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“Ceryx means Clean Air” The QuadCAT Four-Way Catalytic Converter An Integrated Emission Control System for Diesel Engines presented to the: February 3,

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Presentation on theme: "“Ceryx means Clean Air” The QuadCAT Four-Way Catalytic Converter An Integrated Emission Control System for Diesel Engines presented to the: February 3,"— Presentation transcript:

1 “Ceryx means Clean Air” The QuadCAT Four-Way Catalytic Converter An Integrated Emission Control System for Diesel Engines presented to the: February 3, 2000

2 “Ceryx means Clean Air” Ceryx Vision Systems that balance Cost, Performance, Emissions Reduction, and Fuel Penalty to make the economics of pollution control viable

3 “Ceryx means Clean Air” Emission Standards U.S. and Europe COPMNOx grams per brake horsepower hour 2004 U.S. Federal (2002) 15.5 (0%) 0.1 (0%) 2.0 (50%) ULEV (Clean Fleet Program) HC 0.5 (62%)* Euro IV (2005) 0.4 (69%) 1.1 (93%) 0.015 (85%) 2.6 (35%) N/A 7.1 (46%) 0.05 (50%) 2.8 (30%) *Percent reduction in relation to baseline 1998 Baseline 1.315.50.14.0

4 “Ceryx means Clean Air” Emission Standards: Japan HCNOxPM grams per kilometer (mean) CO Passenger Cars <1265 kg (1997) <1265 kg (1997) <1265 kg (2002) <1265 kg (2002) 2.100.400.400.08 0.630.120.280.052 Commercial Vehicles 2,500-12,000 kg (1997/98) 2,500-12,000 kg (1997/98) >12,000 kg (2004) >12,000 kg (2004) 7.402.904.500.25 2.220.873.380.18

5 “Ceryx means Clean Air” QuadCAT Flow Schematic  Integrate heat transfer and chemistry for simultaneous reduction of NOx, CO, HC, & PM LNC (NOx reduction) DPF (CO, HC, and PM oxidation) Dirty Exhaust In Clean Air Out Gain Heat Lose Heat Recuperator Supplementary HC Injection

6 “Ceryx means Clean Air” Temperature Profile Over 8-Mode Heavy-Duty Cycle Exhaust Flow, (SCFM) 0100200300400500600700800 Exhaust Temperature, (°C) 0 100 200 300 400 500 600 Optimal Temperature Range for DPF Regeneration and LNC Performance note: Bubble area is proportional to the magnitude of the mode point weighting factor

7 “Ceryx means Clean Air” Chemical Reactor Platform  Recycle heat from exothermic reactions  Increase catalyst temperature  Effectiveness defined as:  = (T 1 - T in )/(T 2 - T in ) Distance (x) Temperature Transfer Heat Exothermic Heat Release Across Catalyst Total Temperature Rise T in T1T1 T out T2T2 Preheat

8 “Ceryx means Clean Air” Experimental Data with Light-Duty Prototype on 200 Hp Engine Catalyst In Flow Path Temperature, (deg C) 300 350 400 450 500 550 600 650 System In System Out Catalyst Out

9 “Ceryx means Clean Air” Integration Makes Full Use of Resources Reducing agent for NOx catalyst HC + NOx + O 2  CO 2 + H 2 O + N 2 Energy source for DPF regeneration HC + O 2  Heat HC + O 2  Heat Injecting supplementary HC provides:

10 “Ceryx means Clean Air” Diesel Particulate Filters  Very high filtration efficiency (>90%)  Variety of configurations  Regeneration requires elevated temperatures to oxidize PM:  550°C-650°C Uncatalyzed  380°C-450°C Catalyzed  200°C-400°C with fuel borne additives such as cerium or platinum

11 “Ceryx means Clean Air” Lean NOx Catalysts  Many formulations with various temperature windows  Best reductions at elevated temperatures  Low-cost, non- precious metal based catalyst are durable and sulfur tolerant  Could benefit from QuadCAT recuperative approach

12 “Ceryx means Clean Air” Lean NOx Catalyst Mechanism

13 “Ceryx means Clean Air” Ceryx Offers Multiple Configurations in a Single Platform Product  LeanCAT™ (Lean NOx Catalyst +DOC)  QuadCAT™ (Lean NOx Catalyst + DPF)  QuinCAT™ (NOx Trap + DPF) HC>90%>90%>90%CO>90%>90%>90%PM>30%>90%>90%NOx30-50%30-50%>90%

14 “Ceryx means Clean Air” QuadCAT Prototype Testing

15 “Ceryx means Clean Air” Results: NOx Reduction Diesel Fuel:NOx Ratio (gm / gm) 02468 NOx Reduction gm/Hp-hr, (%) 0 10 20 30 40 50 NOx Reduction

16 “Ceryx means Clean Air” Results: PM Reduction AVL 8-Mode Points 12345678 Particulate Concentration (mg/m 3 ) 0 5 10 15 20 25 30 QuadCAT in QuadCATout

17 “Ceryx means Clean Air” DPF Regeneration Data

18 “Ceryx means Clean Air” The QuadCAT System

19 “Ceryx means Clean Air” Heat Recovery & Pressure Drop Recuperator and Catalyst

20 “Ceryx means Clean Air” Summary of Testing  ‘Proof of concept’ demonstrated  30-60% heat recovery  Acceptable back-pressure  > 95% reduction of CO and HC  > 80% PM reduction  Up to 45% NOx reduction depending on amount of fuel injected

21 “Ceryx means Clean Air” Summary: The QuadCAT 4-way Catalytic Converter Features  Elevate catalyst temperature by recycling heat  Noise abatement (replaces muffler/silencer) Elements  Recuperator  Simultaneous oxidation & reduction with controlled HC injection  Rich cycling and high temperature cycling to reverse sulfur poisoning  Regenerate DPF on demand, OR  Optimize for NOx reduction  Lean NOx Catalyst  DPF/DOC  Filter and oxidize PM  Oxidize CO and HC  DOC is non-precious metal based  Fuel Injection and Control System  Reduce NOx with HC as a reductant  Non-precious metal based

22 “Ceryx means Clean Air” Light-Duty QuadCAT Converter  A QuadCAT Converter field unit installed on a Ceryx test vehicle


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