INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 1 INGAS 18 months meeting GDF-SUEZ, Paris - France November 2010 InGas 18 months meeting: SPB2/Ecocat

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 2 InGas 18 months meeting: SPB2/Ecocat Ecocat is taking part in: –WP2.1 (requirements/boundary conditions) –WP2.2 (advanced catalyst development) –WP2.3 (exhaust heating/catalyst concepts)

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 3 InGas 18 months meeting: SPB2/Ecocat Objective and Innovative aspects WP2.1 (requirements/boundary conditions) –The planned objectives in this WP are collection and definition of relevant information about fuels, exhaust, engine characteristics, ECU functions and testing conditions in order to ensure common working basis and guidelines for different partners. –In the beginning Ecocat’s role is to deliver reference catalysts to the partners –In task TB2.1.2 (Catalyst testing/ageing conditions) the reference catalysts have been prepared, which will be used as a reference matrix for the further catalyst (both substrate and washcoat) development  Ecocat´s role is to provide reference catalyst for Daimler´s, POLIMI, USTUTT and ISCS- PAS studies, commercial product. WP2.2 (advanced catalyst development) The main work packet objectives during the project are: –The development of new catalyst formulations for methane oxidation with a light off temperature below 350°C –A high thermal and sulphur stability, –Development of a modelling tool for methane oxidation –Delivery of kinetic data, control strategy for methane (lambda = 1, lambda >1) and NOx abatement (lambda>1) –Development of coating methods for catalyst up scaling and canning  Ecocat´s role is to further develop existing formula based on new innovations from research parties within project (ICSC, POLIMI). Meanwhile, Ecocat does their own development, tasks depend on the engine test results by Daimler and the feed back from the other partners.. WP2.3 (exhaust heating/catalyst concepts) Planned objectives & starting points: –Definition of the EAT concept with heat exchanger and catalyst /integrated or serial concept) –Development of a modelling tool for the whole EAT system –Simulation of the behaviour of the EAT depending on operating conditions –Evaluation of the selected concept on a laboratory scale for methane and NOx removal –Building of 2 prototypes for laboratory investigations and 2 prototypes for engine/vehicle testing  Ecocat´s role is to provide coated heat-exhangers to improve CH4 light-off based on the requests.

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 4 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.1 (Requirements/boundary conditions) Reference samples –Washcoated with stoichiometric NG coating –Washcoat thickness has been specified to 50 g/m 2 –Pd-Rh technology; 200 g/cft Pd:Rh 39:1 –Sent to: Daimler (2 ceramic + 1 metallic) Kracow (1 ceramic) Politecnico Milano (1 ceramic) Universität Stuttgart (1 metallic) Reference catalyst powder –Pd containing catalyst powder (6,3 wt-% Pd) –Sent to: Krakow (20 g) Politecnico Milano (20 g) Ceramic ICeramic IIMetallic Dimensions (mm)118x70118x50118x50,8 Volume (dm 3 )0,770,550,56 Wall thickness (Mills/ µ m) 63,550 Cell density (cpsi) Total surface area, TSA (m 2 ) 2,121,902,26

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 5 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: Advanced catalyst development Washcoat preparation for the CuMn 2 O 4 -oxide (+ Puralox SBa 150) powder achieved from ISC-PAS CuMn 2 O 4 + Alumina + Binder CuMn 2 O 4 + Alumina + Binder + Pd Reference Catalyst + Pd 80 % 20 % Reference CuMn 2 O 4 d 50 = 3,39 µm d 50 = 4,46; 4,24 µm Washcoat properties: pH: 4,973,154,78 Visco: 738 cP2525 cP2477 cp

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 6 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: CuMn 2 O 4 + Alumina + Binder CuMn 2 O 4 + Alumina + Binder + Pd Reference Catalyst + Pd 80 % 20 % Sample preparation for the CuMn 2 O 4 -oxide (+ Puralox SBa 150) powder Pd-loading in ready samples 200 g/cft

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 7 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2 CuMn 2 O 4 + Alumina + Binder CuMn 2 O 4 + Alumina + Binder + Pd Reference Catalyst + Pd 80 % 20 % – Laboratory light off tests (25-600°C): as fresh and LS-1030°C/20h aged (LS = lean 10 min + stoichiometric 50 min; CO, CO 2, H 2 O, C 3 H 6, O 2, N 2 ) Ø 14 mm x L 75 mm Stoich. λ=1 Lean λ=1,78 O 2, %0,810 NO, ppm H 2 O, %108 CO 2, %97,5 CO, ppm H 2, ppm2800- CH 4, ppm C 2 H 6, ppm C 3 H 8, ppm-100 C 2 H 4 O, ppm-150

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 8 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: Laboratory light off test results for fresh samples (λ=1)

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 9 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: Laboratory light off test results for aged samples (λ=1)

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 10 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: Laboratory lambda window test results for fresh samples at 500°C

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 11 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: Laboratory lambda window test results for aged samples at 500°C

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 12 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: Laboratory light off test results for fresh samples (Lean)

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 13 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: Laboratory light off test results for aged samples (Lean)

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 14 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 2 nd 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); with soithiometric test mixture (25-600°C) –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 18 months meeting: SPB2/Ecocat Work performed in WP 2.2:

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 15 Light off tests in laboratory InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2:

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 16 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 h RAH) InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2:

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 17 Cumulative THC results in the engine after 40 h ageing InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2:

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 18 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: Cumulative THC results in the engine after 40 h ageing

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 19 Cumulative CO results in the engine after 40 h ageing InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2:

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 20 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: Cumulative NOx results in the engine after 40 h ageing

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 21 Conclusion –Test with CuMn 2 O 4 powder Washcoat preparation was successfully progressed Adhesion on the metal surface is comparable to the reference Some activity found for CO and NOx; for THC the activity is poor compared to the reference under stoichiometric conditions, in lean the HC activity is better, but not at the reference level Pd clearly improves the activity –Tri metallic catalyst evaluated against standard Pd-Rh CNG catalyst: In the laboratory tests minor improvements were found in the light off (T 50 ) temperatures In engine tests fresh samples are performing equally but tri metallic sample showed better durability against thermal ageing InGas 18 months meeting: SPB2/Ecocat

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 22 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.2: Samples for the test in Daimler/AVL: Ceramic substrates (2 pieces) 152,4 X 101,6 x 76,2 mm V = 0,93 dm 3, 600 cpsi, 3,5 mils 170 g/cft 0:40:1, 50 g/m 2 K5.7

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 23 InGas 18 months meeting: SPB2/Ecocat –Advanced coating High surface area – two layer washcoat Oxygen Storage Rear Earth Stabilizers Active metals – Pt/Pd/Rh Work performed in WP 2.2:

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 24 InGas 18 months meeting: SPB2/Ecocat Work performed in WP 2.3: –Laboratory scale heat exchanger prototype was prepared by Delphi and coated in Ecocat on March/2010 –Proto was coated with CNG washcoat developed for the stoichiometric use: 200 g/cft 0:39:1 Pt:Pd:Rh 50 g/m 2 K5.7 Heat exchanger, Proto 2

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 25 InGas 18 months meeting: SPB2/Ecocat Fins for the vehicle scale prototype will be coated on weeks 21-22/2010 –Vehicle scale heat exchanger will be prepared by Delphi –It consist of 4 similar units which will be coated in Ecocat –Units will be coated with similar CNG washcoat as used in laboratory scale prototypes – Coating is in progress and the units will be sent to the canning on week 22 Work performed in WP 2.3:

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 26 InGas 18 months meeting: SPB2/Ecocat Problems encountered Less time than originally planned and budgeted was spent in activities due to the lack of resources due to the bad economical situation Characterization of the reference material was slightly delayed by the partners => further improvement was planned after the feed back Screening of the new materials is in progress in the partners => washcoating and upscailing activities (planned to start on month 9) will be done after new materials are available (during second and third year); The first material from ISCS-PAS was received and the first washcoating and testing in laboratory scale is in progress The further development on Ecocat is based on the feedback received from the partners; therefore the engine tests will be needed for further development

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 27 InGas 18 months meeting: SPB2/Ecocat Main results WP 2.1: –Reference catalyst both full size catalysts in ceramic and metallic substrate as well as powder catalyst was succesfully delivered for the partners WP 2.2: –To support new catalyst materials development on the partners reference material (powder and full size catalysts) were prepared and delivered –Preliminary washcoat screening in own laboratory and engine tests to see the level of the reference catalyst for the project objectives –Fuether development is dependant on the feed back from the engine and the laboratory results made by partners –The first washcoating trials with a new catalytic material made in ISCS-PAS have been done and the tests are in progress at laboratory level WP 2.3: –Two laboratory scale heat exchange prototypes coated and sent to the partners –Vehicle scale prototype fins will be coated on week 21-22

INGAS “18 Months Meeting ”, “GDF-SUEZ Paris, France”, “20-21 May 2010” INGAS INtegrated GAS Powertrain 28 InGas 18 months meeting: SPB2/Ecocat Next –Continue the laboratory scale development for new catalyst materials for an improved reference Pd-based for methane Promoters, stabilizers Ageing examinations Feed back from the partners needed –Own engine tests: activity and durability –Coating development and upscailing for the new materials in WPB2.2 DB2.7 (catalyst sample Gen1) –The first vehicle scale heat exchanger unit coating is inprogress and will be sent for canning on week 22