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Modern filter systems allow a significant reduction of diesel particulate emissions. The new silicon bonded silicon carbide particulate filters (Si-SiC filters) play an important role in this application, because they provide flexibility in terms of mean pore size and porosity and also have a high thermal shock capability to meet both engineering targets and emission limits for 2005 and beyond. Particulate filters are exposed to high temperatures and a harsh chemical environment in the exhaust gas of diesel vehicles. This paper will present further durability evaluation results of the new Si bonded SiC particulate filters which have been collected in engine bench tests and vehicle durability runs. The Si-SiC filters passed both 100 and 200 regeneration cycles under severe ageing conditions and without any problems. The used filters were subjected to a variety of analytical tests. The back pressure and ash distribution were determined. The filter material was also analysed.

The LEV II and EURO V legislation in 2007/2008 require a high conversion level for nitrogen oxides to meet the emission levels for diesel SUVs and trucks. Therefore, U.S. and European truck manufacturers are considering the introduction of urea SCR systems no later than model year 2005. The current SCR catalysts are based mainly on systems derived from stationary power plant applications. Therefore, improved washcoat based monolith catalysts were developed using standard types of formulations. These catalysts achieved high conversion levels similar to extruded systems in passenger car and truck test cycles. However, to meet further tightening of standards, a new class of catalysts was developed. These advanced type of catalytic coatings proved to be equivalent or even better than standard washcoat formulations. Results will be shown from ESC, MVEG and US-FTP 75 tests to illustrate the progress in catalyst design for urea SCR.

This paper will discuss a number of different matters relating to the regeneration of catalyst coated diesel particulate filters such as: impact of the catalyst on the soot ignition temperature, soot combustion rate and NO2 generation. If catalytic coatings prove to be sufficient compared to certain fuel additives they could be used in second generation diesel particulate aftertreatment systems. Examples will be shown on how catalytic diesel particulate filters (“DPF”) can operate on a common rail passenger car diesel engine. Furthermore, an outlook is given on the future combination of particulate - and NOx - emission control for diesel passenger cars.

This paper describes the function and application of the preoxidation, hydrolysis and SCR catalysts individually and as a combined system for urea SCR both in model gas and engine bench tests. Using the basic system and a non-optimized urea injection strategy 45% NOx conversion was achieved in the ESC engine test. Adding a preoxidation catalyst significantly improved the NOx conversion in the low temperature region of the engine mapping. NOx conversions over 75% can be achieved in the ESC test using this improved system. With a 50% reduced SCR catalyst volume still a NOx conversion of over 65% could be achieved. Tests after 200 hours engine aging show that the activity of the system is stable.

The exhaust emissions of two stroke vehicles like motorbikes and scooters contribute to the pollution in urban areas of developing countries in South East Asia and India to a major extent. But also in Japan and selected European countries exhaust gas limitations become effective from 10/1998 and 06/1999 for these vehicles. To control this emissions catalytic aftertreatment by Hot Tubes® and/or monolith type catalysts are applied. Due to the constant rich operation of the two-stroke engines, common design criteria for three-way catalysts fail. Extremely high exhaust gas hydrocarbon concentrations lead to high exotherms during oxidation which increases the exhaust gas temperature to a range between 800 and 900 °C. Furthermore the lack of oxygen limits the CO and HC oxidation under certain engine operation conditions. Therefore, water-gas shift and steam reforming reactions play an important part in catalytic aftertreatment of two-stroke exhausts.

New catalysts with HC (hydrocarbon) storage ability to improve NOx conversion and to minimize fuel penalty over the US Heavy Duty Transient cycle were developed. Without secondary fuel addition, simultaneous reduction of 13% NOx and about 30% particulate was achieved by storing HC from the engine during low temperature portions of the transient cycle and releasing and using the stored HC for NOx conversion at higher temperatures. With only 1% secondary fuel addition, NOx reduction can be increased to 25%, and the particulate conversion remained relatively constant at about 20%. More than 30% NOx reduction can be obtained with 3% fuel penalty. All the pollutants (NOx, PM, HC and CO) were reduced with 0-1 % secondary fuel addition.

The exhaust emissions from stoichiometric gas engines contain CO, Hydrocarbons and NOx besides CO2 and H2O. The Hydrocarbon emissions consist mostly of unburnt methane. Conventional Pt and Rh based three-way catalysts show a good performance for the conversion of CO and NOx at stoichiometric exhaust gas composition, but methane passes almost unconverted through the catalytic converter. At rich exhaust gas composition (Lambda = 0.995) higher conversion rates are achieved for methane, but the efficiency is still not satisfactory for instationary applications. Therefore specific catalyst formulations based on Pd were developed. Model gas reactor and first engine evaluation results are presented. The model gas data indicate that with Pd/Rh catalysts both a wider lambda window and a methane conversion of more than 90% can be achieved. Furthermore catalysts for lean burn applications were investigated.

Future emission standards for passenger cars are mainly aiming at a stringent reduction of their hydrocarbon (HC) emissions. A key factor to meet these requirements for passenger cars with otto engines and closed-loop three-way catalyst is the improvement of the cold-start behavior of the aftertreatment device. Amongst other concepts HC-adsorber systems have been proposed to cope with this problem. In the present paper, results of a fundamental research program on these molecular sieve adsorber systems are discussed. Model gas reactor experiments were used to select raw materials for hydrocarbon-adsorption capacity. The materials of choice were used either alone or in combination with state-of-the-art three-way catalysts; the performance of these systems was evaluated on two different vehicles according to the FTP 75 cycle. To get quantitative information about the nature of the stored HC, all investigations were supported by a detailed gas chromatographic HC-analysis.

The second stage of the PROCONVE emission legislation, which is effective since model year 1992, was met by various of the Brazilian carmakers through the application of open loop three-way catalysts. As a result of intensive test and development programs, different open loop three-way catalyst designs were selected for ethanol and gasohol fueled vehicles, so as to reach the required emission reduction performance at optimized costs. For the ethanol fueled vehicles, the new washcoats developed allowed precious metal formulations without rhodium. The durability of these systems is supported by the properties of the fuel, since ethanol is basically free of sulphur and lead. For the gasohol fueled vehicles, a Pd/Rh formulation is applied, along with washcoats which guarantee an emission reduction performance in a broad range of A/F engine operation conditions.