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Research Project Information




Research Project Summary Information



NOX Emissions Catalyst(17723)

AirFlow Catalyst Systems, Inc.

Background

AirFlow Catalyst Systems, Inc. is developing new types of catalyzed diesel particulate filters (CDPFs) and diesel oxidation catalysts (DOCs), devices that reduce harmful tailpipe emissions from diesel engines. CDPFs and DOCs employ substrates coated with precious metals (e.g., platinum) that act as catalysts, promoting chemical reactions. The primary role of a CDPF is to capture particulate matter (PM) in the exhaust gas and to cause the trapped PM to combust, reducing the amount of PM exiting the tailpipe and enabling the CDPF to regenerate itself, i.e., continuously operate without becoming plugged. The primary role of the DOC is to oxidize any unburned hydrocarbons and carbon monoxide in the exhaust, converting them to water vapor and carbon dioxide. Working together the CDPF and DOC eliminate all the major pollution constituents in the exhaust, except for nitrogen oxides (NOX).

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Project Description

To provide customers with a complete emissions control system, optimized for efficiency, cost and space utilization, AirFlow has been developing a device to eliminate NOX in the exhaust gas. This “DeNOx catalyst” product works on the principle of hydrocarbon-selective catalytic reduction (HC-SCR), and in its initial form, comprises a catalytic coating on a substrate, a housing to hold the substrate and other components, and a system to inject a small amount of fuel into the exhaust gas as it enters the HC-SCR unit. In the presence of the catalytic material the fuel (i.e., hydrocarbons) will react with the nitrogen oxides and convert them into elemental nitrogen and other nonpollutants. Project tasks have included modification of lab equipment, preparation of test samples, and testing to evaluate the performance of test samples.

Benefits

Diesel engines in highway vehicles produce a large portion of the PM and NOX that pollute the atmosphere and harm human health. As compared to alternative emission control hardware, the new integrated system for PM and NOX control is expected to impose a smaller fuel economy penalty at the legally required level of emissions compliance, and to reduce the cost of compliance by requiring smaller amounts of precious-metal catalysts.

Project Results

Through the work in this project AirFlow was able to develop a product, MinNoCatTM, that incorporates multiple innovations, including the HC-SCR concepts above, and that significantly reduces all major emissions constituents. In addition, for non-highway diesel engines, the product can achieve acceptable levels of emissions control without fuel injection.

Contractor

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

Principle Investigator

Henry Gysling

Universities Involved

Rochester Institute of Technology

Technologies

Project Type:

Product Development


Technologies Types:

Transportation
On-Road
Fuel
After-treatment

NYSERDA Contact Information

Joseph Wagner
JRW@nyserda.ny.gov

Program

R&D -Transport & Power Systems

Contract Details

Start Date: 3/30/2010
Project Status: Active
Contract Number: 17723




Last Updated: 2/4/2014 2