1. Effects of Oil Derived Poisons on Catalyst Performance and Emission Test Considerations Presented to; GF-5 Engine Oil Emissions Systems Compatibility Task Group By Douglas Ball 28 February 2006

2. GF-5 Engine Oil Emissions Systems Compatibility Task Group 2 Content  FTP Emissions of a well calibrated vehicle. –Emission Standards and Catalyst Efficiencies  Effects of Thermal and Engine Oil Poison Degradation on FTP Emissions.  Emission Test Considerations to sort catalyst friendly engine oils.

3. GF-5 Engine Oil Emissions Systems Compatibility Task Group 3 FTP Emissions of a well calibrated vehicle. Observations  Majority of emissions are during cold start when not all of the catalyst is hot. –Improvements in cold start calibration is an enabler to achieve stricter emission standards.  Well calibrated engine has very little NOx emissions after light-off. –NOx emissions are a function of calibration!  Catalysts are very efficient.

4. GF-5 Engine Oil Emissions Systems Compatibility Task Group 4 The Effects of Thermal and Engine Oil Poison Degradation on FTP Emissions Combination of Three Studies  Phosphorus Distribution of Vehicle Aged Catalysts  Development of Rapid Aging Test (RAT sm ) Schedules w/Poisons –RAT sm w/Poisons Feasibility Study  The Effects of Oil Derived Poisons, Thermal Degradation and Catalyst Volume on FTP Emissions.

5. GF-5 Engine Oil Emissions Systems Compatibility Task Group 5 Phosphorus Distribution of Vehicle and RAT sm Aged Catalysts  P Distribution of Catalyst from Nine US Passenger Cars –Catalyst sliced into 25mm segments  Similar Distribution between Vehicle Aged and RAT sm w/Poison Catalysts  P Distribution of RAT sm without Poisons Aged Catalyst not Representative of Vehicle Aged Catalysts

6. GF-5 Engine Oil Emissions Systems Compatibility Task Group 6 Phosphorus Distribution of Vehicle and RAT sm Aged Catalysts  Relationship between Mileage and P found on Vehicle Aged Catalysts.  Weak Relationship –Different Vehicles –No Records of oil Consumption  On Average Could Assume –80,000 km - 1.0% P –160,000 km - 2.0% P

7. GF-5 Engine Oil Emissions Systems Compatibility Task Group 7 RAT sm Schedules w/Poisons Feasibility Study  Three RAT sm Schedules  Three Different Aging Engines  Three Different Oil Acceleration Rates.  27 - 2.8L Pt/Rh Converters  Analyzed for P after Aging RAT sm Schedules

8. GF-5 Engine Oil Emissions Systems Compatibility Task Group 8 RAT sm Schedules w/Poisons Feasibility Study Results  Strong Relationship Between P found on the catalyst and Oil consumption.  P deposition is not a function of RAT schedule temperature.  10 Liters of Equivalent Oil Consumption Equal to 1% P  From Earlier Figure 80,000 km Vehicle Aged Converter 1% P  Could Estimate that the average Oil Consumption of the Vehicles are 8,000 km / Liter (5,000 mile/quart)

9. GF-5 Engine Oil Emissions Systems Compatibility Task Group 9 The Effects of Thermal and Engine Oil Poison Degradation on FTP Emissions Scope  Experimental Parameter # of Levels Levels RAT sm Temp.3 660, 740, 820 Accel. Poisons2 Yes, No Catalyst Vol (L)3 0.52, 1.52, 2.79 Catalyst Tech.2 Pt/Rh, Pd  Catalyst Loadings –Pt/Rh 1.1 g/l @ 10/1 –Pd 5.28 g/l  2.3L Auto-Driver FTP Dyno Stand –Two Modal Benches –Engine-Outs HC 1.94 (g/mile) CO 9.14 NOx 2.69 69 cmEmission Tap

10. GF-5 Engine Oil Emissions Systems Compatibility Task Group 10 The Effects of Thermal and Engine Oil Poison Degradation on FTP Emissions Equivalent Oil Consumption of the Aged Converters (Liters) Pt/Rh ConvertersPd Converters Catalyst Volume (liters) Catalyst Volume (liters) 0.52 1.52 & 2.790.52 1.52 & 2.79 RAT Sch. 660 w/o P0.53L0.32L<0.25L<0.25L 660 w/ P27.424.425.824.5 740 w/o P1.141.160.950.98 740 w/ P18.916.916.615.6 820 w/o P0.951.851.321.59 820 w/P23.524.625.725.1

11. GF-5 Engine Oil Emissions Systems Compatibility Task Group 11 The Effects of Thermal and Engine Oil Poison Degradation on FTP Emissions Pt/Rh Catalysts Pd Catalysts

12. GF-5 Engine Oil Emissions Systems Compatibility Task Group 12 The Effects of Thermal and Engine Oil Poison Degradation on FTP Emissions Pt/Rh Catalysts Pd Catalysts

13. GF-5 Engine Oil Emissions Systems Compatibility Task Group 13 The Effects of Thermal and Engine Oil Poison Degradation on FTP Emissions Pt/Rh Catalysts Pd Catalysts

14. GF-5 Engine Oil Emissions Systems Compatibility Task Group 14 The Effects of Thermal and Engine Oil Poison Degradation on FTP Emissions Phase 1 HC Emissions of the Pd Catalysts  Not a Strong Function of Catalyst Volume –Not all of the Catalyst is active during Phase 1 –Poisons affect the performance of the smallest converters.  RAT-820 Degrades the Performance of the Largest Converters

15. GF-5 Engine Oil Emissions Systems Compatibility Task Group 15 The Effects of Thermal and Engine Oil Poison Degradation on FTP Emissions Phase 2 HC Emissions of the Pd Catalysts  A Strong Function of Catalyst Volume  Largest Converters are Not Significantly Affected by Poisons  Smallest Converters are Affected by Aging Temperature and Poisons

16. GF-5 Engine Oil Emissions Systems Compatibility Task Group 16 The Effects of Thermal and Engine Oil Poison Degradation on FTP Emissions Summary Observation of the Obvious  1) Increasing catalyst volume improves FTP emissions.  2) Reducing aging temperature improves FTP emissions.  3) A Pd catalyst technology with higher precious metals loadings performed better than a traditional Pt/Rh catalyst technology.

17. GF-5 Engine Oil Emissions Systems Compatibility Task Group 17 The Effects of Thermal and Engine Oil Poison Degradation on FTP Emissions Summary (cont.) Observation of the Not Always Obvious  4) In general reducing engine oil consumption decreases catalyst poisoning and improves HC, CO and NOx FTP emissions.  5) HC emissions appear to be more sensitive to oil poisons than CO and NOx emissions.  6) With respect to the HC emissions of the Pd converters –The oil derived poisons appear to only affect the performance of the 0.52L converters during Phase 1. –During Phase 2, the oil derived poisons had a significant impact on the performance of the 1.52 and 0.52L converters.

18. GF-5 Engine Oil Emissions Systems Compatibility Task Group 18 The Effects of Thermal and Engine Oil Poison Degradation on FTP Emissions Summary (cont.) Observation of the Not Always Obvious  7) The effects of oil derived poisons on FTP emissions appear to be a function of catalyst volume.  8) The effects of aging temperature on FTP emissions appears to be independent of catalyst volume. Both the Pt/Rh and Pd converter exhibited this effect.  9) A more active catalyst at high catalyst volumes will reduce the effects of oil poisoning and thermal degradation on FTP emissions.

19. GF-5 Engine Oil Emissions Systems Compatibility Task Group 19 Emission Test Considerations  Aging Engine –Consistent oil consumption –Age to an oil consumption (5-10 quarts?) –Minimize exhaust system surface area.  Catalyst –Current close-coupled catalyst technologies have excellent high temperature durability. –Evaluate a small volume of catalyst.  Aging Schedule –Aging Schedule 600 o C < X < 700 o C »Not an engine durability cycle »Minimize thermal degradation »Minimize S and carbon poisoning  Preconditioning (if needed) –Expose catalyst to 650 o C at stoichiometry for 1 hour to minimize S and C poisoning.

20. GF-5 Engine Oil Emissions Systems Compatibility Task Group 20 Emission Test Considerations (cont.)  Performance Testing –NOx Emissions - Do not worry about. Calibration sensitive. Higher variability. Requires a more complicated performance test. eg. A/F sweep test. Perturbation Control. –CO Emissions – Measure of thermal degradation. Can compare to HC emissions. –Concentrate on HC Emissions. »HC performance is most susceptible to P poisons. »Hot fids do an excellent job of measuring HC emissions »HC performance is not strong function of A/F ratio –Lean Light-Off Test (My favorite) »Measure HC and CO performance as a cold catalyst is exposed to hot lean exhaust.  HC light-off will lag CO light-off. Higher the degree of poisoning the greater the difference between HC and CO light-off (time or temperature.) –A/F Sweep Test »Measures HC, CO and NOx efficiency as the A/F is swept form lean to rich.  Get NOx efficiency! More variable. More complicated.

21. GF-5 Engine Oil Emissions Systems Compatibility Task Group 21 Example of Lean Light-off Test. Performance Metrics?  Temp at 50% Eff.  Temp. at 80% Eff.  % Eff. @ End of test. (eg. % Eff. @ 450 o C.)  Perform performance test sensitivity study to determine best metric.

22. GF-5 Engine Oil Emissions Systems Compatibility Task Group 22 Example of A/F Sweep Test Performance Metrics?  % Eff @ Stoich.  % Eff. 0.1 A/F Lean  % Eff. 0.1 A/F Rich  CO-NOx Xover Eff.  Perform performance test sensitivity study to determine best metric.

23. End of Presentation