INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010” INGAS INtegrated...

INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”

INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain

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INGAS 24 months meeting

Brussels - Belgium

27 - 28 October 2010

InGas 24 months meeting: SPA1/Ecocat



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• WPA1.4 (after treatment system development)– Planned objectives & starting point

• The activity will lead to the definition of a dedicated solution for the aftertreatment system, taking into account fuel characteristics and engine specificities (lay out and operating modes).

• This will be supported in a first step both by the catalyst modelling and by laboratory tests, which will be followed by screening activities at the engine test bed.

• Starting from the engine characteristics and emission targets, new catalyst formulations will be evaluated at laboratory scale and proposed within different lay out solutions.

• Progress of work 12-24 months– Sample preparation for engine tests at IFP

– Ageing of the samples

– Further lab. and own engine tests for washcoat development




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• Sample preparation– According to the task A1.4.3 (catalyst samples manufacturing)

the first full size samples have been prepared for the further evaluation in IFP and CRF.

– Metallic substrate:• Ø = 125 mm, L = 120 mm • V = 1,473 dm3

• 500 cpsi

– Washcoat matrix with stoichiometric CNG coating :• 120 g/cft 0:11:1 9255 proto n:o 23208• 120 g/cft 0:23:1 9256 proto n:o 23207• 200 g/cft 0:19:1 9257 proto n:o 23209• 200 g/cft 0:39:1 9258 proto n:o 23210• 250 g/cft Pd-only 9259 proto n:o 23211




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Catalyst layout



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• Sample preparation: fresh samples




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Gasoline groove height 20% of the channel height

Diesel groove height 50% of the channel height

• Sample preparation: metallic substrate

EcoCat® substrates

• Features groove system for substrate locking and improved flow dynamics (turbulent areas).

• 100 % stainless steel (1.4767/1.4725 substrate, FeCrAl).

• Easy to integrate into the exhaust system.

• Improved heat and mass transfer rate, low thermal inertia.

• High resistance against thermal and mechanical shocks.




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• Sample preparation: washcoat

– Advanced coating

• High surface area – two layer washcoat

• Oxygen Storage

• Rear Earth Stabilizers

• Active metals – Pt/Pd/Rh




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• Sample preparation: ageing 40 h



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• Sample preparation: ageing 40 h



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• 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); test mixture in light off (25-600°C): O2 0,8 %, NO 600 ppm, H2O 10 %, CO2 9 %, CO 8000 ppm, H2 3800, CH4 1800 ppm, C2H6 100 ppm, N2 bal

– 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)




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• Light off tests in laboratory

Light off in laboratory tests

348

135 122

340

132 123

395

167 154

388

176153

0

100

200

300

400

500

THC CO NOx

Lig

ht

off

T5

0 /

°C

Pd-Rh/Fresh Pt-Pd-Rh/Fresh Pd-Rh/Aged Pt-Pd-Rh/Aged


→ Minor improvements found in lab. tests



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• 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 40/80 h)


1 1 11,1

1,0 1,0

1,8

1,6

1,51,4

1,1

1,3

1,8

1,5

1,9

1,7

1,4

1,7

0

0,2

0,4

0,6

0,8

1

1,2

1,4

1,6

1,8

2

THC CO NOx

Re

lati

ve

em

iss

ion

Pd-Rh/ Fresh Pt-Pd-Rh/ Fresh Pd-Rh/40 h Aged

Pt-Pd-Rh/40 h Aged Pd-Rh/80 h Aged Pt-Pd-Rh/80 h Aged

Fresh Fresh Fresh

40 h 40 h 40 h80 h 80 h 80 h

→Tri-metallic catalyst showed better durability against thermal ageing



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• Cumulative THC results in the engine after 40 h ageing


→ Better light off behavior was found after the 3rd urban cycle for tri-metallic



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• Conclusion

– Five proto samples were prepared for the engine bench evaluation at IFP in Fiat engine

– Tri metallic catalyst was 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

– DA1.19 Catalyst samples availability (Task A1.4.3 Catalyst samples manufacturing) Deliverable report was prepared and delivered on 15th August 2010




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• WPA1.5 (global assessment on the validator vehicle)– Samples for the validator vehicle tests will be designed and

prepared based on the first results in engine bench tests at IFP


INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010” INGAS INtegrated...

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