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

Solution for CNG Applications

Light-off Aged/ CNG applications

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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

Cumulative THC Emisions During Engine Test

Results Correspond to Aged Samples- CNG Test

Solution for Bi-fuel (gasoline and CNG) Applications

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

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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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