ingas 6th months meeting: spb2/ecocat

INGAS “General Assembly Meeting ”, “Prague, Czech Republic”, “25-26 May 2009”INGAS “General Assembly Meeting ”, “Prague, Czech Republic”, “25-26 May 2009”

INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain

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InGAS General Assembly Meeting

Prague - Czech Republic

25 - 26 May 2009

InGas 6th months meeting: SPB2/Ecocat



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• Ecocat is taking part in: – WP2.1 (requirements/boundary conditions) – WP2.2 (advanced catalyst development) – WP2.3 (exhaust heating/catalyst concepts)




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• WP2.1 (requirements/boundary conditions)– The planned objectives in this WP are collection and definition of

relevant information about fuels, exhaust, engine characteristics, ECU functions and testing conditions in order to ensure common working basis and guidelines for different partners.

– In the beginning Ecocat’s role is to deliver reference catalysts to the partners

– In task TB2.1.2 (Catalyst testing/ageing conditions) the reference catalysts have been prepared, which will be used as a reference matrix for the further catalyst (both substrate and washcoat) development




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• Reference samples:

Ceramic I Ceramic II Metallic

Dimensions (mm) 118x70 118x50 118x50,8

Volume (dm3) 0,77 0,55 0,56

Wall thickness (Mills/µm)

6 3,5 50

Cell density (cpsi) 400 600 500



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• Reference samples– Washcoated with stoichiometric NG coating– Washcoat thickness has been specified to 50 g/m2

– Pd-Rh technology; 200 g/cft Pd:Rh 39:1– Sent to:

• Daimler (2 ceramic + 1 metallic)• Kracow (1 ceramic)• Politecnico Milano (1 ceramic)• Universität Stuttgart (1 metallic)

• Reference catalyst powder– Pd containing catalyst powder (6,3 wt-% Pd) – Sent to:

• Krakow (20 g)• Politecnico Milano (20 g)



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• WP2.2 (advanced catalyst development)– The main work packet objectives during the project are:

• The development of new catalyst formulations for methane oxidation with a light off temperature below 350°C

• A high thermal and sulphur stability, • Development of a modelling tool for methane oxidation • Delivery of kinetic data, control strategy for methane (lambda = 1, lambda >1)

and NOx abatement (lambda>1) • Development of coating methods for catalyst up scaling and canning.



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• Preliminary washcoat development – Has been started in order to improve catalyst formulation for

requirements introduced in the project

– In Ecocat the development is based on the wide knowledge and the results achieved during the earlier projects in the area

– Both the basic laboratory tests like light off and lambda window tests will be used besides the verification in real engine

– Engine tests are planned to be done in commercial 1.2 LD bi-power vehicle using CNG as a fuel



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• Light off temperatures in laboratory tests (λ=1) for aged samples (20h/LS-

1030°C): Ø 14mm x L 75mm; SV 50 000 1/h


Light-off Aged

287273

315298

256278

254 254 257

0

50

100

150

200

250

300

350

THC CO Nox

tem

per

atu

re a

t 50

% c

on

vers

ion

Previous generation washcoat Gasoline washcoat New CNG washcoat



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• RAH ageing description


40 46 56 60

STOICHIOMETRIC CRUISE

POWER ENRICHMENT4% CO

Time (sec)

AIR INJECTION4% O2

900 °C

1050 °C



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• RAH temperature profile

– 40 h ageing corresponds about 80 000 km on road (< 1.4 l vehicle)


800

850

900

950

1000

1050

1100

0 30 60 90 120 150 180

Gas temperature Inlet Middle Outlet

10mm

10mm

SubstrateSubstrate



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• Engine test results for fresh and aged Pd-Rh samples– 1,2 liter E4 bi-power vehicle– Ø 100mm x L 150mm; 1,18 l; NEDC




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• In task TB2.2.4 (Coating methods/Up-scaling) coating methods are identified and applied for an up-scaling of the new catalyst formulations on full-size monoliths

• After the new catalyst formulations were developed in task TB2.2.1, the coating ability with up-scaling at full-size will be identified and thereby will be investigated in an engine bench

• In the beginning the successful coating will be evaluated in terms of stability and reactivity.



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• WP2.3 (exhaust heating/catalyst concepts)– Planned objectives & starting points

• Definition of the EAT concept with heat exchanger and catalyst /integrated or serial concept)

• Development of a modelling tool for the whole EAT system• Simulation of the behaviour of the EAT depending on operating conditions • Evaluation of the selected concept on a laboratory scale for methane and

NOx removal • Building of 2 prototypes for laboratory investigations and 2 prototypes for

engine/vehicle testing



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• Work in Ecocat– Ecocat has delivered metal foil samples to USTUTT to be used on

preliminary test for building the heat exchange unit

– The preparation of preliminary small scale samples are in progress in USTUTT

– Fixing trials by brazing or welding are in progress in Ecocat

– After the validation the next step would be to make a complete heat exchanger package for a lab scale reactor



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• Next– Continue the laboratory scale development for new catalyst materials

• Pd-based for methane • Promoters, stabilizers

– Own engine tests: activity and durability

– Coating development for the new materials

ingas 6th months meeting: spb2/ecocat

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