Axial characterization of catalytic activity in close-coupled lightoff and underfloor catalytic converters

Abstract A exhaust system consisting of a close-coupled Pd technology 32 in 3 lightoff converter and Pt/Rh technology 170 in 3 underfloor converter was vehicle-aged for 56000 miles on a vehicle equipped with a 3.8 l engine. Following this aging, the converters were taken off the vehicle and cut into 1″ thick sections along their axis and characterized for lightoff and warmed-up activity using a laboratory reactor to simulate vehicle exhaust. Each section was also analyzed for the quantity of oil additive poisons (phosphorus and zinc) deposited. Following this initial characterization, the phosphorus and zinc deposits were removed, and the sections were characterized again for lightoff and warmed-up activity. This procedure was used to qualitatively determine the relative contribution of oil additive poisoning and thermal sintering to the total activity deterioration as a function of axial position in the catalyst monoliths. Analysis of the lightoff converter as taken from the vehicle showed a dramatic axial gradient in the lean and stoichiometric lightoff and warmed-up (600°C) performance for HC, CO and NO x , with most of the deterioration having taken place in the forward-most 1″ section of the converter, which was consistent with the gradient in the deposition of phosphorus (P) and zinc (Zn) in this converter. Comparison of these data sets with those obtained after removal of the P and Zn poisons indicates that most of the total deterioration of lean HC and CO activity can be attributed to P and Zn poisoning of the forwardmost 1″ section. When tested under stoichiometric conditions, most of the deterioration of HC activity is attributable to P and Zn poisoning, while most of the deterioration of CO and NO x activity is attributable to thermal deterioration. A similar activity and poison deposition gradient was detected in the underfloor converter, but to a smaller extent.