InGas 18 months meeting: SPB2/Ecocat

INGAS 18 months meeting GDF-SUEZ, Paris - France 20 - 21 November 2010 InGas 18 months meeting: SPB2/Ecocat

InGas 18 months meeting: SPB2/Ecocat • Ecocat is taking part in: • WP2.1 (requirements/boundary conditions) • WP2.2 (advanced catalyst development) • WP2.3 (exhaust heating/catalyst concepts)

InGas 18 months meeting: SPB2/Ecocat Objective and Innovative aspects • WP2.1 (requirements/boundary conditions) • The planned objectives in this WP are collection and definition of relevant information about fuels, exhaust, engine characteristics, ECU functions and testing conditions in order to ensure common working basis and guidelines for different partners. • In the beginning Ecocat’s role is to deliver reference catalysts to the partners • In task TB2.1.2 (Catalyst testing/ageing conditions) the reference catalysts have been prepared, which will be used as a reference matrix for the further catalyst (both substrate and washcoat) development  Ecocat´s role is to provide reference catalyst for Daimler´s, POLIMI, USTUTT and ISCS-PAS studies, commercial product. • WP2.2 (advanced catalyst development) The main work packet objectives during the project are: • The development of new catalyst formulations for methane oxidation with a light off temperature below 350°C • A high thermal and sulphur stability, • Development of a modelling tool for methane oxidation • Delivery of kinetic data, control strategy for methane (lambda = 1, lambda >1) and NOx abatement (lambda>1) • Development of coating methods for catalyst up scaling and canning  Ecocat´s role is to further develop existing formula based on new innovations from research parties within project (ICSC, POLIMI). Meanwhile, Ecocat does their own development, tasks depend on the engine test results by Daimler and the feed back from the other partners. . • WP2.3 (exhaust heating/catalyst concepts) Planned objectives & starting points: • Definition of the EAT concept with heat exchanger and catalyst /integrated or serial concept) • Development of a modelling tool for the whole EAT system • Simulation of the behaviour of the EAT depending on operating conditions • Evaluation of the selected concept on a laboratory scale for methane and NOx removal • Building of 2 prototypes for laboratory investigations and 2 prototypes for engine/vehicle testing • Ecocat´s role is to provide coated heat-exhangers to improve CH4 light-off based on the requests.

Work performed in WP 2.1 (Requirements/boundary conditions) InGas 18 months meeting: SPB2/Ecocat • Reference samples • Washcoated with stoichiometric NG coating • Washcoat thickness has been specified to 50 g/m2 • Pd-Rh technology; 200 g/cft Pd:Rh 39:1 • Sent to: • Daimler (2 ceramic + 1 metallic) • Kracow (1 ceramic) • Politecnico Milano (1 ceramic) • Universität Stuttgart (1 metallic) • Reference catalyst powder • Pd containing catalyst powder (6,3 wt-% Pd) • Sent to: • Krakow (20 g) • Politecnico Milano (20 g)

CuMn2O4 + Alumina + Binder CuMn2O4 + Alumina + Binder + Pd Reference Catalyst + Pd 80 % 20 % InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: Advanced catalyst development • Washcoat preparation for the CuMn2O4-oxide (+ Puralox SBa 150) powder achieved from ISC-PAS CuMn2O4 d50 = 4,46; 4,24 µm Washcoat properties: pH: 4,97 3,15 4,78 Visco: 738 cP 2525 cP 2477 cp Reference d50 = 3,39 µm

80 % CuMn2O4 + Alumina + Binder CuMn2O4 + Alumina + Binder + Pd Reference Catalyst + Pd 20 % InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: Sample preparation for the CuMn2O4-oxide (+ Puralox SBa 150) powder Pd-loading in ready samples 200 g/cft

80 % CuMn2O4 + Alumina + Binder CuMn2O4 + Alumina + Binder + Pd Reference Catalyst + Pd 20 % InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2 Ø 14 mm x L 75 mm • Laboratory light off tests (25-600°C):as fresh and • LS-1030°C/20h aged • (LS = lean 10 min + stoichiometric 50 min; • CO, CO2, H2O, C3H6, O2, N2)

InGas 18 months meeting: SPB2/Ecocat • Work performed in WP 2.2: • Laboratory light off test results • for fresh samples (λ=1)

InGas 18 months meeting: SPB2/Ecocat • Work performed in WP 2.2: • Laboratory light off test results • for aged samples (λ=1)

InGas 18 months meeting: SPB2/Ecocat • Work performed in WP 2.2: • Laboratory lambda window test results • for fresh samples at 500°C

InGas 18 months meeting: SPB2/Ecocat • Work performed in WP 2.2: • Laboratory lambda window test results • for aged samples at 500°C

InGas 18 months meeting: SPB2/Ecocat • Work performed in WP 2.2: • Laboratory light off test results • for fresh samples (Lean)

InGas 18 months meeting: SPB2/Ecocat • Work performed in WP 2.2: • Laboratory light off test results • for aged samples (Lean)

InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: • Evaluation of tri-metallic catalyst (Pt-Pd-Rh) against Pd-Rh standard CNG washcoat (λ=1) • 200 g/cft: Pd-Rh 39:1 vs. Pt-Pd-Rh 1:38:1 (based on the 2nd quarter 2010 PGM prices latter being about 5 % more expensive) • Laboratory light off tests as fresh and LS-1030°C/20h aged (LS= lean 10 min + stoichiometric 50 min); with soithiometric test mixture (25-600°C) • Engine tests in 1,2 litre bi-power E4 vehicle over the NEDC as fresh and 40 h RAH aged (catalyst size: 100x150 mm, 500 cpsi, 1.18 litre)

InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: • Light off tests in laboratory

InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: • Engine test results for fresh and aged Pd-Rh vs. Pt-Pd-Rh samples • 1,2 liter E4 bi-power vehicle with CNG over NEDC (ageing 40 h RAH)

InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: • Cumulative THC results in the engine after 40 h ageing

InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: • Cumulative CO results in the engine after 40 h ageing

InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: • Cumulative NOx results in the engine after 40 h ageing

InGas 18 months meeting: SPB2/Ecocat • Conclusion • Test with CuMn2O4 powder • Washcoat preparation was successfully progressed • Adhesion on the metal surface is comparable to the reference • Some activity found for CO and NOx; for THC the activity is poor compared to the reference under stoichiometric conditions, in lean the HC activity is better, but not at the reference level • Pd clearly improves the activity • Tri metallic catalyst evaluated against standard Pd-Rh CNG catalyst: • In the laboratory tests minor improvements were found in the light off (T50) temperatures • In engine tests fresh samples are performing equally but tri metallic sample showed better durability against thermal ageing

InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: Samples for the test in Daimler/AVL: • Ceramic substrates (2 pieces) • 152,4 X 101,6 x 76,2 mm • V = 0,93 dm3, 600 cpsi, 3,5 mils • 170 g/cft 0:40:1, 50 g/m2 K5.7

InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: • Advanced coating • High surface area – two layer washcoat • Oxygen Storage • Rear Earth Stabilizers • Active metals – Pt/Pd/Rh

Laboratory scale heat exchanger prototype was prepared by Delphi and coated in Ecocat on March/2010 Proto was coated with CNG washcoat developed for the stoichiometric use: 200 g/cft 0:39:1 Pt:Pd:Rh 50 g/m2 K5.7 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.3: Heat exchanger, Proto 2

Vehicle scale heat exchanger will be prepared by Delphi It consist of 4 similar units which will be coated in Ecocat Units will be coated with similar CNG washcoat as used in laboratory scale prototypes Coating is in progress and the units will be sent to the canning on week 22 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.3: • Fins for the vehicle scale prototype • will be coated on weeks 21-22/2010

InGas 18 months meeting: SPB2/Ecocat Problems encountered • Less time than originally planned and budgeted was spent in activities due to the lack of resources due to the bad economical situation • Characterization of the reference material was slightly delayed by the partners => further improvement was planned after the feed back • Screening of the new materials is in progress in the partners => washcoating and upscailing activities (planned to start on month 9) will be done after new materials are available (during second and third year); The first material from ISCS-PAS was received and the first washcoating and testing in laboratory scale is in progress • The further development on Ecocat is based on the feedback received from the partners; therefore the engine tests will be needed for further development

Main results WP 2.1: Reference catalyst both full size catalysts in ceramic and metallic substrate as well as powder catalyst was succesfully delivered for the partners WP 2.2: To support new catalyst materials development on the partners reference material (powder and full size catalysts) were prepared and delivered Preliminary washcoat screening in own laboratory and engine tests to see the level of the reference catalyst for the project objectives Fuether development is dependant on the feed back from the engine and the laboratory results made by partners The first washcoating trials with a new catalytic material made in ISCS-PAS have been done and the tests are in progress at laboratory level WP 2.3: Two laboratory scale heat exchange prototypes coated and sent to the partners Vehicle scale prototype fins will be coated on week 21-22 InGas 18 months meeting: SPB2/Ecocat

Next Continue the laboratory scale development for new catalyst materials for an improved reference Pd-based for methane Promoters, stabilizers Ageing examinations Feed back from the partners needed Own engine tests: activity and durability Coating development and upscailing for the new materials in WPB2.2 DB2.7 (catalyst sample Gen1) The first vehicle scale heat exchanger unit coating is inprogress and will be sent for canning on week 22 InGas 18 months meeting: SPB2/Ecocat

InGas 18 months meeting: SPB2/Ecocat