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The use of Pd together with Pt/Rh in automotive emission control catalytic converters is discussed. The drawbacks and advantages of Pd are explained for the conversion of CO, HC and NOx. The performance of high loaded Pd-only catalysts is demonstrated in vehicle tests according to the FTP75, ECE and Japan-10-mode procedures. It is shown that the advantageous lean HC-light-off temperature observed with high loaded Pd-only catalyst can also be reached with similar loaded Pt-only catalysts. Various alternative ways to incorporate Pd in multi-brick converters are evaluated in vehicle tests. It is shown that single brick three metal converters with high Pd-content can have advantages over conventional Pt/Rh-three way catalysts. However, the extent of the improvement depends strongly upon the particular application, and with the present trend of increasing Pd-prices these three metal converters might lead to increased precious metal costs over conventional Pt/Rh-catalysts.

Stringent standards for the emission of particulate matter by heavy duty diesel engines will come into effect in the nineties in the US and are anticipated to come into effect in the same period in W-Europe and in Japan. This has lead most of the manufacturers to intensify the evaluation of exhaust aftertreatment devices. Although particulate filtering systems proved to be valuable in limited fleet applications, the general introduction did not take place because of complicated and limited durability regeneration. Flow-through catalysts which were introduced for passenger cars in 1989 drew a lot of attention for potential heavy duty diesel applications. In this paper the major parameters affecting the performance of these flow-through catalysts and the particularities related to heavy duty diesel application are outlined. The parameters deal with the fuel sulfur content, the test cycles applied, the catalyst formulation and washcoat composition.

This paper reports first results of research and development work to achieve Nox reduction under lean diesel exhaust gas conditions by using a special coated, zeolite based monolith catalyst. Much attention is paid to the optimization of the activated zeolite system and the influence of group Ib and VIII elements of the periodic system. A major part of the paper deals with the influence of hydrocarbons, carbon monoxide, sulfur dioxide and water on the activity of the catalyst. Another aspect discussed is the influence of the residence time of the exhaust gas components. The thermal stability and the influence of poisoning elements on the catalyst performance is demonstrated by model gas reactor tests on oven and engine aged samples. Finally, first results on the performance of the catalyst system in a vehicle dynometer test are given.

Future emission standards for passenger cars are mainly aiming at a stringent reduction of their hydrocarbon (HC) emissions. A key factor to meet these requirements for passenger cars with otto engines and closed-loop three-way catalyst is the improvement of the cold-start behavior of the aftertreatment device. Amongst other concepts HC-adsorber systems have been proposed to cope with this problem. In the present paper, results of a fundamental research program on these molecular sieve adsorber systems are discussed. Model gas reactor experiments were used to select raw materials for hydrocarbon-adsorption capacity. The materials of choice were used either alone or in combination with state-of-the-art three-way catalysts; the performance of these systems was evaluated on two different vehicles according to the FTP 75 cycle. To get quantitative information about the nature of the stored HC, all investigations were supported by a detailed gas chromatographic HC-analysis.

An overview is given on the state of the art of a new catalytic exhaust gas aftertreatment device for diesel engines. The function of a precious metal based, flow-through type diesel oxidation catalyst is explained. Much attention is paid to the durability of the diesel oxidation catalyst and especially to the influence of poisoning elements on the catalytic activity. Detailed data on the interaction of poisoning elements such as sulfur, zinc and phosphorus with the catalytic active sites are given. Finally it is demonstrated that it is possible to meet the stringent emission standards for diesel passenger cars in Europe with a new catalyst generation over 80.000 km AMA aging.

The reduction of precious metal usage especially the rhodium content for three-way catalysts application due to limited resources and high precious metal prices seems to be favoured worldwide. Various platinum-rhodium and palladium-rhodium catalysts with different precious metal loadings and increasing ratios as well as catalysts containing no rhodium, i.e. only platinum-palladium were evaluated. Engine dynamometer sweep data and vehicle tests (US FTP 75) indicated that several catalyst formulations exhibit three-way catalyst performance even after high temperature engine aging and severe laboratory oven air treatment. Thus, the application of three-way catalysts with improved alumina washcoat technology and reduced loadings of rhodium and platinum seems to be possible.

The performance of two catalyst preparations, styled base and base/noble, were determined employing a simulated mining vehicle loading cycle. Such cycles are characterized by sufficiently high exhaust temperatures to cause auto-regeneration of the filter units when these catalyst preparations are employed. Such loading is exhibited in raining service by some moderate and most high production load-haul-dump vehicles plus some haulage trucks. These preparations were shown to be capable of depressing the nominal, ‘untreated’ steady-state minimum soot ignition temperature of approximately 500°C (932°F), to a range varying from 395°C to 424°C (743°F to 797°F). Results of gaseous constituent analyses, particulate determinations, polynuclear aromatic hydrocarbon sampling, catalytic sulphur conversion (SO2 to H2SO4) and Ames testing are presented for the two catalyst preparations studied.