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The conversion effects of a three-way catalyst are simulated in previous works using single and multiple representative channel approaches with detailed surface kinetic models. In addition, this article introduces global gas phase chemistry to the model. This allows reflecting ongoing reactions due to incomplete combustion products in low temperature regime. The 1D single-channel model representative for the catalyst is used here. Next to the comparison of the catalyst outlet emissions with and without gas phase chemistry, the transient temperature increase is simulated in order to model the catalysts light off temperature. Additionally, the transient inlet emissions are enhanced to show the influence of water and hydrogen on the modeling results. The heat transfer is modeled by wall heat losses to provide proper heat dissipation out of the catalyst. The modeling results show a good agreement to the experimental data with low computational cost.
In contrast to the currently primarily used liquid fuels (diesel and gasoline), methane (CH4) as a fuel offers a high potential for a significant reduction of greenhouse gas emissions (GHG). This advantage can only be used if tailpipe CH4 emissions are reduced to a minimum, since the GHG impact of CH4 in the atmosphere is higher than that of carbon dioxide (CO2). Three-way catalysts (TWC - stoichiometric combustion) and methane oxidation catalysts (MOC - lean combustion) can be used for post-engine CH4 oxidation. Both technologies allow for a nearly complete CH4 conversion to CO2 and water at sufficiently high exhaust temperatures (above the light-off temperature of the catalysts). However, CH4 combustion is facing a huge challenge with the planned introduction of Euro VII emissions standard, where stricter CH4 emission limits and a decrease of the cold start starting temperatures are discussed.
The aim of the present study is to develop a reliable kinetic catalyst model for MOC conversion prediction in order to optimize the catalyst design in function of engine operation conditions, by combining the outputs from the predicted transient engine simulations as inputs to the catalyst model. Model development and training has been performed using experimental engine test bench data at stoichiometric conditions as well as engine simulation data and is able to reliably predict the major emissions under a broad range of operating conditions. Cold start (-7°C and +20°C) experiments were performed for a simplified worldwide light vehicle test procedure (WLTP) driving cycle using a prototype gas engine together with a MOC. For the catalyst simulations, a 1-D catalytic converter model was used. The model includes detailed gas and surface chemistry that are computed together with catalyst heat up. In a further step, a virtual transient engine cold start cycle is combined with the MOC model to predict tail-pipe emissions at transient operating conditions. This method allows to perform detailed emission investigations in an early stage of engine prototype development.
In this work, a reliable kinetic reaction mechanism was revised to accurately reproduce the detailed reaction paths of steam reforming of methane over a Ni/Al2O3 catalyst. A steady-state fixed-bed reactor experiment and a 1D reactor catalyst model were utilized for this task. The distinctive feature of this experiment is the possibility to measure the axially resolved temperature profile of the catalyst bed, which makes the reaction kinetics inside the reactor visible. This allows for understanding the actual influence of the reaction kinetics on the system; while pure gas concentration measurements at the catalytic reactor outlet show near-equilibrium conditions, the inhere presented temperature profile shows that it is insufficient to base a reaction mechanism development on close equilibrium data. The new experimental data allow for achieving much higher quality in the modeling efforts. Additionally, by carefully controlling the available active surface via dilution in the experiment, it was possible to slow down the catalyst conversion rate, which helped during the adjustment of the reaction kinetics. To assess the accuracy of the revised mechanism, a monolith experiment from the literature was simulated. The results show that the fitted reaction mechanism was able to accurately predict the experimental outcomes for various inlet mass flows, temperatures, and steam-to-carbon ratios.
In more or less all aspects of life and in all sectors, there is a generalized global demand to reduce greenhouse gas (GHG) emissions, leading to the tightening and expansion of existing emissions regulations. Currently, non-road engines manufacturers are facing updates such as, among others, US Tier 5 (2028), European Stage V (2019/2020), and China Non-Road Stage IV (in phases between 2023 and 2026). For on-road applications, updates of Euro VII (2025), China VI (2021), and California Low NOx Program (2024) are planned. These new laws demand significant reductions in nitrogen oxides (NOx) and particulate matter (PM) emissions from heavy-duty vehicles. When equipped with an appropriate exhaust aftertreatment system, natural gas engines are a promising technology to meet the new emission standards. Gas engines require an appropriate aftertreatment technology to mitigate additional GHG releases as natural gas engines have challenges with methane (CH4) emissions that have 28 times more global warming potential compared to CO2. Under stoichiometric conditions a three-way catalytic converter (TWC - stoichiometric combustion) can be used to effectively reduce emissions of harmful pollutants such as nitrogen oxides and carbon monoxide (CO) as well as GHG like methane. The aim of the present study is to understand the performance of the catalytic converter in function of the engine operation and coolant temperature in order to optimize the catalyst operating conditions. Different cooling temperatures are chosen as the initial device temperature highly affects the level of warm up emissions such that low coolant temperatures entail high emissions. In order to investigate the catalyst performance, experimental and virtual transient engine emissions are coupled with a TWC model to predict tail-pipe emissions at transient operating conditions. Engine experiments are conducted at two initial engine coolant temperatures (10°C and 25°C) to study the effects on the Non-Road Transient Cycle (NRTC) emissions. Engine simulations of combustion and emissions with acceptable accuracy and with low computational effort are developed using the Stochastic Reactor Model (SRM). Catalyst simulations are performed using a 1D catalytic converter model including detailed gas and surface chemistry. The initial section covers essential aspects including the engine setup, definition of the engine test cycle, and the TWC properties and setup. Subsequently, the study introduces the transient SI-SRM, 1D catalyst model, and kinetic model for the TWC. The TWC model is used for the validation of a NRTC at different coolant temperatures (10°C and 25°C) during engine start. Moving forward, the next section includes the coupling of the TWC model with measured engine emissions. Finally, a virtual engine parameter variation has been performed and coupled with TWC simulations to investigate the performance of the engine beyond the experimental campaign. Various engine operating conditions (lambda variation for this paper) are virtually investigated, and the performance of the engine can be extrapolated. The presented virtual development approach allows comprehensive emission evaluations during the initial stages of engine prototype development
Accurate and computational cost-effective modeling tools for the optimization of processes and devices of all kinds are needed in nearly all scientific fields. While experimental optimization entails high expenses in terms of cost and time virtual optimization may be a promising alternative. In this work, the suitability and accuracy of a 1D heterogeneous catalytic model is investigated. First, the influence of cell discretization and residence time on the convergence in a 1D catalyst model are investigated. Second, the catalyst model is investigated and validated with use of a stoichiometric steady state three-way catalyst experiment. With the help of these investigations the reaction mechanism is further developed and new reaction rates for two reactions are presented. The modeling results are compared to a 2D simulation approach in terms of computational time and catalyst conversion behavior. The presented model is capable to capture the experimental results with a drastically reduced computational time in comparison to the 2D simulation presented in literature.
The importance of catalytic after-treatment for automotive emissions is not neglectable concerning current environmental protection discussions. A reasonable and time efficient catalyst model can help to reduce the necessity of time consuming experimental investigations on physical parameters for catalytic converter construction. It can further support the preparation of necessary experimental setups to analyze physical and chemical phenomena in catalysts. Physical parameter and/or chemical kinetic optimizers can be an advanced tool to support computational models in terms of adjustment to an experiment. In this work a physical parameter optimizer is developed and validated against a transient three-way catalyst experiment. The modeling results are compared to the measured data in terms of temperature and emission conversion behavior and show a good agreement.
The importance to reduce automotive exhaust gas emissions is constantly increasing. Not only the country-specific laws are getting more stringent also the global increase of automobiles is requiring a responsible handling of the issue. The three-way-catalytic converter (TWC) is one of the most common catalysts for the engine exhaust gas after treatment. The reduction of CO, NO and unburned hydrocarbons is fulfilled via oxidation of carbon monoxide and hydrocarbons, and reduction of nitrogen oxides.
These conversion effects were simulated in previous works using single channel approaches [e.g. Fröjd/Mauss, SAE International 2011-01-1306] and detailed kinetic models [e.g Chatterjee et al., Faraday Discussions 119 (2001) 371-384 and Koop et al., Appl. Catal.B: Environmental 91 (2009), 47-58]. In this work multiple representative catalyst channels are used to take heat variations in between the catalyst into account. Each channel is split into a user given number of cells and each cell is treated like a perfectly stirred reactor (PSR). The simulation is validated against an experimental four-stroke engine setup with emission outputs fed into a TWC.
Next to the emissions the transient temperature increase is simulated in order to model the catalyst light off temperature. The heat transfer is modelled by wall heat losses to provide a proper heat dissipation out of the catalyst. The simulation results show a good agreement to the experimental data with low computational cost.