Post on 04-Jul-2018
Catalytic Solutions for Emission Controlof Natural Gas Vehicles
Toni Kinnunen, Osmo Jahkola, Sergio Del ReEcocat Oy
Dr. Toni KinnunenOsmo JahkolaSergio Del ReDr. Andreina Moreno
Ecocat Group
Ecocat is an international and fast growingclean air technology company headquarteredin Finland.
Ecocat develops and manufactures catalyticconverters, in other words mechanicalsubstrates with chemical coatings forautomotive industry, small engines andindustrial applications.
Ecocat’s global market share is close to 20%of metallic substrates and 3% of all substrates.
The company has manufacturing plants inFinland, India, Italy, Middle-East and the U.S.
Ecocat cleans the air for the world
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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
CNG: Compressed Natural GasComposition: 95-98% Methane (CH4)
•CNG is a very economic fuel since there is no need to refine it•There are around 6.182 trillion ft3 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!!
Hence Ecocat’s strategy of focusing on CNG
Ecocat has both the technical and logistical ability to provide substrate,coating and canning as an integrated one-piece solution
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
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-off
Advanced Coating
Introduction
• 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
Metal substrates enable reduced emissions
Introduction
• Features groove system for substrate locking andimproved 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 thermalinertia.
• High resistance against thermal and mechanicalshocks.
Introduction
Lower bumps, decreased back pressureExcellent mechanical durability by brazing
Brazed Ecocat 500 cpsi
Introduction
Light-off Aged/ CNG applications
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THC CO Nox
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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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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
Light-off Aged/ Bi-fuel applications
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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 lower light-off!
Gasoline engine test
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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
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
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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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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
Ecocat is unique in the world by providing thewhole 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
SUMMARY