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The effect of various fuel-cut agings, on a Volvo Cars 4-cylinder gasoline engine, with bimetallic three-way catalysts (TWCs) was examined. Deactivation during retardation fuel-cut (low load) and acceleration fuel-cut (high load, e.g. gearshift or traction control) was compared to aging at λ=1. Three-way catalysts were aged on an engine bench comparing two fuel-cut strategies and their impact on of the life and performance of the catalysts. In greater detail, the catalytic activity, stability and selectivity were studied. Furthermore, the catalysts were thoroughly analyzed using light-off and oxygen storage capacity measurements. The emission conversion as a function of various lambda values and loads was also determined. Fresh and 40-hour aged samples showed that the acceleration fuel-cut was the strategy that had the highest contribution towards the total deactivation of the catalyst system.

In order to achieve ultra low emission levels with three-way catalysts, an early accurate air/fuel ratio control is essential. Positioning the oxygen sensor in the first part of the substrate helps to protect the oxygen sensor from being splashed by water during cold start, so that early heating and activation becomes a less limiting factor. For emission control purpose, a position of a rear sensor in the warm part of the catalyst gives improved possibilities for oxygen buffer control during catalyst warming up conditions. This enhances balancing HC and NOx in an early phase. In addition, for OBD reasons it is possible to locate the sensor in any axial position in the catalyst, which improves design possibilities for cold start detection, even for single brick catalyst systems. The paper describes the construction of the catalyst with an integrated oxygen sensor.

Methane and nitric oxide conversion was studied over a Pd-based catalyst at steady state conditions. The gas mixture contained methane (0.125 %), Nitric oxide (0.125 %), carbon monoxide (0.7 %), oxygen and argon as carrier gas. The experiments were performed in a well-stirred reactor (Berty reactor) which provided constant gas composition over the catalyst. Lambda scans from λ=1.01 to 0.99 and back performed by varying the oxygen content, revealed a hysteresis in both the methane conversion and the nitric oxide conversion. The temperature and presence of nitric oxide affected the hysteresis. Complementary experiments in a synthetic exhaust gas rig revealed a more pronounced hysteresis in the presence of carbon dioxide and water. An attempt to model the hysteresis effect as a function of the palladium and palladium-oxide transformations was made.

Recently Volvo Car Corporation introduced the new PremAir® catalyst system from Engelhard Corporation on their S80 luxury sedan and the new V70 estate wagon. In this paper, performance results of this catalyst system after long-term mileage accumulation will be presented. Urban taxi vehicles were used to test the catalyst over 110,000 miles. The rate of deactivation in long-term catalyst performance was found to be dependent on the radiator design, and was least for the radiator design with the highest total geometric surface area. Subsequently, a new catalyst version was developed in order to minimize the deactivation rate. This new catalyst has been evaluated under similar taxi driving conditions over 80,000 miles, and has shown improved durability performance.

A system for stratifying recycled exhaust gas (EGR) to substantially increase dilution tolerance has been applied to a multi-cylinder port injected four-valve gasoline engine. This system, dubbed Combustion Control through Vortex Stratification (CCVS), has shown greatly improved fuel consumption at stoichiometric conditions whilst retaining ULEV compatible engine-out NOx and HC emission levels. A production feasible variable air motion system has also been assessed which enables stratification at part load with no loss of performance or refinement at full load.

The formation of Nitrous Oxide (N2O) over an aged three way catalyst was analysed in a laboratory reactor for a variety of simulated Otto engine exhaust gas conditions. Nitrous Oxide formation was further analysed during FTP75 dynamometer test with a car. The car was equipped with either an aged catalyst or a fresh one. A fast response diode laser system was modified to enable detection of Nitrous Oxide and Carbon Monoxide simultaneously. From laboratory data the kinetics of Nitrous Oxide formation were evaluated with mathematical simulations and a mechanism was suggested. The results were compared to data from vehicle tests and the results were discussed in the light of the laboratory study. Two general trends were confirmed, i) N2O formation increases at slightly lean conditions: ii) catalysts with a low degree of deterioration gave lower N2O emissions, iii) the extent of N2O formation goes though a maximum with respect to dissociation rate of NO.

Five field-aged catalysts with different mileages were analysed with respect to emission performance and structural changes. The FTP-75 emission results were compared to synthetic exhaust gas tests including: i) light-off, ii) lambda screening at stationary and oscillating stoichiometry, iii) space velocity variation. Several samples from different positions of one catalyst were used to achieve the spatially resolved activity profile for that catalyst. Surface characterisation was used to characterise accumulated catalyst poison. Laboratory space velocity test was concluded to be a sensitive probe for catalyst performance: good correlation to vehicle emission data was found. An analysis of the influence of temperature and λ oscillation on the catalyst conversion performance was made, with particular emphasis on the ageing effects.

Catalysts aged under different on-road conditions were analysed with respect to their conversion of CO and HC at step changes of the synthetic exhaust gas composition. Time resolved diode laser spectroscopy and fast response FID analysis were used to characterise the catalyst response to transient changes of CO and hydrocarbons in the exhaust gas. The oxygen storage capacity was monitored at various conditions; flow rate, catalyst temperature, previous exposure to oxidizing or reducing atmosphere and amplitude of the perturbation. The technique appeared to provide a sensitive probe for analysis of the dynamic oxygen storage capacity of new and aged catalysts at exhaust like conditions. The results correlate well with the transient emission performance during vehicle tests. Further, surface characterization using SEM/EDS and XPS techniques indicated that phosphate formation was the most probable cause of deactivation.