Diesel Emission Control by Oxidation Catalyst andParticle Oxidation Catalyst (DOC+POC ® )

ECT 2009, New DelhiNovember 6-7, 2009

Dr Toni KinnunenCTO, Ecocat Group

toni.kinnunen@ecocat.comwww.ecocat.com

Ecocat Group

Ecocat is an international and growing cleanair technology company headquartered inFinland.

Ecocat develops and manufactures catalyticconverters, in other words mechanicalsubstrates with chemical coatings forautomotive industry, small engines andindustrial applications.

Ecocat’s global market share is close to 20%of metallic substrates and 3% of all substrates.

The company has manufacturing plants inFinland, India, Italy and the U.S.

Ecocat cleans the airfor the world

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•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

What are diesel particulates?

- Soot is formed in the engine through theincomplete combustion process

- VOF condensates on soot particles duringexhaust gas cooling and dilution

- In addition sulfates can be found in dieselparticulate matter

How to decrease particle emissions?

- Diesel oxidation catalyst (DOC)- effective reduction of HC and CO- some reduction of PM (reduction of VOF)- typical PM reduction 10-30%

- Diesel particulate filter (DPF)- effective reduction of PM (soot)- typical PM reduction 80-95%- regeneration of filter needed (to avoid backpressure increase, blocking risk)

- Particle oxidation catalyst (POC)- first target: to increase particle depositionin oxidation catalyst without significant backpressure increase

POC® open filter

• POC is an open filter structure, developedto trap Particulate Matter in LD and HDdiesel vehicles.

• Maintenance free flow throughconstruction.

• 100% stainless steel structure, coatedwith specific washcoat.

• Flexible size and low weight - easy tointegrate into exhaust system.

• In combination with Ecocat pre-oxicat ororiginal oxidation catalyst.

• High resistance against thermal andmechanical shocks.

Typical lay-out of the DOC+ POC combination

DOC (Pt or Pt-Pd) POC (Pt)oxidation of THC &CO PM collectionpartial oxidation of VOF additional oxidation of THC & CONO2 formation for regeneration total oxidation of VOF

NO2 formation and utilisationfor soot oxidation (= regeneration)

Two alternative structures of POCPOC-X and POC-L

Basic POC-X vs POC-L

- Basic POC-X structureSubstrate channels are designed with severalcorrugated screen layers which are subsequentlywelded together [EP 1 230 978 B1, 2002].

- POC-L structurePlacing additional straightmesh between corrugated wire meshes

Test results of POC-X and POC-L

LDD-results: Emissions downstream of DOC+POC-X vs DOC+POC-L

Error bars in figure show thestandard deviation of thetest results (minimum 3 testrepetitions are made)

Test vehicle:VW Touran 1.9 TDI, Euro 4

Basics of POC samples:Basics of POC samples:D127, L152,D127, L152,POCPOC--X 400cpsi,X 400cpsi,POCPOC--L 300cpsiL 300cpsi10g/m10g/m22, Pt10g/ft, Pt10g/ft33

PM Emissions downstream of DOC+POC-X

Test vehicle:VW Touran 1.9 TDI, Euro 4

With POC we can reduce both volatile and non-volatile (soot) fraction of PM.

Basics of POC samples:Basics of POC samples:D127, L152,D127, L152,POCPOC--X 400cpsi,X 400cpsi,10g/m10g/m22, Pt10g/ft, Pt10g/ft33

Dynamometer tests/ HDD

PM emissions and reductions over POC-X and POC-L

DOC = 350cpsi,d334 L150,30g/m2, 40g/ft3

POC =300cpsi/30°, d334L150, 10g/m2,10g/ft3, Aisi 310

HD Scania, PM emissions, ESC-test

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PM Total PM Total NVF VOF CO THCmg g/kWh mg mg g/kWh g/kWh

Raw emission 0,651 0,0527 0,411 0,24 4,33 0,258After POC emission 0,217 0,0176 0,205 0,012 0,025 0,013POC Efficiency [%] 66,7 66,7 50,1 95,0 99,4 95,0

ETC Results

PM Total PM Total NVF VOF CO THCmg g/kWh mg mg g/kWh g/kWh

Raw emission 0,429 0,0347 0,309 0,12 2,808 0,133After POC emission 0,1705 0,0138 0,162 0,0085 0,013 0,005POC Efficiency [%] 60,3 60,3 47,6 92,9 99,5 96,2

ESC Results

Euro4 - 5L - 4 CylinderPOC: 180x304 mm (7,8 dm3) 300 cpsiDOC: 180x74,5 mm (1,9 dm3) 200 cpsi 20g/ft3

MAN D0826 LOH 17, 6.9L, Euro II -- ESC-test -- Mass emissions

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ESC 1 = idle

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Example of mass concentration in ESC –upstream and downstream of ’DOC+POC-L’

Measurements upstream of the ’DOC+POC’are made before (raw-1) andafter (raw-2) the measurements downstream of ’DOC+POC’(3 test repetitions)

Particle collection efficiency of POC-L substrate

Test engine:Cummins, 4,5 Litre, Euro 4

Basics of POC sample:Basics of POC sample:D240, L300, 300cpsi,D240, L300, 300cpsi,10g/m10g/m22, Pt10g/ft, Pt10g/ft33 (POC(POC--L)L)

ESC 11 –load 25%ESC 3 –load 50%ESC 12 –load 75%ESC 10 –load 100%

SOF emissions after POC –comparison to DPF

Note:SOF and VOF are typically parts of the nucletion mode,ie. they are small healthy-hazardous nano-particles

Regeneration of POC

• Test plan: (Engine: MAN D0826 LOH 17, 6.9L, Euro II)

1. Soot collection phase- Weighing of POC substrate- Exhaust T < 250°C (no passive regeneration)- Test time 60 h- Continuous back pressure and temperature measurement- Emissions measurements 0h, 20h, 40h, 60h- Weighing of POC substrate

2. Regeneration phase :- Weighing of POC substrate- Exhaust T 350-400°C (regeneration should happen)- Test time 2 h- Continuous back pressure and temperature measurement- Continuos NO/NOx measurement, PM measurement (30 min each), particle mass

concentration in real time with DMM- Weighing of POC substrate

• Samples DOC+POC– DOC (d220, L74.5, 350cpsi, 30g/m2, 40g/ft3) + POC (d220, L304, 400cpsi/30°, 10 g/m2)– 3 different Pt loading in POC (0, 10 and 20 g/ft3)

Back pressure 0h-20h-40h-60hWeighing POC after 60h - POC (Pt 0) +65g

- POC (Pt 10) +64g

The back pressure increases during the 60 h driving,the Pt level of POC has no effect on the soot collection at this phase

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Regeneration phase... POC (Pt 10) weighing after regeneration phase: - 64g (all soot collected is oxidized)

Back pressure & NO2

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NOx measurement starts

NO2 measurements upstream of DOC

The soot collected in POC is oxidized by NO2 –the back pressuredecreases as the amount of soot collected deacreases and the NO2 levelincreases as it is no more consumed in oxidizing the soot

Regeneration phase... POC-X with different Pt loading(the same DOC is utilized upstream of each POC substrate)

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When using Pt in POC substrate the soot collected is more easilyoxidized –the back pressure is seen to deacrease more quickly

With Pt 10g/cft all the PM oxidised in 15 minutes

The back pressure comparison at constat speed testPOC- X D140 mm L150 mm vs Notox 200 D144 L154 mm

VW Touran constant speed tests- 3 repetitions by using same DOC pr 20882

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POC (140x150mm) vs SiC DPF (144x154 mm)

On-road tests

On-road tests / HDD –two different trialsFirst trial by using truck (Scania F124, Euro II) equipped with ‘DOC+POCDOC+POC--XX’

DOC=d334 L74.5 120cpsi 40g/m2 Pt 40g/ft3

POC=d334 L152 400cpsi 10g/m2 Pt 10g/ft3

Second trial by using truck (Volvo F13, Euro III) equipped with ‘DOC+POCDOC+POC--LL’DOC=d334 L152 350cpsi 30g/m2 Pt 40g/ft3

POC=d334 L152 300cpsi 10g/m2 Pt 10g/ft3

Data acquisition by Futecontrol unit, based on GSM /GPRS –data

• Temperature, 4 channels:– Environment temperature– Inlet temperature– Outlet temperature– Substrate temperature

• Pressure, 1 channel

• Sampling rate 1/h

On-road tests / HDD

Example of canning:DOC+POC-X inside theScania muffler

HDD road aging Scania R124 (E II), 200 000 km, DOC+POC-X

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Mainly highway driving (80km/h)

HDD road aging Scania R124 (E II), 100 000 km, DOC+POC-X

Pressure August of 2007Pressure April of 2007

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No dramatic pressure gain during aging from 40 000 km to 100 000 km

Visual checking after 200 000 km- DOC + POC-X

Inlet side, DOC Outlet side, POC-X

On-road tests / HDD

Example of canning:DOC+POC-L inside theVolvo muffler

HDD road aging Volvo F13 (E III), 100 000 km, DOC+POC-LDaily route of HDD truck

Both highway + non-highwaydriving, with frequent stops

HDD road aging Volvo F13 (E III), 100 000 km, DOC+POC-L

Typical Exhaust gas (Temp 1)histogram

Average value 192 °C

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HDD road aging Volvo F13 (E III), 100 000 km, DOC+POC-LThe calculated fuel consumption (l/100 km)The calculated fuel consumption (l/100 km)

Volvo F 13 (EIII) road aging DOC pr 21530 POC L pr 21532 (Installed on 18.01.2008)106 000 km

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On-road tests / HDD –emission testing

Emission tests are done in engine test bench over ESC-test

- Testing place: VTT Technical research center on Finland

- Engine: Scania DT 1211 420, model year 2005, Euro IV, 11.7L

Tested:- as fresh- after ~100 000km on road trial- after ~200 000km on road trial

DOC+POC-X, Emission test results: particle emissions

PM emissions, ESC-test

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Error bars in figure show thestandard deviation of thetest results (minimum 3 testrepetitions are made)

DOC+POC-X, Emission test results: gaseous emissions

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DOC+POC-L, Emission test results: particle emissions

Error bars in figure show thestandard deviation of thetest results (minimum 3 testrepetitions are made)

PM emissions, ESC-test

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DOC+POC-L, Emission test results: gaseous emissions

Note: Detection limitfor CO and HC 0.02g/kWh

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Conclusions from HDD on-road trial(For both POC-X on road 200 000km and POC-L on road 100 000km)

No significant pressure increase during aging

No increase of average fuel consumption

No mechanical failure of substrates

PM efficiency as well as CO and HC efficiencies at the same level asthey were before aging

Summary

Designed novel structures, optimized for both numerical and mass-basedtargets –two alternative structures

Proven efficiency in both LDD and HDD applications

Tailored coating needed for PM efficiency, regeneration and enhancedoxidation

Proven thermal and mechanical durability

No significant backpressure increase

Several running projects and commercial references in both OE andretrofit

SAE 2007-24-0093SAE 2009-01-2705EP 1230978