 g/ft3Pd/Rh 300 g/ft3Pt/Pd/Rh 200 g/ft3

Catalysts:Pd/Ce2O3 300 g/ft3Pd-Rh/CeO3 300 g/ft3

Catalysts:Best formulation

Deliverable/MS: New delivery date

New time table

INGAS - SPB2 New Time TableYear2 Year3

AprilMonth Main Partner 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

DB2.6 Bench proto.1 (Delphi)DB2.7 Catalyst samples Gen.1/new formulations (Ecocat)

Input Deliverables DB2.8 CH4/NOx operation strategy (DAI)DB2.9 EAT Operation strategy 1 (ICVT)

DB2.10 Bench/vehicle proto.2 (Delphi)DB2.12 Catalyst samples Gen.2/new formulations (Ecocat)

WPB2.4: Engine Testing/EAT System ManagementLeader: AVLPartner: DAI, ICVTTaskB2.4.1: Engine/EAT Set-up/Base Line Investig. AVL

AVL

TaskB2.4.2: EAT/CH4-Catalyst Evaluation AVL, DAI HEX CH4 Cat. HEXDB2.11 EAT operation strategy 2 (AVL)

WPB2.5: Engine Bench System Integration/OptimizationLeader: AVLPartner: DAI, Delphi, ICVTTaskB2.5.1: System Integration/Calibration AVL HEX

TaskB2.5.2: System Management/Optimiz.Transient AVL HEX CH4 Cat. HEX + Cat. In SPA2 HEX + Cat in SPA2DB2.13 Vehicle/EAT/Strategy to A2 (AVL)

DB2.14 Results Summary/Assessment

MilestonesMB2.2 Potential Heat exchanger Concept/New Catalyst Formulation demonstrated

MB2.3 Principle Feasibility demonstrated

ingas 30 months meeting / ecocat

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