TY - JOUR
T1 - Advanced Ceramic Substrate with Ordered and Designed Micro-Structure for Applications in Automotive Catalysis
AU - Kingsbury, Benjamin
AU - Stewart, Jonathan
AU - Wu, Zhentao
AU - Douglas, Roy
AU - Li, Kang
PY - 2014/10/13
Y1 - 2014/10/13
N2 - This study describes an innovative monolith structure designed for applications in automotive catalysis using an advanced manufacturing approach developed at Imperial College London. The production process combines extrusion with phase inversion of a ceramic-polymer-solvent mixture in order to design highly ordered substrate micro-structures that offer improvements in performance, including reduced PGM loading, reduced catalyst ageing and reduced backpressure. This study compares the performance of the novel substrate for CO oxidation against commercially available 400 cpsi and 900 cpsi catalysts using gas concentrations and a flow rate equivalent to those experienced by a full catalyst brick when attached to a vehicle. Due to the novel micro-structure, no washcoat was required for the initial testing and 13 g/ft3 of Pd was deposited directly throughout the substrate structure in the absence of a washcoat. Initial results for CO oxidation indicate that the advanced micro-structure leads to enhanced conversion efficiency. Despite an 79% reduction in metal loading and the absence of a washcoat, the novel substrate sample performs well, with a light-off temperature (LOT) only 15°C higher than the commercial 400 cpsi sample. To test the effects of catalyst ageing on light-off temperature, each sample was aged statically at a temperature of 1000°C, based on the Bench Ageing Time (BAT) equation. The novel substrate performed impressively when compared to the commercial samples, with a variation in light-off temperature of only 3% after 80 equivalent hours of ageing, compared to 12% and 25% for the 400 cpsi and 900 cpsi monoliths, respectively.
AB - This study describes an innovative monolith structure designed for applications in automotive catalysis using an advanced manufacturing approach developed at Imperial College London. The production process combines extrusion with phase inversion of a ceramic-polymer-solvent mixture in order to design highly ordered substrate micro-structures that offer improvements in performance, including reduced PGM loading, reduced catalyst ageing and reduced backpressure. This study compares the performance of the novel substrate for CO oxidation against commercially available 400 cpsi and 900 cpsi catalysts using gas concentrations and a flow rate equivalent to those experienced by a full catalyst brick when attached to a vehicle. Due to the novel micro-structure, no washcoat was required for the initial testing and 13 g/ft3 of Pd was deposited directly throughout the substrate structure in the absence of a washcoat. Initial results for CO oxidation indicate that the advanced micro-structure leads to enhanced conversion efficiency. Despite an 79% reduction in metal loading and the absence of a washcoat, the novel substrate sample performs well, with a light-off temperature (LOT) only 15°C higher than the commercial 400 cpsi sample. To test the effects of catalyst ageing on light-off temperature, each sample was aged statically at a temperature of 1000°C, based on the Bench Ageing Time (BAT) equation. The novel substrate performed impressively when compared to the commercial samples, with a variation in light-off temperature of only 3% after 80 equivalent hours of ageing, compared to 12% and 25% for the 400 cpsi and 900 cpsi monoliths, respectively.
UR - http://www.scopus.com/inward/record.url?scp=84938543429&partnerID=8YFLogxK
UR - https://saemobilus.sae.org/content/2014-01-2805/
U2 - 10.4271/2014-01-2805
DO - 10.4271/2014-01-2805
M3 - Conference article
AN - SCOPUS:84938543429
SN - 0148-7191
VL - 2014-October
JO - SAE Technical Papers
JF - SAE Technical Papers
M1 - 2014-01-2805
T2 - SAE 2014 International Powertrains, Fuels and Lubricants Meeting, FFL 2014
Y2 - 20 October 2014 through 22 October 2014
ER -