INGAS INtegrated GAS Powertrain
InGas 24 months meeting: SPA1/Ecocat
INGAS 24 months meeting
Brussels - Belgium
27 - 28 October 2010
INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”
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INGAS INtegrated GAS Powertrain
InGas 24 months meeting: SPA1/Ecocat
• 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
INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”
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INGAS INtegrated GAS Powertrain
InGas 24 months meeting: SPA1/Ecocat
• 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
120 g/cft 0:23:1
200 g/cft 0:19:1
200 g/cft 0:39:1
250 g/cft Pd-only
9255 proto n:o 23208
9256 proto n:o 23207
9257 proto n:o 23209
9258 proto n:o 23210
9259 proto n:o 23211
INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”
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INGAS INtegrated GAS Powertrain
InGas 24 months meeting: SPA1/Ecocat
Catalyst layout
INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”
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INGAS INtegrated GAS Powertrain
InGas 24 months meeting: SPA1/Ecocat
• Sample preparation: fresh samples
INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”
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INGAS INtegrated GAS Powertrain
InGas 24 months meeting: SPA1/Ecocat
• Sample preparation: metallic substrate
EcoCat® substrates
Gasoline groove height 20%
of the channel height
Diesel groove height 50%
of the channel height
INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”
•
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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INGAS INtegrated GAS Powertrain
InGas 24 months meeting: SPA1/Ecocat
• Sample preparation: washcoat
– Advanced coating
•
•
•
•
High surface area – two layer washcoat
Oxygen Storage
Rear Earth Stabilizers
Active metals – Pt/Pd/Rh
INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”
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INGAS INtegrated GAS Powertrain
InGas 24 months meeting: SPA1/Ecocat
• Sample preparation: ageing 40 h
INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”
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INGAS INtegrated GAS Powertrain
InGas 24 months meeting: SPA1/Ecocat
• Sample preparation: ageing 40 h
INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”
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INGAS INtegrated GAS Powertrain
InGas 24 months meeting: SPA1/Ecocat
• 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)
INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”
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INGAS INtegrated GAS Powertrain
InGas 24 months meeting: SPA1/Ecocat
• Light off tests in laboratory
Light off in laboratory tests
Light off T 50 / °C
500
400
395 388
348 340
300
200
135 132
167 176
122 123
154 153
100
0
THC
Pd-Rh/Fresh
Pt-Pd-Rh/Fresh
CO
Pd-Rh/Aged
NOx
Pt-Pd-Rh/Aged
→ Minor improvements found in lab. tests
INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”
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INGAS INtegrated GAS Powertrain
InGas 24 months meeting: SPA1/Ecocat
• 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)
2
1,8
1,8
1,8
1,9
1,7
1,7
1,6
1,6
1,5
Relative emission
1,4
1,5
1,4
1,3
1,4
1,2
1
1,1
1,1
1 1,0
1
1 1,0
0,8
0,6
Fresh
40 h
80 h
Fresh
40 h
80 h
0,4
Fres
h
40 h
80 h
0,2
0
THC Fresh
Pd-Rh/
Pt-Pd-Rh/CO
Fresh
NOx
Pd-Rh/40 h Aged
Pt-Pd-Rh/40 h Aged
Pd-Rh/80 h Aged
Pt-Pd-Rh/80 h Aged
→Tri-metallic catalyst showed better durability against thermal ageing
INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”
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INGAS INtegrated GAS Powertrain
InGas 24 months meeting: SPA1/Ecocat
• Cumulative THC results in the engine after 40 h ageing
→ Better light off behavior was found after the 3rd urban cycle for tri-metallic
INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”
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INGAS INtegrated GAS Powertrain
InGas 24 months meeting: SPA1/Ecocat
• 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
INGAS “24 Months Meeting ”, “Brussels, Belgium”, “27-28 October 2010”
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INGAS INtegrated GAS Powertrain
InGas 24 months meeting: SPA1/Ecocat
• 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”
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