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THE DEVELOPMENT of a novel precious metal catalyst system supported on a metal substrate is outlined. The key nature of the metallic species is demonstrated. A high performance alloy, FECRALLOY STEEL®, is identified as a suitable material. Conversion of this alloy into a durable catalyst using a proprietary pre-treatment to render it compatible with existing catalysts and production procedures is discussed. The flexibility in processing with respect to key design features e.g. cell density, is emphasised. The influence of support variables such as volume, cell density etc., on the performance of an oxidation catalyst is reported together with comparable data for ceramic supported catalyst. It is shown that at zero hours, equivalent performance, at no power loss penalty relative to ceramics, can be secured by judicious choice of cell density/volume combinations. Such equivalence can be achieved with significantly lower volumes and significant scope exists for further optimisation.

In response to the demands for catalysts to meet the emerging autocatalyst market in Europe, Johnson Matthey Catalytic Systems Division (Europe) has designed and commissioned an improved catalyst evaluation facility. The aim of the project was to provide a more efficient means of screening catalyst technology from formulation development stages to pre-production validation, against a wide variety of synthetic mileage accumulation cycles. This paper describes how the extensive use of computer technology interfaced with modern analytical instrumentation has achieved a significant increase in productivity. This includes the ability to carry out evaluations unattended under full computer control.