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InGas 30 months meeting / Ecocat

InGas 30 months meeting / Ecocat. INGAS 30 months meeting Oulu - Finland 25 - 26 May 2011. AVL, DAI, Delphi, Ecocat, ICSC-PAS, ICVT, Katcon, PoliMi. B2: Aftertreatment for Passenger Car CNG Engine. WPB2.1 Requirements / Boundary Conditions. WPB2.2 Advanced Catalyst Development. WPB2.3

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InGas 30 months meeting / Ecocat

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  1. InGas 30 months meeting / Ecocat INGAS 30 months meeting Oulu - Finland 25 - 26 May 2011 AVL, DAI, Delphi, Ecocat, ICSC-PAS, ICVT, Katcon, PoliMi

  2. B2: Aftertreatment for Passenger Car CNG Engine WPB2.1 Requirements / Boundary Conditions WPB2.2 Advanced Catalyst Development WPB2.3 Exhaust Heating/ Catalyst Concepts WPB2.4 Engine Testing/ EAT System Management WPB2.5 EAT System Integration/Optimiz. Boundary conditions Reference catalyst Catalyst samples Coated heat exchanger CH4/NOx operation strategy EAT operation strategy 1 EAT operation strategy 2 Fuel Requirements/ specifications Exhaust boundaries Engine/injection system Control management Engine for EAT implementation Engine with EAT for final validation A1 – A2 – A3 B0 A2

  3. 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)

  4. 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)

  5. 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 made according to the recipe achieved from POLIMI Pd % in ready powder: 6,1 wt-% for POLIMI and 6,15 wt-% for Ecocat made powder

  6. InGas: SPB2/WPB2.2 Catalyst sample made from the Ecocat 6%-Pd/CeO2-Al2O3 material/powder • Good coating abilities • found on the metal surface • Combarable adhesion • compared to the reference 6%-Pd/CeO2-Al2O3 + Binder coated on the metal foil Rolled sample for the tests

  7. InGas: SPB2/WPB2.2 Light off tests at lean (HT-700°C/20h aged) • Quite similar light off curves for CO • for all the samples after HT-ageing • After HT-ageing, THC light off for the • new samples is clearly better

  8. InGas: SPB2/WPB2.2 Light off tests at λ=1 (LS-1030°C/20h aged) • At λ=1 tests as LS-aged the new samples • show better light off performance, • especially for THC

  9. InGas: SPB2/WPB2.2 Lambda tests at λ=1 (LS-1030°C/20h aged) • After LS-ageing at λ=1 tests the new • samples has better lambda for THC; for • CO and NOx the window is very similar

  10. 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 compared to 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 fresh the 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 powder could 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 scale • samples for the engine tests

  11. 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)

  12. Development work • TB2.3.2: Optimization of cold start operation strategies / design • Influence of certain (design) parameters on accumulated amount of CH4 Ltot Material thickness of corrugated spacer structures Lc • 2 degrees of freedom for optimizer: • Lc • Flap switch time Varied parameters • Varied parameters (const. in each optimization run: • sspacer • Ltot Optimized parameters 12/25

  13. Design modifications 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.

  14. MK2 hex generation • Bench-scale prototype: • Lab-scale prototype (already at USTUTT): Exhaust out Flap 1 Flap 3 Flap 2 Exhaust in Flap 2 • Increase of cross sectional surface (0.0025 m2 0.0042 m2 (only lab-scale) Flap 3 TWC coating • High cell density (30 fpi≈ 250 cpsi) for complete hex, coating length 10 cm Flap 4 (optional, for complete decoupling of hex) • 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) Flap 1 • EMICAT electric heater as cold start support for low exhaust temperatures (only lab scale!)

  15. Development work • TB2.3.2: Optimization of cold start operation strategies / design MK 2 Proto MK 1 Proto MK 1 Proto MK 2 Proto • Ltot = 0.3 m • Atot = const. = 0.01618 m2 MK 2 Proto MK 1 Proto

  16. 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)

  17. SPB2 WPB2.4 Comparison of exhaust gas composition at Lambda 1, using different operation strategies The 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 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) 5000 5% 4000 4% 3% 3000 CO, O2 [%] THC, CH4, NOx [ppm] 2000 2% 1% 1000 0 0 THC CH4 NOx CO O2

  18. SPB2 WPB2.4 Catalyst Characterization 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 Significantly more exothermic reaction due to CO increase

  19. Hex testing engine operation points @ AVL 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 19 19

  20. Lambda Sweep 0.97->1.02 , 1600 rpm/2 bar Tin Catalyst operating temperature significantly increased due to amplification of hex! 20

  21. 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)

  22. SPB2: Road Map Catalyst / HEX testing Catalysts: Pd/Rh 170 g/ft3 Pd/Rh 200 g/ft3 Pd/Rh 300 g/ft3 Pt/Pd/Rh 200 g/ft3 Catalysts: Pd/Ce2O3 300 g/ft3 Pd-Rh/CeO3 300 g/ft3 Deliverable/MS: New delivery date Catalysts: Best formulation New time table

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