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The QuadCAT Four-Way Catalytic Converter

The QuadCAT Four-Way Catalytic Converter. An Integrated Emission Control System for Diesel Engines presented to the:. February 3, 2000. Emissions Reduction. Cost. Fuel Penalty. Performance. Ceryx Vision.

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The QuadCAT Four-Way Catalytic Converter

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  1. The QuadCAT Four-Way Catalytic Converter An Integrated Emission Control System for Diesel Engines presented to the: February 3, 2000

  2. Emissions Reduction Cost Fuel Penalty Performance Ceryx Vision Systems that balance Cost, Performance, Emissions Reduction,and Fuel Penaltyto make the economics of pollution control viable

  3. HC CO PM NOx grams per brake horsepower hour 1998 Baseline 1.3 15.5 0.1 4.0 2004 U.S. Federal (2002) 0.5(62%)* 15.5(0%) 0.1(0%) 2.0(50%) 0.4(69%) 1.1(93%) 0.015(85%) 2.6(35%) Euro IV (2005) ULEV (Clean Fleet Program) N/A 7.1(46%) 0.05 (50%) 2.8(30%) *Percent reduction in relation to baseline Emission Standards U.S. and Europe

  4. CO HC NOx PM grams per kilometer (mean) Commercial Vehicles 2,500-12,000 kg (1997/98) >12,000 kg (2004) Passenger Cars <1265 kg (1997) <1265 kg (2002) 7.40 2.90 4.50 0.25 2.10 0.40 0.40 0.08 2.22 0.87 3.38 0.18 0.63 0.12 0.28 0.052 Emission Standards:Japan

  5. Supplementary HC Injection Dirty ExhaustIn LNC (NOx reduction) GainHeat DPF (CO, HC, andPM oxidation) LoseHeat Clean AirOut Recuperator QuadCAT Flow Schematic • Integrate heat transfer and chemistry for simultaneous reduction of NOx, CO, HC, & PM

  6. 600 Optimal Temperature Range for DPF Regeneration and LNC Performance 500 400 300 Exhaust Temperature, (°C) 200 100 note: Bubble area is proportional to the magnitude of the mode point weighting factor 0 0 100 200 300 400 500 600 700 800 Exhaust Flow, (SCFM) Temperature Profile Over 8-Mode Heavy-Duty Cycle

  7. Recycle heat from exothermic reactions Increase catalyst temperature Effectiveness defined as:  = (T1 - Tin)/(T2 - Tin) T2 Exothermic HeatRelease AcrossCatalyst Total Temperature Rise Tout Temperature TransferHeat T1 Preheat Tin Distance(x) Chemical Reactor Platform

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

  9. Injecting supplementary HC provides: Energy source for DPF regeneration HC + O2 Heat Reducing agent for NOx catalyst HC + NOx + O2 CO2 + H2O + N2 Integration Makes Full Use of Resources

  10. 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. 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. Lean NOx Catalyst Mechanism

  13. HC >90% >90% >90% CO >90% >90% >90% PM >30% >90% >90% NOx 30-50% 30-50% >90% Ceryx Offers Multiple Configurations in a Single Platform Product • LeanCAT™ (Lean NOx Catalyst +DOC) • QuadCAT™ (Lean NOx Catalyst + DPF) • QuinCAT™ (NOx Trap + DPF)

  14. QuadCAT Prototype Testing

  15. 50 NOx Reduction 40 30 NOx Reduction gm/Hp-hr, (%) 20 10 0 0 2 4 6 8 Diesel Fuel:NOx Ratio (gm / gm) Results: NOx Reduction

  16. QuadCAT in QuadCATout 30 25 20 15 Particulate Concentration (mg/m3) 10 5 0 1 2 3 4 5 6 7 8 AVL 8-Mode Points Results: PM Reduction

  17. DPF Regeneration Data

  18. The QuadCAT System

  19. Heat Recovery & Pressure DropRecuperator and Catalyst

  20. 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. Features Elevate catalyst temperature by recycling heat Noise abatement (replaces muffler/silencer) Elements Recuperator Summary: The QuadCAT 4-way Catalytic Converter • Fuel Injection and Control System • 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 • Reduce NOx with HC as a reductant • Non-precious metal based • DPF/DOC • Filter and oxidize PM • Oxidize CO and HC • DOC is non-precious metal based

  22. Light-Duty QuadCAT Converter • A QuadCAT Converter field unit installed on a Ceryx test vehicle

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