Catalytic Solutions for Emission Controlof Natural Gas Vehicles

Dr. Toni Kinnunen*Osmo JahkolaSergio Del ReDr. Andreina MorenoDr. Kauko Kallinen

toni.kinnunen@ecocat.comwww.ecocat.com

Ecocat Group

Ecocat is an international and fast growingclean air technology company headquarteredin Finland.

Substrates and coatings for exhaust gasaftertreatment

Global market share is close to 20% ofmetallic catalysts

Global presence

Ecocat cleans the air for the world

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2005 2006 2007

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

Natural Gas –Potential solution

Advantages

• Lower CO2 emissions compared to gasoline and diesel

• No particulate emissions

• Significantly lower NOx emissions

• Other benefits

Global natural gas sources

Lower noise level

Odourless exhaust gas

No need to refine it

Disandvantages

• Lack of distribution network

• Need for specific engine development

• Methane emissions specific CNG catalysts is needed

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-offCost-efficiency (PGM)

Advanced Coating

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

Metallic Substrates

• 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

Metallic substrates enable reduced emissions

• Features groove system for substrate lockingand improved flow dynamics.

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

• Easy to integrate into the exhaust system.

• Brazed only when absolutely needed

• Maximum diameter in serial production 600mm

One of the metallic substrates - mechanically locked Ecocat®

EcoCat® substrates have been supplied to PCV, LCV, HCVand Industry for diesel, gasoline and CNG applications

Solution for CNG-only Applications

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Gas temperature Inlet Middle Outlet

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Time (sec)Time (sec)

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10mm

SubstrateSubstrate

RA-H ageing temperature profile

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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THC CO Nox

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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

Lambda window for THC in laboratory tests

THC

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K5.7 Methane K5.7 Gasoline

•After laboratory ageing (LS - 1030°C/20h)

Solution for Bi-fuel (gasoline and CNG) Applications

Light-off Aged/ Bi-fuel applications

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THC CO Nox

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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 faster 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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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

Competitive solutions for CNG and Bi-fuel√Low-Dp durable metallic substrate√Enhanced promotion effect√Fast light-off, high activity√Excellent thermal durability√Pd-rich = cost effective

SUMMARY