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Research Project Information




Research Project Summary Information



Catalyzed Diesel Particulate Filter(ST9390-1)

AirFlow Catalyst Systems, Inc.

Background

AirFlow Catalyst Systems is developing new types of catalyzed diesel particulate filters (CDPFs) and diesel oxidation catalysts (DOCs), devices that reduce harmful emissions from diesel engines. CDPFs and DOCs employ substrates coated with catalytic material that promotes chemical reactions. The primary role of a CDPF is to cause particulate matter (PM) in the exhaust gas to combust, reducing the amount of PM exiting the tailpipe and enabling the CDPF to regenerate itself, i.e., continuously operate without becoming plugged. By eliminating energy intensive means of regeneration (e.g., injection of fuel into the exhaust) and by keeping the CDPF cleaner, the subject technology has the potential to reduce the fuel economy penalty associated with competing technologies. The primary role of the DOC is to promote chemical reactions that convert gaseous pollutants, such as hydrocarbons and carbon monoxide, into less harmful compounds. Relative to other DOCs the new technology has the key advantage of being able to initiate these reactions at relatively low exhaust temperatures, such as at engine start up or when the engine is idling or under low load.

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Project Description

Phase 1 of the project covered laboratory proof-of-concept of the proposed coating and catalyst strategies. Phase 2 focused on building and testing a prototype of the new CDPF. Phase 3 comprised additional prototype development and testing, including work with a customer to install the subject CDPF for tests on a mass-produced diesel engine. Phase 4 encompassed development of detailed production designs for both the CDPF and DOC, and expansion of the product portfolio for the subject technology. Phase 5 comprises commissioning of an upgraded production coating line, development of additional coatings in response to customer requests for specific product features, and securing patents and emissions certifications in support of marketing plans.

Benefits

Compared to the impacts of alternative emissions cleanup hardware, this technology may provide significant reductions in diesel fuel consumption and tailpipe emissions, and lower equipment cost as well.

Project Results

AirFlow was successful in developing commercial versions of its DOC and CDPF, and an integrated DOC-CDPF system as well, and began limited deployment of these products in niche applications. The company also was able to expand the technical capabilities and production capacity at its Pilot Plant in Wayland (NY), such that it can accommodate a growing sales volume and also offer coating services to third parties.

Contractor

AirFlow Catalyst Systems, Inc.
2144 Bri-Hen TL Rd Suite 700
Rochester, NY 14623

Principle Investigator

Stephanie Labarr

Universities Involved

Technologies

Project Type:

Product Development


Technologies Types:

Transportation
On-Road
Vehicles
Med/Heavy Duty

NYSERDA Contact Information

Joseph Wagner
JRW@nyserda.ny.gov

Program

R&D -Transport & Power Systems

Contract Details

Start Date: 1/11/2010
Project Status: Active
Contract Number: ST9390-1




Last Updated: 2/4/2014 2