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New technologies, incorporating the platinum group metals, are available to meet the exhaust
emission regulations for cars, light-duty and heavy-duty vehicles and motorcycles being
adopted by the European Unionfor implementationduring the new century. These technologies
include low light-offcatalysts, more themlly-durable catalysts, impmved substrate technology,
hydrocarbon adsorbers, electrically heated catalysts, DeNOx catalysts and adsorbers, selective
catalytic reduction and diesel particulate filters. This large range of technologies will allow
exhaust emissions from all engines, both on- and non-road, to be lowered to unprecedented
levels. This paper examines the state of emission control technologies currently available
for all types of engine.
Catalyst-equipped cars were fist introduced in challenge is to abate the remaining pollutants emit-
the U.S.A. in 1974 (1) but only appeared on ted while enabhg use of fuel-efficient engine
European roads in 1985. Indeed, it was not until technologies. This is paramount for achieving
1993 that the European Union (ELI) set new car good air quality and the targets for greenhouse gas
emission standards that effectively mandated the reductions given the large increase in the number
installation of emission control catalysts on gaso- of vehicles on European roads, the projections for
he-fuelled cars. Worldwide, now more than 275 further increases in vehicle numbers and the
million of the world's 500 million cars and over 85 greater distances driven each year.
per cent of all new cars produced are equipped
with autocatalysts. Emissionsfmm On-Road Vehickr
In the EU directives are being adopted to leg- The EU emission limits for passenger cars that
islate the maximum exhaust emissions permitted came into effect from 1993 were lowered in 1996
from a wide range of vehicles and equipment pow- and again in 2000. For passenger cars (Tables I and
ered by the internal combustion engine. Exhaust Il)and hght commercial vehicles the emission
emission catalyst technology is increasingly being standards have been agreed for 2000 and 2005 (3).
fitted on heavy-duty vehicles, buses, motorcycles Lght commercial vehicle limit values are adjusted
and on non-road engines and vehicles. The 13 to compensate for the &her vehicle weights.
candidate countries currently negotiating entry to Heavy-duty diesel (HDD) vehicles have new
the EU (includingPoland, Hungary and the Czech test cycles and tougher emission standards
Republic) d, as a result of adopang the limit val- finalised for 2000 and 2005. The limit values for
ues of the EU, increase the application of the enhanced environmentally friendly vehicles
technologies developed to control emissions in (EEVs) are set to serve as a basis for fiscal incen-
the EU. tives by EU Member States. The 2005 (Euro W)
emission standards set limit values for carbon
European Union Exhaust Emission monoxide (CO) (1.5 g/kWh), hydrocarbons (HCs)
and Fuel Legislation (0.46 g/kWh) and nitrogen oxides (NOx) (3.5
The final report of the European Auto Oil II g/kWh) and also PM limit values intended to force
programme (2) concluded that some ait quality the use of particulate traps/diesel particulate filters
problems, such as atmospheric levels of particulate (DPFs). The PM limits are 0.02 g/kWh on the
matter (PM) and ozone, are not yet solved. The steady state cycle (ESC) and 0.03 g/kWh on the
' Limit values corrected to current EU test cycle with no 4 0 second idle at start of test
transient cycle (ETC). The new limit values are a being ratified by the European Parliament and
30 per cent reduction in CO, HC and NOx and an Council. Tighter emission limits from 2003 for
80 per cent reduction in PM from Euro III limit new types of motorcycles are agreed and corre-
values of October 2000. spond to a reduction of 60 per cent for HCs and
In 2008 (Euro V), the NOx limit of 2.0 g/kWh CO for four-stroke motorcycles, and 70 per cent
reflects the need for DeNOx or Selective Catalytic for HCs and 30 per cent for CO for two-stroke
Reduction (SCR) catalysts. The limit is subject to a motorcycles. A second stage with new mandatory
European Commission study, which will report by emission limits for 2006 is proposed, to be based
the end of 2002, on technical progress of the on the new worldwide motorcycle emission test
required emission control technologies (4). cycle 0, which is also being developed by
The Working Party on Pollution and Energy the UNECE in Geneva.
(GRPE), an expert group of the World Forum for
Harmonization of Vehicle Regulations’ (WP.29) at Emissionsfrom Engines Used in Nan-RoadApplications
the United Nations Economic Commission for The process of bringing emission limit values
Europe (UNECE) in Geneva, is developing a and fuel quality in non-road applications in line
worldwide heavy-duty certification procedure with those of on-road vehicles has begun.
(WHDC) and is l o ow at new measurement pro- Technology adopted and proven in on-road appli-
tocols in order to ensure that ultra h e particles are cations will in time be transferred to non-road
controlled by hture emission legislation to mir- applications. The first European legislation to reg-
imise the health effects of diesel patticle emissions. ulate emissions from non-road mobile equipment
Another current action is a proposal by the is being implemented in two stages (5):
European Commission to set tougher, catalyst- Stage I implemented in 1999
requiring emission limits for motorcycles. This is Stage I1 implemented from 2001 to 2004,
Table II
Diesel Car Limit Values, g/km
Limit vulues corrected to currenr EU test cycle with no 40 second idle at starr oftest
Values.for Direct Injection Diesels
Stage II
130-560 kW 3.5 1 .o 6.0 0.2
75-1 30 kW 5.0 1 .o 6.0 0.3
37-75 kW 5.0 1.3 7.0 0.4
18-37 kW 5.5 1.5 8.0 0.8
dependmg on the engine power output. emission limits for small spark-ignition engines
The equipment covered indudes mobile con- below 19 kW used in lawn mowers, chain saws,
struction machinery, forklift trucks, road bush cutters, trimmers and snow removal equip-
maintenance equipment, ground support equip- ment. The proposal, which is now being
ment in airports, aedal lifts and mobile cranes. considered by the European Parliament and
Agricultural and forestry tractors have the same Council, has been developed in cooperation with
emission standards but with different implementa- the US. Environmental Protection Agency in a
tion dates (6). Engines used in ships, railway move toward worldwide harmonisation.
locomotives, aircraft, and generating sets, not yet The proposal indudes two stages of limit val-
covered by the directive, are being considered by a ues: the first to be met 18 months after the
Commission working group and will be included directive comes into force and the second one
in the future. between 2004 and 2010 dependmg on the catego-
Stages I and I1 are based on a steady-state 8- ry of the engine. The second stage will lower
mode test procedure, and emission limit values are emissions from handheld engines by about 80 to
shown in Table 111. 85 per cent.
Values for the Stage 111limits using a new tran- Gasoline and diesel engines installed in recre-
sient test procedure (NRTC) are under discussion ational crafts and personal watercrafts are already
in a European Commission working group. The subject to some emission and noise requirements
intention is to develop global solutions and to and limits (8). The European Commission pro-
develop the legislation in dose cooperation with posed amendmentsin October 2000 to the current
the U.S.A. and Japan, using the global agreement directive, fuaher reducing the exhaust pollutants.
under UNECE in Geneva as the basis for legisla-
tion. Fuels
A European Commission Task Force has been The mandatory standards for fuel sulfur levels
set up to improve the fuel quality for non-road for on-road fuels were set in 1998 (9). However
applications. Reducing sulfur content in non-road after a full technical study the European
fuels in line with those being introduced in the Commission adopted a proposal in May 2001 to
road sector would allow engine makers to use the require the introduction of sulfur-free (< 10 ppm)
advanced emission control technologies of cata- gasoline and diesel by each EU Member State
lysts and traps to reduce gaseous and particulate from 1 January 2005. Under the proposal, still to
emissions. A Commission proposal was issued be ratified, gasoline and diesel fuel with ‘a sulfur
at the end of 2000 (7) and established the first content’ would be banned from the EU market
Fast Lgbt-off Catahsts three-way operation and indicate the 'health' of the
The catalytic converter has to work soon after catalytic converter for onboard diagnostic (OBD)
the engine is switched on, and to achieve this the systems. Figure 2 shows the progress made with
exhaust temperature at which it starts to function mixed cerium and zirconium oxides (14).
needs reducing so that untreated exhaust emitted
at the start of the legislated emissions test and on Substrate Technology
short journeys in the real world is minimised. Great progress has been made in the technolo-
Reductions in the thermal capacity of substrates gy of the substrates on which the active catalyst is
and improvements to the type and composition of supported. In 1974 ceramic substrates based on
the active pgm catalyst have reduced light-off cordierite (2Mg0.W203.5SiO$ had a density of
times from as long as one to two minutes down to 200 cells per square inch (cpsi) of cross-section (31
less than 20 seconds (12). In Figure 1, the effect of cells cm-7 and a wall thickness of 0.012 inch or 12
different catalyst compositions as they affect the mil (0.305 mm). By the end of the 1970s the cell
light-off temperature are shown. density had increased through 300 to 400 cpsi and
The introduction of a new generation of Pt/Rh wall thickness had been reduced by 50 per cent to
technologies for current and future emission star- 6 mil. Now 400,600,900 and 1200 cpsi substrates
dards is a technically and commercially amactive are available and wall thickness can be reduced to
alternative to Pd-based technologies for high 2 mil - almost 0.05 mm (15-19). Further increas-
demanding applications in close-coupled and es in cell density and reductions in wall thickness
underfloor positions using different cold start are in development.
strategies (13). Substrates derived from ultra thin foils of cor-
rosion-resistant steels came onto the market in the
More Thermally Durable Catalysts late 1970s. In the beginning the foils were made
Increased stability of the catalytic converter at from material 0.05 mm thick, allowing high cell
high temperature allows it to be mounted closer to densities to be achieved and complex internal
the engine and increases its life, particularly during structures could be developed. Today, wall thick-
demanding driving. Catalysts with stabilised pgm ness is down to 0.025 mm and cell densities of 800,
crystallites and washcoat materials which maintain 1000 and 1200 cpsi substrates are available (20,21).
high surface area at temperatures around 1000°C Progress in ceramic and metal substrate tech-
are necessary. The surface area of the washcoat is nology has given major benefits. A larger catalyst
stabilised by improved oxygen storage compo- surface area can be incorporated into a given con-
nents that also maximise the air-fuel 'window' for verter volume and this allows better conversion
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