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Selective Catalytic Reduction (SCR) catalysts have been demonstrated as effective for controlling NOx emissions from diesel engines, maintaining high NOx conversion even after the extended high temperature exposure encountered in systems with active filter regenerations. As future diesel emission regulations are expected to be further reduced, packaging a large volume of SCR catalysts in diesel exhaust systems, along with DOC and particulate filter catalysts, will be challenging. One method to reduce the total volume of catalysts in diesel exhaust systems is to combine the SCR and DPF catalysts by coating SCR catalyst technology on particulate filters. In this work, engine evaluation of SCR coated filters has been conducted to determine the viability of the technology. Steady-state engine evaluations demonstrated that high NOx conversions can be achieved for SCR coated filters after high temperature oven aging.

Catalytic emission control systems are installed on nearly all automobiles and heavy-duty trucks produced today to reduce exhaust emissions for the vehicles to meet government regulations. Current systems can achieve very high efficiencies in reducing tailpipe emissions once the catalytic components reach their operating temperatures. They are, however, relatively ineffective at temperatures below their operating temperature windows, especially during the cold start period of the vehicles. With the increasingly stringent government regulations, reducing the emissions during the cold start period before the catalytic components reach their operating temperatures is becoming a major challenge. For cold start HC control, HC traps based on zeolites have been investigated and commercialized for certain applications. For cold start NOx control, especially in lean burn engine exhaust, NOx storage and release catalysts have been evaluated.

Selective catalytic reduction (SCR) of NOx by NH3 is under intensive development as a technology to enable diesel engines to meet stringent NOx emission regulations. Cu/zeolite SCR catalysts are leading candidates because of their ability to catalyze NOx reduction at the low temperatures encountered on many diesel vehicles. However, both engine evaluation and laboratory studies indicated that commonly available Cu/zeolite SCR catalysts did not have sufficient thermal stability to maintain performance during the full useful life of a vehicle (with steady-state NOx conversion decreasing ~ 10% over 64 hours of hydrothermal aging at 670 °C). Characterization of aged Cu/zeolite catalysts revealed that the loss of zeolite acidity was the main deactivation mechanism; while the zeolite support maintained its framework structure and surface area after aging. Improvement of the hydrothermal stability of the acid sites resulted in a new generation of SCR catalysts.

Within the next decade, all light-duty vehicles in the United States will be required to meet Tier 2 or LEV 2 tailpipe emission standards. As emission standards have tightened over time catalyst systems have increased in cost. The factors that have contributed to the growth in cost include increases in both precious metal content and catalyst volumes. Calibration strategy, catalyst, and substrate technology improvements have also enabled previous emission standards to be met. The recent dramatic fluctuations in precious metal price, coupled with the increasing desire to reduce system cost, have led catalyst companies to develop converter technologies containing decreasing amounts of precious metal, and still meet Tier2/LEV2 standards. In this paper the development of a novel, near base metal, catalyst technology is described. The effects of precious metal support type and catalyst preparation method are reported using model engine bench and vehicle tests.

FTP hydrocarbon emissions were measured on a sport utility vehicle comparing two catalyst systems. One system consisted of a close-coupled three-way catalyst and an underbody catalyst-only version of a hydrocarbon trap catalyst. The other system consisted of the same closed-coupled catalyst and underbody hydrocarbon trap catalysts. Thus, these systems compared a non-hydrocarbon trap system and a hydrocarbon trap catalyst system. Fresh and 50-hour aged testing showed that the hydrocarbon emissions were approximately 10% lower for the hydrocarbon trap catalyst system. When an air pump was used to inject air into the exhaust system, the hydrocarbon emissions of the hydrocarbon trap catalyst system were approximately 20% lower than the non-trap system. Hydrocarbon speciation demonstrated that the magnitude of the benefit of the hydrocarbon trap catalyst system was related to the characterization of the blend of hydrocarbon species in the exhaust after the close-coupled catalysts.

As one method of meeting current and future emission regulations on vehicles, automakers have increased PGM loadings in three-way catalysts. Engine dynamometer and FTP testing after accelerated engine agings were performed to compare current Pd:Rh and Pt:Rh catalysts with new Pd:Rh and Pt:Rh catalysts. This comparison demonstrated that enhanced three way performance can be obtained in the new catalysts with reduced Pd loadings or with the use of Pt:Rh instead of Pd:Rh. These improved catalysts will reduce the demand for high PGM loadings as well as provide flexibility in the PGM combinations used in exhaust systems.