ingas 30 months meeting / ecocat
DESCRIPTION
InGas 30 months meeting / Ecocat. INGAS 30 months meeting Oulu - Finland 25 - 26 May 2011. AVL, DAI, Delphi, Ecocat, ICSC-PAS, ICVT, Katcon, PoliMi. B2: Aftertreatment for Passenger Car CNG Engine. WPB2.1 Requirements / Boundary Conditions. WPB2.2 Advanced Catalyst Development. WPB2.3 - PowerPoint PPT PresentationTRANSCRIPT
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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INGAS 30 months meeting
Oulu - Finland
25 - 26 May 2011
InGas 30 months meeting / Ecocat
AVL, DAI, Delphi, Ecocat, ICSC-PAS, ICVT, Katcon, PoliMi
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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WPB2.1Requirements /
Boundary Conditions
WPB2.2Advanced Catalyst
Development
WPB2.3Exhaust Heating/
Catalyst Concepts
WPB2.4Engine Testing/
EAT System Management
WPB2.5EAT System
Integration/Optimiz.
B2: Aftertreatment for Passenger Car CNG Engine
B0 A1 – A2 – A3 A2
Fuel Requirements/specifications
Exhaust boundaries
Engine/injection systemControl management
Engine for EATimplementation
Engine with EAT forfinal validation
Boundary conditionsReference catalyst
Catalyst samples
Coated heat exchanger
CH4/NOx operation strategy
EAT operation strategy 1
EAT operation strategy 2
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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SPB2: Technologies and Approach
Development of specific active methane oxidation catalysts (WPB2.2) Catalyst preparation (precious metal and metal oxide technologies) Test of powdered catalysts, structured catalysts, substrates (metal and ceramics) Characterization studies
Development of a dedicated thermal management system (WPB2.3) Design and set-up of an integrated exhaust gas heating device (catalytic coated HEX) Modelling of heating device and catalytic combustion, simulation of behaviour Manufacturing, testing and optimisation of HEX
Development of operation strategies on engine test bench (WPB2.4) Identification of engine measures for faster light-off Testing of catalyst materials and HEX Optimization of operation strategies for improved CH4-Conversion
Demonstration of an exhaust gas aftertreatment system for Euro 6 (WPB2.5) Set-up of CNG engine with the exhaust aftertreatment system (transient bench) Optimization of the catalyst heating including cold-start Demonstration of the system performance (Euro 6 legislation) in NEDC on engine test bench Validation of the catalyst activity in a vehicle configuration for Euro 6 compliance (SPA2)
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
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SPB2: Technologies and Approach
Development of specific active methane oxidation catalysts (WPB2.2) Catalyst preparation (precious metal and metal oxide technologies) Test of powdered catalysts, structured catalysts, substrates (metal and ceramics) Characterization studies
Development of a dedicated thermal management system (WPB2.3) Design and set-up of an integrated exhaust gas heating device (catalytic coated HEX) Modelling of heating device and catalytic combustion, simulation of behaviour Manufacturing, testing and optimisation of HEX
Development of operation strategies on engine test bench (WPB2.4) Identification of engine measures for faster light-off Testing of catalyst materials and HEX Optimization of operation strategies for improved CH4-Conversion
Demonstration of an exhaust gas aftertreatment system for Euro 6 (WPB2.5) Set-up of CNG engine with the exhaust aftertreatment system (transient bench) Optimization of the catalyst heating including cold-start Demonstration of the system performance (Euro 6 legislation) in NEDC on engine test bench Validation of the catalyst activity in a vehicle configuration for Euro 6 compliance (SPA2)
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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InGas: SPB2/WPB2.2
6%-Pd/CeO2-Al2O3 material/powder made in Ecocat
(vs. made by POLIMI)
At the first stage 100 g ready powder ( 6% Pd) was madeaccording to the recipe achieved from POLIMI
Calcined alumina powder by Ecocat
Calcined alumina powder by POLIMI
Ce-Al powder by Ecocat
Ce-Al powder by POLIMI
SSA, m2/g 120 117 82 70
Pore volume, cm3/g 0,5 0,44 0,29 0,3
Pd % in ready powder: 6,1 wt-% for POLIMI and 6,15 wt-% for Ecocat made powder
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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InGas: SPB2/WPB2.2
Catalyst sample made from the Ecocat 6%-Pd/CeO2-Al2O3 material/powder
• Good coating abilitiesfound on the metal surface • Combarable adhesion compared to the reference
Rolled sample for the tests
6%-Pd/CeO2-Al2O3
+ Bindercoated on themetal foil
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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InGas: SPB2/WPB2.2
• Quite similar light off curves for COfor all the samples after HT-ageing
• After HT-ageing, THC light off for thenew samples is clearly better
Light off tests at lean (HT-700°C/20h aged)
CO Conversion in Light-off performance
0
20
40
60
80
100
100 150 200 250 300 350 400 450 500 550 600
Temperature before catalyst, °C
Co
nv
ers
ion
, %
1090 6Pd/CeO2-Al2O3 by Ecocat
640 REF (Pd)
896 6Pd/CeO2-Al2O3 by POLIMI
THC Conversion in Light-off performance
0
20
40
60
80
100
100 150 200 250 300 350 400 450 500 550 600Temperature before catalyst, °C
Co
nve
rsio
n, %
1090 6Pd/CeO2-Al2O3 by Ecocat
640 REF (Pd)
896 6Pd/CeO2-Al2O3 by POLIMI
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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InGas: SPB2/WPB2.2
• At λ=1 tests as LS-aged the new samplesshow better light off performance, especially for THC
Light off tests at λ=1 (LS-1030°C/20h aged)
CO Conversion in Light-off performance
0
20
40
60
80
100
100 150 200 250 300 350 400 450 500 550 600Temperature before catalyst, °C
Co
nv
ers
ion
, %
1090 6Pd/CeO2-Al2O3 by Ecocat
ref. 640 REF (Pd)
896 6Pd/CeO2-Al2O3 by POLIMI
THC Conversion in Light-off performance
0
20
40
60
80
100
100 150 200 250 300 350 400 450 500 550 600Temperature before catalyst, °C
Co
nv
ers
ion
, %
1090 6Pd/CeO2-Al2O3 by Ecocat
ref. 640 REF (Pd)
896 6Pd/CeO2-Al2O3 by POLIMI
NOx Conversion in Light-off performance
0
20
40
60
80
100
100 150 200 250 300 350 400 450 500 550 600Temperature before catalyst, °C
Co
nv
ers
ion
, %
1090 6Pd/CeO2-Al2O3 by Ecocat
ref. 640 REF (Pd)
896 6Pd/CeO2-Al2O3 by POLIMI
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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InGas: SPB2/WPB2.2
• After LS-ageing at λ=1 tests the new samples has better lambda for THC; for CO and NOx the window is very similar
Lambda tests at λ=1 (LS-1030°C/20h aged)
500°C CO Conversion in Lambda performance
0
20
40
60
80
100
0,97 0,98 0,99 1,00 1,01Lambda value
Co
nv
ers
ion
, %
1090 6Pd/CeO2-Al2O3 by Ecocat
ref. 640 REF (Pd)
896 6Pd/CeO2-Al2O3 by POLIMI
500°C THC Conversion in Lambda performance
0
20
40
60
80
100
0,97 0,98 0,99 1,00 1,01
Lambda value
Co
nv
ers
ion
, %
1090 6Pd/CeO2-Al2O3 by Ecocat
ref. 640 REF (Pd)
896 6Pd/CeO2-Al2O3 by POLIMI
500°C NOx Conversion in Lambda performance
0
20
40
60
80
100
0,97 0,98 0,99 1,00 1,01
Lambda value
Co
nv
ers
ion
, %
1090 6Pd/CeO2-Al2O3 by Ecocat
ref. 640 REF (Pd)
896 6Pd/CeO2-Al2O3 by POLIMI
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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InGas: SPB2/WPB2.2
Conclusions for the tests made for the 6%-Pd/CeO2-Al2O3 based samples:
At lean conditions the new samples has better light off peformance comparedto the reference, especially for THC, both as fresh and after ageing
At stoichiometric conditions after ageing the new samples has little better light off performance as well as better lambda window for THC; as freshthe sample made by Ecocat powder seems to have little better performance
The POLIMI powder was succesfully prepared by Ecocat
The catalyst based on the 6 wt-% containing Pd-CeO2-Al2O3 powdercould be a good candidate for a methane catalyst in In-Gas project
Scale up to 1 kg of the powder is in progress in order to make proto scalesamples for the engine tests
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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SPB2: Technologies and Approach
Development of specific active methane oxidation catalysts (WPB2.2) Catalyst preparation (precious metal and metal oxide technologies) Test of powdered catalysts, structured catalysts, substrates (metal and ceramics) Characterization studies
Development of a dedicated thermal management system (WPB2.3) Design and set-up of an integrated exhaust gas heating device (catalytic coated HEX) Modelling of heating device and catalytic combustion, simulation of behaviour Manufacturing, testing and optimisation of HEX
Development of operation strategies on engine test bench (WPB2.4) Identification of engine measures for faster light-off Testing of catalyst materials and HEX Optimization of operation strategies for improved CH4-Conversion
Demonstration of an exhaust gas aftertreatment system for Euro 6 (WPB2.5) Set-up of CNG engine with the exhaust aftertreatment system (transient bench) Optimization of the catalyst heating including cold-start Demonstration of the system performance (Euro 6 legislation) in NEDC on engine test bench Validation of the catalyst activity in a vehicle configuration for Euro 6 compliance (SPA2)
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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Influence of certain (design) parameters on accumulated amount of CH4
Material thickness of corrugated spacer structures
L tot
Lc
Varied parameters
Optimized parameters
2 degrees of freedom for optimizer:•Lc
•Flap switch time
Varied parameters (const. in each optimization run:•sspacer
•Ltot
Development work TB2.3.2: Optimization of cold start operation strategies / design
12/25
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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Fins
• Design modifications from Gen 1 to gen 2:– Increase number of fins– by decreasing the fin pitch from 1.8mm to 0.8mm
– Reduce the material thickness – to reduce the thermal inertia
• Risk assessment?– High risk of erosion of the material during the brazing – Gas leakage
– A new time/temperature profile of the brazing and the quantity of the brazing filler metal have been modified.
Design modifications
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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MK2 hex generation
Flap 1
Flap 2
Flap 3
TWC coating
Exhaust in
Exhaust outFlap 1
Flap 2
Flap 3Flap 4 (optional, for complete decoupling of hex)
Lab-scale prototype (already at USTUTT): Bench-scale prototype:
Reduction of spacer structure wall thickness (0.15 mm 0.075 mm)
Hex turned by 180° to use hot exhaust more efficiently during heat up Additional flow configuration for heat up (see upcoming slides) EMICAT electric heater as cold start support for low exhaust temperatures
(only lab scale!)
Increase of cross sectional surface (0.0025 m2 0.0042 m2 (only lab-scale) High cell density (30 fpi ≈ 250 cpsi) for complete hex, coating length 10 cm
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Ltot = 0.3 m Atot = const. = 0.01618 m2
Development work TB2.3.2: Optimization of cold start operation strategies / design
MK 1 Proto
MK 2 Proto
MK 1 Proto
MK 2 Proto
MK 1 Proto
MK 2 Proto
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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SPB2: Technologies and Approach
Development of specific active methane oxidation catalysts (WPB2.2) Catalyst preparation (precious metal and metal oxide technologies) Test of powdered catalysts, structured catalysts, substrates (metal and ceramics) Characterization studies
Development of a dedicated thermal management system (WPB2.3) Design and set-up of an integrated exhaust gas heating device (catalytic coated HEX) Modelling of heating device and catalytic combustion, simulation of behaviour Manufacturing, testing and optimisation of HEX
Development of operation strategies on engine test bench (WPB2.4) Identification of engine measures for faster light-off Testing of catalyst materials and HEX Optimization of operation strategies for improved CH4-Conversion
Demonstration of an exhaust gas aftertreatment system for Euro 6 (WPB2.5) Set-up of CNG engine with the exhaust aftertreatment system (transient bench) Optimization of the catalyst heating including cold-start Demonstration of the system performance (Euro 6 legislation) in NEDC on engine test bench Validation of the catalyst activity in a vehicle configuration for Euro 6 compliance (SPA2)
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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SPB2 WPB2.4
Comparison of exhaust gas composition at Lambda 1, using different operation strategiesThe diagram below shows the exhaust gas composition range with different operation strategies. With the used
configurations (MPI balanced / unbalanced) for TWC characterization the exhaust gas composition is in the same range as it is with direct injection. So the results done with MPI are valid also for DI
THC
MPI or DI operation / Variation of composition due to unbalancing
DI operation / Variation of composition due to homogenization (injection timing)
MPI operation / balanced (as used for catalyst characterization step 2 / balanced)
MPI operation / unbalanced (as used for catalyst characterization step 2 / unbalanced)
CH4 CO O2NOx
5000 5%
3000
2000
4000
1000
0
4%
3%
2%
1%
0
CO
, O
2 [
%]
TH
C,
CH
4,
NO
x [p
pm]
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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1600rpm 3,4bar / catalyst #1Comparison between balanced and unbalanced operation
0
20
40
60
80
100
120
140
160
180
200
0,90 0,95 1,00 1,05 1,10 1,15
Lambda [-]
Te
mp
.Ra
ise
in c
ata
lys
t [K
]M
eth
an
e c
on
ve
rsio
n [
%]
Traise in cat
Methane conversion
TRaise in cat / unbalanced
Methane conversion / unbalanced
SPB2 WPB2.4
This example of the comparison between balanced an unbalanced cylinders shows the significant increase in conversion efficiency. Also the Lambda range with high conversion is much wider than with balanced cylinders
Catalyst Characterization
Significantly more exothermic reaction due to CO increase
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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Hex testing engine operation points @ AVL
LFNR N PME MD P_Eff GHSV (λ = 1) V_dot (λ = 1)
- 1/min bar Nm kW 1/h Nm3/h
2 1200 0.77 10.95 1.38 ~ 8100 15.8
3 1600 2.03 29.05 4.87 ~ 14700 28.2
4 1600 3.41 48.68 8.16 ~ 19300 37.2
5 1600 4.74 67.77 11.36 ~ 23500 45.2
6 1800 3.41 49 9 ~ 21000 41.8
7 1800 6 86 16 ~ 30000 59.5
1 750 0.7 10.8 0.85 ~ 5300 10.0
For every load point measuring CO, CH4, NOX, NO, O2, lambda emissions upstream, at U-turn and downstream of hex.
Preliminary stationary results at this operating point will be presented
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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Lambda Sweep 0.97->1.02 , 1600 rpm/2 bar
0.94 0.95 0.96 0.97 0.98 0.99 1.00 1.01 1.02 1.03 1.04LAVS_41
LAV
S_C
[1]
0.92
0.96
1.00
1.04LAVS_C1LAVS_C2LAVS_C3LAVS_C4
CO
_EO
[ppm
]
0
5000
10000
15000
CO_EO
Con
v_ra
te_C
H4
[ppm
]
40
60
80
100Conv_rate_CH4_EO_TP
Tem
pera
ture
hex
bric
k [°
C]
350
400
450
500
550
600
650
700
M_SP11M_SP17M_SP18
M_SP20M_SP25M_SP27
M_SP30
T_31
Tem
pera
ture
hex
pip
ing
[°C
]
50
100
150
200
250
300
350
400
450
500
M_SP21
M_SP23
M_SP24
M_SP26
M_SP29
T_31
M_SP28M_SP40
CH
4_E
O [p
pm]
0
1000
2000
3000
2011_03_08.001 D[1,7]2011_03_08.001 D[1,8]
N_avg 1/min 1600Name bar 2.01
C_SP26_avg - 1C_SP27_avg - 0
Catalyst operating temperature significantly increased due to amplification of hex!
Tin
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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SPB2: Technologies and Approach
Development of specific active methane oxidation catalysts (WPB2.2) Catalyst preparation (precious metal and metal oxide technologies) Test of powdered catalysts, structured catalysts, substrates (metal and ceramics) Characterization studies
Development of a dedicated thermal management system (WPB2.3) Design and set-up of an integrated exhaust gas heating device (catalytic coated HEX) Modelling of heating device and catalytic combustion, simulation of behaviour Manufacturing, testing and optimisation of HEX
Development of operation strategies on engine test bench (WPB2.4) Identification of engine measures for faster light-off Testing of catalyst materials and HEX Optimization of operation strategies for improved CH4-Conversion
Demonstration of an exhaust gas aftertreatment system for Euro 6 (WPB2.5) Set-up of CNG engine with the exhaust aftertreatment system (transient bench) Optimization of the catalyst heating including cold-start Demonstration of the system performance (Euro 6 legislation) in NEDC on engine test bench Validation of the catalyst activity in a vehicle configuration for Euro 6 compliance (SPA2)
INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010”
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SPB2: Road Map Catalyst / HEX testing
Catalysts:Pd/Rh 170 g/ft3Pd/Rh 200 g/ft3Pd/Rh 300 g/ft3Pt/Pd/Rh 200 g/ft3
Catalysts:Pd/Ce2O3 300 g/ft3Pd-Rh/CeO3 300 g/ft3
Catalysts:Best formulation
Deliverable/MS: New delivery date
New time table
INGAS - SPB2 New Time TableYear2 Year3
AprilMonth Main Partner 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
DB2.6 Bench proto.1 (Delphi)DB2.7 Catalyst samples Gen.1/new formulations (Ecocat)
Input Deliverables DB2.8 CH4/NOx operation strategy (DAI)DB2.9 EAT Operation strategy 1 (ICVT)
DB2.10 Bench/vehicle proto.2 (Delphi)DB2.12 Catalyst samples Gen.2/new formulations (Ecocat)
WPB2.4: Engine Testing/EAT System ManagementLeader: AVLPartner: DAI, ICVTTaskB2.4.1: Engine/EAT Set-up/Base Line Investig. AVL
AVL
TaskB2.4.2: EAT/CH4-Catalyst Evaluation AVL, DAI HEX CH4 Cat. HEXDB2.11 EAT operation strategy 2 (AVL)
WPB2.5: Engine Bench System Integration/OptimizationLeader: AVLPartner: DAI, Delphi, ICVTTaskB2.5.1: System Integration/Calibration AVL HEX
TaskB2.5.2: System Management/Optimiz.Transient AVL HEX CH4 Cat. HEX + Cat. In SPA2 HEX + Cat in SPA2DB2.13 Vehicle/EAT/Strategy to A2 (AVL)
DB2.14 Results Summary/Assessment
MilestonesMB2.2 Potential Heat exchanger Concept/New Catalyst Formulation demonstrated
MB2.3 Principle Feasibility demonstrated