INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010” INGAS INtegrated GAS Powertrain 1 INGAS 30 months meeting Oulu - Finland 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 INtegrated GAS Powertrain 2 WPB2.1 Requirements / Boundary Conditions WPB2.2 Advanced Catalyst Development WPB2.3 Exhaust Heating/ Catalyst Concepts WPB2.4 Engine Testing/ EAT System Management WPB2.5 EAT System Integration/Optimiz. B2: Aftertreatment for Passenger Car CNG Engine B0 A1 – A2 – A3 A2 Fuel Requirements/ specifications Exhaust boundaries Engine/injection system Control management Engine for EAT implementation Engine with EAT for final validation Boundary conditions Reference 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 INtegrated GAS Powertrain 3 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 INtegrated GAS Powertrain 4 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 INtegrated GAS Powertrain 5 InGas: SPB2/WPB2.2 6%-Pd/CeO 2 -Al 2 O 3 material/powder made in Ecocat (vs. made by POLIMI) At the first stage 100 g ready powder ( 6% Pd) was made according 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, m 2/ g Pore volume, cm 3 /g0,50,440,290,3 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 INtegrated GAS Powertrain 6 InGas: SPB2/WPB2.2 Catalyst sample made from the Ecocat 6%-Pd/CeO 2 -Al 2 O 3 material/powder Good coating abilities found on the metal surface Combarable adhesion compared to the reference Rolled sample for the tests 6%-Pd/CeO 2 -Al 2 O 3 + Binder coated on the metal foil

INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010” INGAS INtegrated GAS Powertrain 7 InGas: SPB2/WPB2.2 Quite similar light off curves for CO for all the samples after HT-ageing After HT-ageing, THC light off for the new samples is clearly better Light off tests at lean (HT-700°C/20h aged)

INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010” INGAS INtegrated GAS Powertrain 8 InGas: SPB2/WPB2.2 At λ=1 tests as LS-aged the new samples show better light off performance, especially for THC Light off tests at λ=1 (LS-1030°C/20h aged)

INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010” INGAS INtegrated GAS Powertrain 9 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)

INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010” INGAS INtegrated GAS Powertrain 10 InGas: SPB2/WPB2.2 Conclusions for the tests made for the 6%-Pd/CeO 2 -Al 2 O 3 based samples:  At lean conditions the new samples has better light off peformance compared to 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 fresh the 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-CeO 2 -Al 2 O 3 powder could 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 scale samples for the engine tests

INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010” INGAS INtegrated GAS Powertrain 11 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 INtegrated GAS Powertrain 12  Influence of certain (design) parameters on accumulated amount of CH4 Material thickness of corrugated spacer structures L tot LcLc Varied parameters Optimized parameters 2 degrees of freedom for optimizer: L c Flap switch time Varied parameters (const. in each optimization run: s spacer L tot 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 INtegrated GAS Powertrain 13 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 INtegrated GAS Powertrain 14 MK2 hex generation Flap 1 Flap 2 Flap 3 TWC coating Exhaust in Exhaust out Flap 1 Flap 2 Flap 3 Flap 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  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 ( m 2  m 2 (only lab-scale)  High cell density (30 fpi ≈ 250 cpsi) for complete hex, coating length 10 cm

INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010” INGAS INtegrated GAS Powertrain 15 L tot = 0.3 m A tot = const. = m 2 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 INtegrated GAS Powertrain 16 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 INtegrated GAS Powertrain 17 SPB2 WPB2.4 Comparison of exhaust gas composition at Lambda 1, using different operation strategies The 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) CH 4 COO2O2 NOx % % 3% 2% 1% 0 CO, O 2 [%] THC, CH 4, NOx [ppm]

INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010” INGAS INtegrated GAS Powertrain 18 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 INtegrated GAS Powertrain 19 Hex testing engine operation AVL LFNR NPMEMDP_EffGHSV (λ = 1)V_dot (λ = 1) - 1/minbarNmkW1/hNm 3 /h ~ ~ ~ ~ ~ ~ ~ For every load point measuring CO, CH 4, NO X, NO, O 2, 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 INtegrated GAS Powertrain 20 Lambda Sweep 0.97->1.02, 1600 rpm/2 bar Catalyst operating temperature significantly increased due to amplification of hex! T in

INGAS “30 Months Meeting ”, “Oulu, Finland”, “25-26 May 2010” INGAS INtegrated GAS Powertrain 21 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 INtegrated GAS Powertrain 22 SPB2: Road Map Catalyst / HEX testing Catalysts: Pd/Rh 170 g/ft3 Pd/Rh 200 g/ft3 Pd/Rh 300 g/ft3 Pt/Pd/Rh 200 g/ft3 Catalysts: Pd/Ce2O3 300 g/ft3 Pd-Rh/CeO3 300 g/ft3 Catalysts: Best formulation Deliverable/MS: New delivery date New time table