ingas integrated gas powertrain ingas – spb2 – 24-month meeting brussels 27/28 october 2010 1...

INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain

INGAS – SPB2 – 24-Month Meeting Brussels 27/28 October 2010INGAS – SPB2 – 24-Month Meeting Brussels 27/28 October 2010 1

INGAS 24-Month Meeting BrusselsOctober 28. 2010Integrated GAS powertrain - Low emission, CO2 optimised and efficient CNG engines for passenger cars (PC) and light duty vehicles (LDV) Grant agreement no. 218447

SPB2

M. Weibel, K. Kallinen, M. Rink, M. Certic

Partners: Ecocat, Delphi, Katcon, AVL, Daimler, USTUTT, ICSC-PAS, POLIMI

Aftertreatment for Passenger Car CNG Engine



AFTERTREATMENT B2 (DAI) Aftertreatment for Passenger Car CNG EngineFocus on CH4 abatementAssessment of Options for NOx Abatement (NSC)

Valid

ator

Project Structure



SPB2: References and Objectives

INGAS: references and targets of the project

CH4 conversion efficiency (*)HC conversion efficiency

stoichiometric conditions (**)CH4 light off temperature (**) NOx conversion efficiency (**) NOx conversion efficiency (**)

[%] [%] [°C] [%] [%]

Reference SoA CNG (DoW) <80 on 100.000 km 90 gasoline starting 400 not developped not developped

Target INGAS SPB2 >90 on 160.000 km 90 CNG starting 330 >50 >90

NICE final status

Where we are (month 12) currently no value in NEDC currently no value in NEDCcurrently between 330°C and 400°C

depending on test and ageing conditions (laboratory scale)

no value in NEDC - regenerability of NSC as well as H2 production during

rich spike demonstrated

Where we are going (month 36) 90% 90%350°C after long term ageing + exhaust heat management for

faster lightoff>50% (based on modelling)

Key advantages SP B2 - 50 °C vs SoA DoWNSC to apply on technology way 2

(SP A2)SCR to apply on technology way 3 (SP A3)

(*) page 9 of DoW(**) page 38 of DoW

SP B2

not applicable

Main focus: Catalyst activity under = 1 conditions related to SPA2 objectives



1. Counter current HEX with 3-way catalyst (TWC)

SPB2: Technical Approach

Methane

air

Cold startburner

TWC

TWC

- Integrated system (catalytic coated HEX) - Amplification of adiabatic temperature rise- Efficient control of catalyst operation temperature

3. Engine measures - for faster light-offwithout fuel penalty- Lambda strategies for enhanced CH4 conversion

TWC

2. Improved catalyst material for better CH4-lightoff

Three technological approaches for improving the methane conversion



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 and vehicle 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)



Del. N Deliverable Name Responsible Nature Due Date (month) Delivery Date (month)

DB2.1 Fuel requirements to B0 DAI R 3 delivered/approved P1DB2.2 Reference catalyst Ecocat P 3 delivered/approved P1DB2.3 Boundary/testing conditions DAI R 4 delivered/approved P1DB2.4 CH4-kinetics/model Polimi R 10 delivered/approved P1DB2.5 2 laboratory prototypes Delphi P 10 delivered/approved P1DB2.6 Bench prototype 1 Delphi P 13 delivered 22DB2.7 Catalyst samples Gen. 1/new formulations Ecocat P 16 delivered 21DB2.8 CH4/NOx strategy DAI R 18 completed in 25DB2.9 EAT operation strategy 1 USTUTT R 18 delivered 22DB2.10 Bench/vehicle prototype 2 Delphi P 21 delayed 28DB2.11 EAT operation strategy 2 AVL R 22 delayed 27DB2.12 Catalyst samples Gen. 2/new formulations Ecocat P 24 delayed 28DB2.13 Vehicle/EAT/Strategy to SPA2 DAI AVL R 31 31DB2.14 Results summary/assessment DAI R 33 33

Milestone N Milestone Name Due Date (month) Delivery Date (month)

MB2.1 Concept decision 11 delivered/approved P1MB2.2 Potential heat exchanger concept 18 delayed 27MB2.3 Principle feasibility 33 33

Reasons for delay:DB2.10 delayed from month 21 to 28: Optimization of HEX design – technical improvement of thermal inertiaDB2.11 delayed from month 22 to 27: Availability of engine test bench/mechanical engine problems and delayed delivery HEX1/CatalystsDB2.12 delayed from month 24 to 28: Optimization of catalyst formulations and availability of engine test benchMB2.2 delayed from month 18 to 27: Coupled to DB2.11

no critical delay in deliverables: MB2.3 will be completed

SPB2: Deliverables/Milestones



SPB2: Presentation WP Activities

WPB2.2: Advanced Catalyst Development K. Kallinen, EcocatPartners: Ecocat, Polimi, ICSC-PAS, Daimler

WPB2.3: Exhaust heating/Catalyst Concepts M. Rink, USTUTTPartners: USTUTT, Delphi, Katcon, Daimler, Ecocat

WPB2.4: Engine Testing/EAT System Management M. Certic, AVLPartners: AVL, Daimler

Conclusion, Roadmap M. Weibel, Daimler



24 months meeting Brussels – Belgium 27 - 28 October 2010

Results summary

WPB2.2

Advanced Catalyst Development

ECOCAT/POLIMI/ICSC-PAS/DAIMLER

InGas 24 months meeting: SPB2/WP2.2




Objectives

• New catalyst formulations for methane oxidation – Light off temperature below 350°C– High thermal and sulfur stability

• Development of a modelling tool for methane oxidation, delivery of kinetic data and control strategy for methane

• Development of coating methods for up scaling and canning



• Mixed oxides: Spinels, perovskites, hexaaluminates, pillared clays– Cu, Mn, Co, Cr, Ce, Zr, Pd, La, Al, different stoichiometries)

• Novel Pd-based formulations based on:– Identification of effective activation process

– Definition of role of support and active metal load (Al2O3, CeO2-Al2O3, La2O3-

Al2O3, ZrO2)

– Modification of active phase

• Physical and chemical characterization

– XRD, FT-IR, SEM/TEM, TG/DSG/DSC, BET,XPS, ICP-OES, TPR

• Catalytic testing under relevant boundary conditions

– Activity tests with different operation strategies

- Sulfur poisoning

- Hydrothermal ageing


Strategies, materials and methods




50 000 h-1 aged 10h 800 deg - most active

0

20

40

60

80

100

100 200 300 400 500 600 700Temperature [oC]

CH

4 c

on

vers

ion

[%

]

CuMn(1:2)Cit/Puralox

Pd-1-CuMnAl(2.5:5:1)Ht/Puralox

Pd-2-CuMnAl(2.5:5:1)Ht/Puralox

Pd-2-Puralox

Ecocat

Pd-6-Puralox(org)

• Over 100 mixed oxide based catalyst formulations, over 150 catalytic tests (powder samples)

• Best catalysts are based on CuMn system and show activity exceeding the activity described in literature for mixed oxide catalysts

• Pd (6% loading) from organic precursor supported on modified alumina showed activity better than the reference




0 2000 4000 6000 80000

20

40

60

80

100

lean @ 350°C

% C

H4

Con

vers

ion

Time (s)

Ecocat

2% Pd/La2O

3-Al

2O

3

2% Pd/CeO2-Al

2O

3

2% Pd/Al2O

3

2% Pd/ZrO2

At 1/3 Pd loading (2% w/w vs 6.3% w/w) CH4 conversion is slightly lower than the reference catalyst

• Pd based catalysts: effect of support and Pd loading (powder samples)

Significantly higher conversion perfomances have been obtained with 6% w/w Pd/CeO2-Al2O3

0 1 2 3 4 5 6 7 8 9 10 11 12 13 140

10

20

30

40

50

60

70

80

90

100

CH

4 con

vers

ion

(%)

Number of cycles

6% Pd/CeO2-Al

2O

3

2% Pd/Al2O

3

ecocat 2% Pd/CeO

2-Al

2O

3

T = 350 °C




• Up-scaling and coating of the catalyst materials on the metal foil

CuMn2O4

+ Alumina+ Binder

CuMn2O4 + Alumina+ Binder+ Pd

ReferenceCatalyst + Pd

CuMn2O4 6-Pd/CeO2-Al2O3

• Good coating abilitiesfound on the metal surface • Combarable adhesion compared to the reference

6-Pd/CeO2-Al2O3

+ Binder




• Laboratory testing for the new materials

– Laboratory light off tests (25-600°C): as fresh and

LS-1030°C/20h aged

(LS = lean 10 min + stoichiometric 50 min;

CO, CO2, H2O, C3H6, O2, N2)

Stoich.

λ=1

Lean

λ=1,78

O2, % 0,8 10

NO, ppm 600 500

H2O, % 10 8

CO2, % 9 7,5

CO, ppm 8000 1200

H2, ppm 2800 -

CH4, ppm 1800 1500

C2H6, ppm 100 300

C3H8, ppm - 100

C2H4O, ppm - 150

Samples are containing 195 g/cft Pd loading correspondingPd loading in 200 g/cft 0:39:1 Pt:Pd:Rh reference catalyst




• Pd-CeO2-Al2O3 material in light off test at lean (fresh)

THC Conversion in Light-off performance

0

10

20

30

40

50

60

70

80

90

100

100 150 200 250 300 350 400 450 500 550 600Temperature before catalyst, °C

Co

nv

ers

ion

, %

896 6-PdCeO2-Al2O3

640 REF (Pd)

• Significant performance improvement achieved in respect of the reference• λ=1 tests as well as tests for the aged catalyst samples are in progress



• The effect of Platinum addition in reference catalyst– 1,2 liter E4 bi-power vehicle with CNG over NEDC (ageing 40/80 h RAH)


• Increased catalyst durability found

1 1 11,1

1,0 1,0

1,8

1,6

1,51,4

1,1

1,3

1,8

1,5

1,9

1,7

1,4

1,7

0

0,2

0,4

0,6

0,8

1

1,2

1,4

1,6

1,8

2

THC CO NOx

Re

lati

ve

em

iss

ion

Pd-Rh/ Fresh Pt-Pd-Rh/ Fresh Pd-Rh/40 h Aged

Pt-Pd-Rh/40 h Aged Pd-Rh/80 h Aged Pt-Pd-Rh/80 h Aged

Fresh Fresh40 h 40 h 40 h80 h 80 h 80 hFresh




Sample Fresh S-poisoning* Lean regeneration

@ 750°C

Rich regeneration

@ 600°C

Ecocat 74%** 28% 15% 50%

Pd/Al2O3 68 % 3% 17% 39%

Pd/CeO2-Al2O3 70% 3% 10% 55%

Pd/La2O3-Al2O3 63% 3% 6% 47%

Pd/ZrO2 47% 0% 42% 37%

*1 g S @ 300°C; ** Conversion data under lean conditions @ 350°C

• All the samples suffer for the sulfur poisoning• Significant regeneration achieved under rich conditions at 600°C

• S-poisoning/regeneration behaviour (powder samples)




• Effect of Sulfur poisoning on Ref. catalyst

• DeSOx1: λ= 1 up to 750°C• DeSOx2: λ= 0.9 up to 750°C

=> Stoichiometric desulfation leads to nearly complete sulfur removal




0 3 6 9 12 15 18 21 24 27 300

10

20

30

40

50

60

70

80

90

100

T=60s T=30s T=20s T=10s

Time [min]

CH

4 con

vers

ion

[%]

T = 450°C

150 200 250 300 350 400 450 500 550 6000

10

20

30

40

50

60

70

80

90

100 GHSV=100000h-1

GHSV=50000h-1

CH

4 con

vers

ion

[%]

Temperature [°C]

Ramp UP

• Identification of superior and more stable CH4 conversion performances under -sweep (0.98-1.02) than under constant feed conditions

-sweepConstant feed

• Improvement by the operation strategy (reference catalyst)




• Ideal operation point is correlated to temperature and lambda• Sligthly rich operation under transient conditions improves CH4 conversion

• Improvement by the operation strategy (reference catalyst)




• NOx Storage Catalyst

• Regeneration of NSC possible with methane above 400°C• Hydrogen can be produced by engine and it enables the regeneration at lower temperatures




• The samples for the first round tests in engine bench

Samples for the test in AVL:• Ceramic substrates• 152,4 X 101,6 x 76,2 mm • V = 0,93 dm3, 600 cpsi, 3,5 mils• Washcoat K5.7, 50 g/m2:

– Sample 1: 170 g/cft Pt:Pd:Rh 0:40:1– Sample 2: 200 g/cft Pt:Pd:Rh 0:39:1– Sample 3: 200 g/cft Pt:Pd:Rh 1:38:1– Sample 4: 300 g/cft Pt:Pd:Rh 0:59:1

• Coated by Ecocat – canned by Catcon



• Conclusion– Developed mixed oxides are better than systems described in the

literature but not alternatives for Pd based catalysts– Novel active Pd based formulations have been indentified and

scaled up for real catalytic testing, showing better performances than the reference catalyst

– Additional Pt on reference catalyst improved durability– Sulfur poisoning is an issue for the Pd based catalysts, but

regeneration is feasible– Operation strategy based on optimal controlling of lambda

oscillation provides improvement of catalyst performances

– Deliverables • DB2.4 CH4 kinetics/model and DB2.7 Catalyst samples Gen. 1/new

formulations




InGas 24month meetingOct. 27th/28th 2010

Brussels

WPB2.3: Exhaust heating/Catalyst concepts

USTUTT/DELPHI/DAIMLER/KATCON



• Improvement of operation strategies (cold start) based on simulation model

Outline / focus of 2nd year activity

• Experimental investigation of laboratory scale hex (USTUTT)

Identification of three main cold start strategies (DB2.9) (USTUTT)

• Successful development/manufacturing of bench scale prototype + setup (DELPHI / USTUTT / ECOCAT / KATCON)

• Design improvements for 2nd generation hex

Task B2.3.2

Task B2.3.1/2.4.1

Task B2.3.3

• Cold start experiments



Development work TB2.3.3: Experimental investigation of lab scale EAT

FIC

Air

H2

CH4

FIC

FIC

TIR TIR

TIR

TC

Hood

TIR TIR TIR TIR

TIRTIRTIR

FID

PIR

PIR

General conditions:• Air flows up to 30 m3/h• CH4 conc. up to 5000

ppm • Inflow temperatures:

20 – 400 °C• Fuel lean operation• Hydrogen-assisted

heat up

Flowchart of test rig:

Measurement of axial temperature profiles, Δp, CH4 conversion

Assess heat exchanger efficiency, i.e. determine amplification factor adF T

Ta

max



Strong influence of axial heat conduction in wall material!

Relation between hex efficiency and Amplification

factor:

Ahex

11

ICVT: 73 – 78 %

Delphi: 71 – 78 %

Both heat exchanger reach defined targets

Development work TB2.3.3: Experimental investigation of lab scale EAT

• Tin = 278 – 293 °C; Tmax = 630 °C; yCH4,in = 3400 – 4400 ppm



Development work TB2.3.3: Cold start experiments: Cold start burner

1. Standalone Investigation of Promeos cold-start burner :• Characterization of stationary output (power, exhaust composition, mass flux)• Ignition procedure (burner exhaust + secondary air)

2. Cold start experiments with attached heat exchanger:• Burner exhaust + secondary air exit through outflow channels

• Same target temperature (600 °C) as for experiments before Lower values measured for CH4

intake due to backpressure of hex Setup with air fan and passive fuel

dosage is not appropriate

• Burner replaced in favour of more reliable and promising cold start solutions!



Development work TB2.3.2: EAT operation strategies / simulation work

• Development of different operation strategies with simulation tool. Details can be found in DB2.9 (EAT operation strategy I)

• Basic idea: replace cold start burner with bypass/flap setup:

• Normal mode:Exhaust flows through

inflow and outflow channels of hex

• Bypass mode (test bench only!):

Hex is separated from exhaust flow

Protection in case of engine malfunction

• Cold start mode:Hot exhaust enters hex

at U-turn and exits through outflow channels.

Cat. light-off can be further reduced with H2 / CO – rich exhaust




• Bypass-Flap-Strategy simulated over complete NEDC:

• Exhaust via bypass from 0-80s

• During bypass phase, addition of hot gas flow

• After this phase, switch to normal mode

• EU 5/6 THC limits undercut in ANY case




• Simulation results were promising for bypass/flap strategy:

• System will be tested with 1st generation bench scale prototype at AVL

• Additionally, an electrically heated pre-cat will be implemented in the 2nd generation bench scale prototype:

Emitec EMICAT®

• In combination with hex, only short initial operation period required Rapid heat up Good controllability No secondary emissions




• Electric heater strategy simulated over complete NEDC:

• Heater operation during bypass phase (0-80 s)

• After this phase, switch to normal mode

• EU 5/6 THC limits significantly undercut



• Main challenge during 2nd year: Scale-up of manufacturing process, i.e.:

Development work TB2.3.1: Hex development

• Assembly of “tubes” and stack: 1st brazing

• Attachment of header plates + 2nd brazing:

DELPHI: Scale-up is delicate due to multiple brazing steps!



outflow

outflow

inflow

inflow

outflow U turn

outflow

outflow

inflow

inflow

outflow U turn

311

34

Development work TB2.3.1: Bench scale prototype development

Different approach proposed: split hex core into 4 single modules

Total cross sectional surface is increased by a factor of 6.7 Similar GHSV as laboratory experiments

Welding

TWC



Development work TB2.4.1: Bench scale prototype development

Uncoated, single core (1 of 4) after brazing:

Complete package after coating and welding:

Insulation



Development work TB2.4.1: Design improvements for 2nd generation hex

Channel height 2.9 mm

Channel width 50mm

Number of tubes 14x4=56

Number of channels 27x4=108

Metal sheet thickness tubes 0.15 mm

Metal sheet thickness fins 0.15

Cell density hex/coated part 133/250 cpsi

Coated length 120 mm

Overall finned length 301 mm

Channel height 2.9 mm

Channel width 50mm

Number of tubes 14x4=56

Number of channels 27x4=108

Metal sheet thickness tubes 0.15 mm

Metal sheet thickness fins 0.075 mm

Cell density hex/coated part 250/250 cpsi

Coated length 100 mm

Overall finned length 301 mm

• Gen. 1: • Gen. 2:

• Benefits: Lower thermal mass reduced thermal inertia Higher cell density heat exchange surface increased Decreased coated length increased hex length increased amplification



Conclusions

• Simulation (Task B2.3.2):

Identification of EAT operation strategy on laboratory scale at USTUTT Promeos burner tested with coupled heat exchanger

• Engineering (Task B2.3.4):

Cold start strategies identified for efficient hex heat up (DB 2.9 ) Identification of hex design improvements

• Experimental (Task B2.3.3):

1st generation of laboratory and bench scale hex successfully manufactured by DELPHI, ECOCAT and KATCON (DB 2.5+2.6 )

Design modifications for 2nd generation defined



Outlook

• Experimental (Task B2.3.3):

Tests with lambda-oscillations Testing of 2nd generation laboratory prototype: Setup of bypass/valve system similar to engine test bench + Cold start tests

• Simulation (Task B2.3.2):

Further improvement / validation of simulation model, based on lab and bench scale tests

Basic investigation of NSC strategy Simulations with non-NEDC data

• Engineering (Task B2.3.4):

2nd generation bench and laboratory scale prototypes (DB 2.10)



24 Month Meeting Brussels,Subproject B2, WPB 2.4

AVL/DAIMLER

Status AVL (month 13-24) -Marko Certic , AVL List GmbH

Alois Fuerhapter, AVL List GmbH

INGAS Subproject SPB2



• Main objectives:– To do baseline tests as input for the catalyst development – To perform engine tests with new TW catalyst formulations – To perform engine tests with HEX system – To develop operation / calibration strategies for HEX/EAT system – To evaluate the emission potential of EAT system

• Status Summary:– MCE engine is having various hardware problems causing delay also in A2 project

(camshafts phasing, cylinder head damage, DI injector not stabile, blow-by system, valve train, cyl. head bolt threads in block)

– Baseline testing performed both with DI and MPI, data evaluated and used as input for development of new catalyst coating formulas

– EAT/CH4 catalyst evaluation started – 2 formulations are tested in preconditioned condition

– HEX system on engine test bed ready for testing

SPB2: Overview WPB2.4



SPB2: Baseline investigations with H2 analysis

No. N BMEP MD PWR

- 1/min bar Nm kW

1 750 0.72 10.3 0.809

2 1200 0.72 10.3 0.809

3 1600 2.01 28.66 4.801

4 1600 3.41 48.76 8.169

5 1600 4.71 67.37 11.287

6 1800 3.4 48.55 9.153

7 1800 6.02 86.08 16.229



SPB2: HEX setup on the test bed

HEX monolith

Status of work• Mechanical installation completed

• Test program defined in cooperation with DAI/USTUTT

• Exact operation with three flaps to be defined

Flaps

TWC(to compare sizes)



SPB2: Catalyst heating with strategy similar to DI gasoline engine

0

10

20

30

40

50

60

70

80

MF_NOXEO MF_THCEO MF_EXH IMEP-Var SA SM_VAL2(multiplied by 100)

T_bef_cat(divided by 10)

[g/h] [g/h] [kg/h] [%] [°CAaTDC] [FSN] [°C]

InGAS DI single

InGAS MPFI

InGAS DI double

Refernce gasoline same T_ex

Refernce gasoline opt

No significant difference between DI and MPI for homogeneous operation

Significantly lower gaseous emissions at same exhaust gas temperature for postinjection, but combustion stability and soot emission have to be improved

N=1200 rpmBMEP= 1 bar



0.50

1.82

0.60

1.4

2.8

1.04

2.73

6.03

0.99

1.37

4.21

2350

110

2040

116

CO [%] THC [ppm] deltaT exothermic [K] VPI[%] Smoothness Index[%]

Cylinders balanced, EOI 220Cylinders balanced, EOI 70 (1%CO)Cylinders unbalanced, EOI 220 (1%CO)

With DI technology cylinder unbalancing is possible, increasing CO and O2 content which promote exothermic reaction in catalyst

SPB2: Advanced operation strategy for Cat heating

At the same (increased) CO content the strategy of unbalanced cylinders shows better combustion stability and better over all running smoothness

N=2000 rpmBMEP= 2 bar



• Testing plan and measurement procedure defined together with Daimler

• EAT/CH4 catalyst testing steps

– Evaluation of each catalyst formulation itself by exact defined procedure for advanced catalyst characterisation

– Testing of advanced operation strategies • cylinder unbalancing for enhanced exothermic CO reaction• lambda oscillations (toggling) to simulate real life operation

• Following 2 samples tested at the moment

– cat #1: commercial product with 300 g/cft

– cat #2a: protoype cat with 170 g/cft

• Further 2 samples with different formulation are delivered to AVL last week and will be tested within the next weeks

• Measuring procedure to be improved if possible in order to shorten total time required per catalyst and to improve quality of resutls

SPB2: EAT/CH4 Catalyst Evaluation



• Peak of conversion reached with rich mixture• Exact positioning of conversion peak is

temperature and/or engine operating point dependant

• Improvement of light off through adaption of lambda strategy

• Further improvement expected with usage of advanced engine operating strategies (cylinder unbalancing)

Methane conversion & Temperature rise in cat1600rpm/4.7bar bmep

0

20

40

60

80

100

120

0,850 0,900 0,950 1,000 1,050 1,100 1,150

Lambda [-]

Met

han

e C

on

vers

ion

[%

],

Tem

p. r

ise

in c

atal

yst

[K]

Cat #2a

Cat #1

SPB2: Lambda variations for TWC characterization

Comparison after PreconSummary Best points from Characterisation Step2

0

20

40

60

80

100

120

140

160

100 150 200 250 300 350 400 450 500

Temp. before cat [deg C]

Me

tha

ne

Co

nv

ers

ion

[%

],

Te

mp

. ris

e in

ca

taly

st

[K]

0,96

0,97

0,98

0,99

1,00

Lam

bd

a fo

r o

pti

mu

m c

on

v.

effi

cien

cy [

-]

Cat #1 Methane conv.

Cat #1 Temp. rise

Cat #2a Methane conv.

Cat #2a Temp. rise

Cat #1 Lambda opt.

Cat #2a Lambda opt.

Cat #2a

Cat #1

Comparison before PreconSummary Quick Characterisation (Lambda 1.00 +/-0.005)

0

20

40

60

80

100

120

100 150 200 250 300 350 400 450 500

before cat temp. [deg C]

Met

han

e C

on

vers

ion

[%

], T

emp

. ris

e in

cat

alys

t [K

]

Cat #1 CH4 Conv.

Cat #1 delta T

Cat #2a CH4 Conv.

Cat #2a delta T

Cat #2aCat #1



• Continuation of advanced catalyst testing according to test procedure– 2 catalyst samples with 200 g/cft available and to be tested

– 1 catalyst sample with 300 g/cft is in procurement

– 2 additional sample open

• Tests with advanced operation strategies from combustion side (e.g. cylinder unbalancing)

• HEX System testing– basis evaluation same as for other prototype catalysts

– development of the strategies for operation with HEX

SPB2: Next Steps in WPB2.4 AVL (month25-30)



SPB2: Summary / Conclusion

WPB2.2: Advanced catalyst development

- Developed mixed oxides are better than systems described in the literature but not alternatives for Pd based catalysts

- Novel active Pd based formulations have been indentified and scaled up for real catalytic testing, showing better performances than the reference catalyst

- Additional Pt on reference catalyst improved durability

- Sulfur poisoning is an issue for the Pd based catalysts, but regeneration is feasible

- Operation strategy based on optimal controlling of lambda oscillation and lambda setting provide improvement of catalyst performances

- Implementation of the NSC technology on a CNG engine possible. Regeneration of NSC with H2 generated in the rich phase



WPB2.3: Exhaust heating – Catalyst concepts

- Identification of EAT operation strategy on laboratory scale

- Cold start strategies identified for efficient HEX heat up

- Identification of hex design improvements. Implementation on 2d generation HEX

- 1st generation of laboratory and bench scale HEX successfully manufactured

WPB2.4: Engine testing / EAT system management

- Baseline testing performed both with DI and MPI

- Engine measures for faster lightoff identified

- EAT/CH4 catalyst evaluation started – 2 formulations are tested in preconditioned condition. Improvement of light-off through adaption of lambda strategy

- HEX system on engine test bed ready for testing

SPB2: Summary / Conclusion



SPB2: Road Map Catalyst / HEX testing

INGAS - SPB2 New Time TableYear2 Year3

Month Main Partner 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

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 SPA2DB2.13 Vehicle/EAT/Strategy to A2 (DAI)

DB2.14

Results Summary/Assessment

to B0.2 (DAI)

MilestonesMB2.2 Potential Heat exchanger Concept/New Catalyst Formulation demonstrated

MB2.3 Principle Feasibility demonstrated

Catalysts tested: Catalysts tested: Catalysts tested:Pd/Rh 170 g/ft3 Pd/CeO2 200 g/ft3 Best formulationPd/Rh 200 g/ft3 Pd/CeO2 300 g/ft3Pd/Rh 300 g/ft3 New formulationPt/Pd/Rh 200 g/ft3

Catalysts tested:Pd/Rh 170 g/ft3Pd/Rh 200 g/ft3Pd/Rh 300 g/ft3Pt/Pd/Rh 200 g/ft3

Catalysts tested:Pd/CeO2 200 g/ft3Pd/CeO2 300 g/ft3New formulation ?

Catalysts tested:Best formulation

ingas integrated gas powertrain ingas – spb2 – 24-month meeting brussels 27/28 october 2010 1...

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