Quantifying Aerogel Catalyst Usage in Catalytic Converters and Modification of the Union Catalytic Aerogel Testbed

Catalytic converters, otherwise known as Three-Way Catalysts (TWCs), reduce the harmful emissions from gasoline internal combustion engines by converting hydrocarbons (HCs), carbon monoxide (CO), and oxides of nitrogen (NOx) into less harmful gases. A possible path to improve the performance of TWCs, or reduce the amount of expensive and environmentally problematic platinum group metals (PGMs) needed to maintain equivalent performance, is by incorporating aerogels. Aerogels, characterized by low density and high surface area, present promising alternatives in catalytic settings. Their highly porous structure allows for efficient pollutant conversion by facilitating contact between PGMs and the pollutant gases. The Union Catalytic Aerogel Testbed (UCAT), a custom designed system, serves as the research platform to evaluate the performance of TWC catalysts developed at Union. This talk discusses two aspects of the aerogel lab’s recent catalyst development work: (1) Using UCAT to measure the performance of “traditionally processed” (i.e. non-aerogel) rhodium-based catalysts produced in the lab for use as comparators to previously developed and tested aerogel and xerogel rhodium catalysts, and (2) the design and development of an automated valve system to improve the functionality of UCAT itself. Currently, manually operated valves in UCAT pose safety risks and decrease the usability of the UCAT system. A redesigned prototype valve system aims to automate operations increasing ease of use and user safety. UCAT testing on the “traditionally processed” Rh catalyst comparators showed catalytic activity and replicated tests showed consistently repeatable results. The light-off temperature for this catalyst, the temperature at which 50% of the HC, CO, and NOx are converted, is reached at 250°C. A prototype of an automated bypass valve was created with the intention of implementing it into the UCAT system. Testing of the prototype showed promising results for replacing the current bypass valve system.