Ceramics for Environment Grand Challenges Ceramics for Environment (Industrial Vision) Hasan MANDAL Anadolu University, Eskisehir, Turkey MDA Advanced Ceramics, Eskisehir, Turkey

Grand Challenges (ICC1, 2006) Ceramics for Energy and Environment Critical Enablers: New cost effective materials and manufacturing techniques Ref: 1st ICC Road Map, Toronto, 2006

Ceramics for Environment Ceramics for a clean environment Cellular Ceramics for gas microfiltration and ultrafiltration Gas separation Hot gas filters Diesel particulate filters Porous ceramics for catalyst supports Membrane reactors Ceramics for reverse osmasis Ceramics for hot processes in gas power stations, incinerators, other industrial plants Catalysts and Catalysts Supports Oxides, zeolites, catalytic cumbustors in automotive Catalyst support for oil, petrochemical, chemical and pharmaceutical industry

WHY THESE SUBJECTS? PUBLIC AWARENESS INCREASED COST OF ENERGY LEGISLATION (National and International)

Ref: Unit F.1 (Automotive Industry), Directorate-General for Enterprise and Industry, European Commission, 18 January, 2008

Ref: Unit F.1 (Automotive Industry), Directorate-General for Enterprise and Industry, European Commission, 18 January 2008

Ref: Unit F.1 (Automotive Industry), Directorate-General for Enterprise and Industry, European Commission, 18 January 2008

Diesel Car Sales Penetration in Europe Current European penetration currently at 55 %, Belgium 73.4 % Spain 70%, France 70 % Germany 44 % , UK 38 % Italy 59 % Potential for further market growth Attractions – powerful, bottom end torque, excellent fuel economy, low CO2 emissions Ref: M.V. Twigg, presentation, ICC2, 2008

Ceramic Monolith Substrates Physical Characteristic Compromises Good Thermal Shock Resistance High Compressive Strength High Geometric Surface Area Low Heat Capacity Low Back Pressure High Cell Density Thin Wall Thickness High Porosity Ref: M.V. Twigg, presentation, ICC2, 2008

Summaries of Contributions Ceramics for Environment (Industrial Vision)

The role of ceramic materials and technologies for environmental protection is already highly visible and will increase in future (e.g. porous materials). Automotive industry will likely remain a principal driving force for development of ceramics with high environmental impact (high porosity, ash resistant compositions, four way catalytic filtrations systems, high filtration effeciency, more efficient and robust catalysts, higher sensitivity ceramic sensors). This will create technology that can be leveraged to other areas (filtration, separation) and other applications in chemical, petrochemical and power generation industries. Other key areas: harvesting and use of clean energy, clean water and green construction materials Ref: A.J.Pyzik, The Dow Chemical Company “Ceramic Technologies For Environmental Protection”

Gasoline Monolithic catalysts substrate Oxygen Sensors Ceramic materials have important roles in controlling emissions from vehicles Gasoline Monolithic catalysts substrate Oxygen Sensors TWC Catalyst thermal stability Diesel Monolithic catalysts substrates Catalyst thermal stability Ceramic wall flow filters The Future Integration of more catalyst functionality into single ceramic filter units Huge demands on catalytic chemistry and ceramic science Ref: M.V. Twigg, Johnson Matthey Catalyts “Roles of Ceramics in Controlling Car Exhaust Emissions”

Extruded synthetic Cordierite with low CTE has been successfully used as macro-cellular body for exhaust catalyst support during the last 30 years Ceramic filters have successfully been applied to Diesel Particulate Filters with active regeneration for 20 years and extensively during the last 10 years Challenges to use oxide ceramics for this particular demanding application have been overcome The use of oxide cellular ceramics honeycombs as high surface area extruded catalyst remains an active area of research with many promising applications for remediation of both mobile and stationary emissions as well as for use in the chemical processing industry Ref: J.J. Theron, Corning European Technology Center “Oxide-based ceramic monoliths in catalysis and filtration application” In conclusion…… 1’

A re-crystallized porous SiC material was obtained by mixing a coarse powder and a fine powder of SiC at a fixed rate and firing the mixture at a high temperature of 2000ºC or more. The material obtained has a uniform pore diameter distribution compared with other materials, and is suitable as a DPF material. Ref. K. Ohno, Ibiden Co. Ltd. “A New Technology with Porous Materials, Progress in the Development of the Diesel Vehicle Business”

Functional ceramics enable significantly reduced vehicle emissions (fuel injection system - piezoelectric multilayer actuators, exhaust gas sensor - ceramic sensor element, park pilot - piezoelectric transducer, diesel particulate filter - ceramic filter substrate) To take advantage of the full potential for reduction of emissions, a thorough understanding of material properties and sophisticated modeling approaches are necessary. Ref: M. Selten, Robert Bosch GmbH “Functional ceramics for emission control strategies”

Challenges Industrial attention is limited to certain applications. There are many other applications to be innovated (e.g. chemical, petrochemical and power generation industries) including on the current usage (e.g. particulate filter for gasoline engines) – be proactive rather than reactive. System design rather than parts. Therefore, Interdisiplinary and transdisciplinary research is needed – ”open innovation” Education and public awareness should be improved Cost

Enablers Regulations (more link with policy makers) Chemistry (catalysts, substrate materials) Processing and manufacturing technologies Design (system, crystal chemistry, microstructure) Material (alternative materials) Modelling