The Catalytic Challenges of Implementing a Euro VI Heavy Duty Emissions Control System for a Dedicated Lean Operating Natural Gas Engine

Natural gas as a fuel for heavy duty applications has advantages in terms of lower CO2 and PM compared to Diesel applications. This makes operating heavy duty applications on natural gas attractive. However, in terms of aftertreatment, the challenge becomes one of controlling methane emissions over a range of vehicle operating conditions. Methane light off occurs>400 degrees C and requires highly loaded precious metal catalysts (Raj in Johnson Matthey Technol Rev 60:228-235, 2016). This temperature is manageable in stoichiometric applications. However, for lean operating applications, the exhaust temperature can be below this posing a significant challenge for CH4 control. When operating lean the NOx emissions also become a challenge hence the requirement for a dedicated NOx control system. As part of the EU funded HD GAS project, an aftertreatment system was developed to meet the challenges of both NOx and CH4 control for a lean operating natural gas heavy duty engine. Fundamental studies were performed by the academic partners focusing on CH4 and NOx control, with the implementation and calibration on the engine performed by the industrial partners. This paper will discuss the steps taken from fundamental catalyst characterisation and catalyst specification to full size catalyst implementation onto a newly developed natural gas engine in order to meet Euro VI emissions legislation.