Advanced Catalyst Substrate Technology Development for Cost Efficient Exhaust Gas Aftertreatment Systems 2009-01-1073
Modern powertrain systems, both diesel and gasoline, have achieved an extremely high level of complexity in order to comply with customer demands on performance, fuel efficiency, comfort, as well as regulatory requirements. This leads to relatively high costs of the complete engine and exhaust gas after-treatment system of a vehicle. Therefore, every component needs to be optimized.
Metallic substrate catalyst components have been developed and manufactured with optimized fluid dynamic and turbulent flow characteristics leading to smaller components, offering equal or better performance compared to conventional straight channel substrates. The smaller, advanced metal substrate components are easier to package, can be installed closer to the engine, weigh less, and can reduce the necessary precious metal content. This helps in conserving natural resources, and enables original equipment manufacturer to meet their technical targets at lower costs.
This paper describes the successful development of several unique, specific metal substrate technologies utilizing intensive internal research and development to support the original equipment manufacturers in developing highest efficiency and cost effective emission reduction systems. Further, the application of these technologies is described, which results in associated levels of cost reduction and improved performance of several exhaust after-treatment components. In detail, the results of a new advanced diesel oxidation catalyst substrate design which has been applied to and tested on a current US medium duty truck application are presented.