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Solid and metallic ash particle number (PN) and particulate matter (PM) mass emission measurements were performed on a heavy-duty (HD) on-highway diesel engine and a compressed natural gas (CNG) engine. Measurements were conducted under transient engine operation that included the FTP, WHTC and RMC. Both engines were calibrated to meet CARB ultra low NOX emission target of 0.02 g/hp-hr, a 90% reduction from current emissions limit. The HD diesel engine final exhaust configuration included a number of aftertreatement sub-systems in addition to a selective catalytic reduction filter (SCRF). The stoichiometric CNG engine final configuration included a closed coupled Three Way Catalyst (ccTWC) and an under floor TWC (ufTWC). The aftertreatment systems for both engines were aged for a full useful life (FUL) of 435,000 miles, prior to emissions testing. PM mass emissions from both engines were comparable and well below the US EPA emissions standard.

Small impurities in the fuel can have a significant impact on the emissions control system performance over the lifetime of the vehicle. Of particular interest in recent studies has been the impact of sodium, potassium, and calcium that can be introduced either through fuel constituents, such as biodiesel, or as lubricant additives. In a collaboration between the National Renewable Energy Laboratory and the Oak Ridge National Laboratory, a series of accelerated aging studies have been performed to understand the potential impact of these metals on the emissions control system. This paper explores the effect of the rate of accelerated aging on the capture of fuel-borne metal impurities in the emission control devices and the subsequent impact on performance. Aging was accelerated by doping the fuel with high levels of the metals of interest. Three separate evaluations were performed, each with a different rate of accelerated aging.

Gaseous and particle emissions from a gasoline direct injection (GDI) and a port fuel injection (PFI) vehicle were measured at various ambient temperatures (22°C, -7°C, -18°C). These vehicles were driven over the U.S. Federal Test Procedure 75 (FTP-75) and US06 Supplemental Federal Test Procedure (US06) on Tier 2 certification gasoline (E0) and 10% by volume ethanol (E10). Emissions were analyzed to determine the impact of ambient temperature on exhaust emissions over different driving conditions. Measurements on the GDI vehicle with a gasoline particulate filter (GPF) installed were also made to evaluate the GPF particle filtration efficiency at cold ambient temperatures. The GDI vehicle was found to have better fuel economy than the PFI vehicle at all test conditions. Reduction in ambient temperature increased the fuel consumption for both vehicles, with a much larger impact on the cold-start FTP-75 drive cycle observed than for the hot-start US06 drive cycle.

Original equipment (OE) catalytic converters are designed to last the life of properly tuned and maintained vehicles. Many high mileage vehicles require a replacement converter because the original catalyst was damaged, destroyed, or removed, and the cost of a new OE converter on an older vehicle is difficult to justify. In the U.S., a federal aftermarket converter program has been in place since 1986 (California in 1988) and it has resulted in the replacement of over 50 million converters. Both Federal and California programs have required aftermarket converters to meet minimum performance and durability standards. Increasingly tighter emission standards and durability requirements for new light-duty vehicles have resulted in significant technology improvements in three-way automotive catalysts, however these advancements have not always made their way into aftermarket converters.

Alkali and alkaline earth metal impurities found in diesel fuels are potential poisons for diesel exhaust catalysts. Using an accelerated aging procedure, a set of production exhaust systems from a 2011 Ford F250 equipped with a 6.7L diesel engine have been aged to an equivalent of 150,000 miles of thermal aging and metal exposure. These exhaust systems included a diesel oxidation catalyst (DOC), selective catalytic reduction (SCR) catalyst, and diesel particulate filter (DPF). Four separate exhaust systems were aged, each with a different fuel: ULSD containing no measureable metals, B20 containing sodium, B20 containing potassium and B20 containing calcium. Metals levels were selected to simulate the maximum allowable levels in B100 according to the ASTM D6751 standard. Analysis of the aged catalysts included Federal Test Procedure emissions testing with the systems installed on a Ford F250 pickup, bench flow reactor testing of catalyst cores, and electron probe microanalysis (EPMA).

Gaseous compounds, particle number and size distribution measurements on a gasoline direct injection (GDI) vehicle and a port fuel injection (PFI) vehicle were conducted over the U.S. Federal Test Procedure 75 (FTP-75) and US06 Supplemental Federal Test Procedure (US06) on Tier 2 certification gasoline (E0) and a 10% by volume ethanol (E10). Overall the GDI test vehicle was observed to have lower fuel consumption than the PFI test vehicle by 6% and 3% for the FTP-75 and US06 drive cycles, respectively. When using E10, this GDI vehicle had a better fuel consumption than the PFI vehicle by 7% and 5% for the FTP-75 and US06 drive cycles, respectively. For particle emissions, the solid particle number emission rates for the GDI, equipped with a 3-way catalyst in its original equipment manufacturer configuration (i.e., stock GDI), were 10 and 31 times higher than the PFI vehicle for the FTP-75 and US06 drive cycles, respectively.

It is estimated that operating continuously on a B20 fuel containing the current allowable ASTM specification limits for metal impurities in biodiesel could result in a doubling of ash exposure relative to lube-oil-derived ash. The purpose of this study was to determine if a fuel containing metals at the ASTM limits could cause adverse impacts on the performance and durability of diesel emission control systems. An accelerated durability test method was developed to determine the potential impact of these biodiesel impurities. The test program included engine testing with multiple DPF substrate types as well as DOC and SCR catalysts. The results showed no significant degradation in the thermo-mechanical properties of cordierite, aluminum titanate, or silicon carbide DPFs after exposure to 150,000 mile equivalent biodiesel ash and thermal aging. However, exposure of a cordierite DPF to 435,000 mile equivalent aging resulted in a 69% decrease in the thermal shock resistance parameter.