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A new adsorber system for reducing cold start HC emissions has been developed that offers a passive and simplified alternative to previous HC adsorber technologies. The series flow in-line adsorber concept combines existing catalyst technology with a zeolite based HC adsorber by simply incorporating one additional adsorber catalyst substrate into conventional catalytic converters without any valving, purging lines or special substrates. The HC adsorber catalyst consist of a durable zeolite, a washcoat binder, precious group metals and rare earth promoters on standard monolithic substrates. For selected vehicle applications, a single converter containing a light off catalyst, a catalyzed HC adsorber and a standard three-way catalyst can be used in the underfloor position. Even after severe engine aging, the vehicle FTP results show that this new technology remains effective in reducing the cold start HC emissions while providing good CO and NOx conversions.

The understanding of deactivation mechanisms is critical to the development of NOx adsorber catalysts with improved durability. The thermal deactivation of a state-of-the-art Pt/Rh based NOx adsorber catalyst is evaluated following oven agings at 800 and 900°C. Sulfur poisoning during lean/rich cycling is studied as a function of catalyst inlet temperature and SO2 concentration. Complementing these studies utilizing synthetic exhaust gas compositions, deactivation resulting from three different engine aging schedules is examined. The performance of engine-aged catalysts is evaluated as received, and following desulfurization procedures differing in inlet temperature and air/fuel ratio. The impact of aging schedules on NOx adsorption and three-way catalyst function is discussed with respect to precious metal dispersion, washcoat sintering, as well as sulfur build-up and oil-derived poisonings.

A new single-brick Ba + alkali metals NOx-Trap catalyst has been developed to replace a two-brick NOx-Trap system containing a downstream three-way catalyst. Major development efforts include: 1) platinum group metals selection for higher HC oxidation with potassium-containing washcoat, 2) alumina and ceria selection, and Rh architecture design for more efficient NOx reduction and 3) NiO to suppress H2S odor. Mitsubishi Motors' 1.8L GDI™ with this Delphi new NOx-Trap catalyst with H2S control achieves J-LEV standard with less cost and lower backpressure compared to the previous model. It is further discovered that incorporation of NiO into the NOx-Trap washcoat is effective for H2S control during sulfur purge but has a negative impact on thermal durability and sulfur resistance. Further study to improve this trade-off has been made and preliminary results of an advanced washcoat design are presented in this paper. Details will be reported in a future publication.

Close-coupled or manifold catalysts have been extensively employed to reduce emissions during cold start by achieving quick catalyst light-off. These catalysts must have good thermal durability, high intrinsic light-off activity and high HC/CO/NOx conversions at high temperature and flow conditions. A number of studies have been dedicated to engine control, manifold design and converter optimization to reduce cold start emissions. The current paper focuses on the effect of catalyst design parameters and their performance response to different engine operating conditions. Key design parameters such as catalyst formulation (CeO2 vs. non CeO2), precious metal loading and composition (Pd vs. Pd/Rh), washcoat loading, catalyst thermal mass, substrate properties and key application (in use) parameters such as catalyst aging, exhaust A/F ratio, A/F ratio modulation, exhaust temperature, temperature rise rate and exhaust flow rate were studied on engine dynamometers in a systematic manner.

Dual-brick catalyst systems containing Pd-only catalysts followed by Pt/Rh three-way catalysts (TWCs) provide an effective strategy for managing Pt, Pd and Rh precious metal inventories while achieving LEV/ULEV emission standards. Engine aged dual-brick converters containing front Pd catalysts followed by rear Pd/Rh or Pt/Rh TWCs demonstrated LEV emission levels in an underfloor location on a TLEV calibrated 3.8L vehicle, and achieved ULEV emissions with air addition. Using identical advanced washcoat formulations stabilized with ceria-zirconia promoters, single-brick Pt/Rh TWCs demonstrated equivalent performance to Pd/Rh TWCs after thermally severe aging, and dual-brick [Pd + Pt/Rh] systems also had equivalent performance to [Pd + Pd/Rh] catalyst systems. While a Pd-only system also achieved 100K mi equivalent LEV emissions, both dual-brick options lowered emissions further using substantially lower loadings and more balanced precious metal usage.