Introduction to Clean Air

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant
authorities/agencies to perform emissions testing. These are indicative data and do not represent a guarantee that the
tested catalyst or emissions system will pass the relevant emissions legislation.
Outline

• Introduction
• Clean Air (CA) portfolio
• Gasoline exhaust systems
• Diesel exhaust systems
• Engine operation
• Constraints due to normal operation
• Case studies
• Future for CA & ENR

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 2
Introduction

N2O

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 3
Introduction
LDD Emissions Legislation - Europe

IUPR – In Use Performance Ratio

Standard OBD IUPR Year Emissions (g/km) Particulate PN#

started CO THC+NOx NOx

(mg/km) /km

Euro 4 2005 0.50 0.30 0.25 25 -

Euro 5+ 2011 0.50 0.23 0.18 4.5 6x1011

Euro 6a Tax Inc. 0.50 0.17 0.08 4.5 6x1011

Euro 6b Euro 6.1 0.1 2014 0.50 0.17 0.08 4.5 6x1011

Euro 6c Euro 6.2 0.33 2017 0.50 0.17 0.08 4.5 6x1011

Euro7 2020 0.5 0.085 0.08-0.04 4.5 6x1011

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform e
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legisl
Introduction to flow through (FT)
How does CA make catalysts?

Ceramic material

Suppliers: Corning, NGK.

No visibility on supply.

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform e
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legisl
Introduction to filter design
Filter Design

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform e
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legisl
Introduction: WC processing steps

Add the base alumina slurry

PGM salts
organic acid
Continuous stirring

Add organic acid

Add PGM salts

pH adjust

Adjust solids to require wt.%

Add thickener – for rheology control

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation.
7
Introduction: DOC WC processing steps

Add the base alumina slurry

Continuous stirring

Add organic acid

Add PGM salts

pH adjust

Adjust solids to require wt.%

Add thickener – for rheology control

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation.
8
Introduction: Role of organic acid addition
IEP = isoelectric point, the pH
when no net electrical charge is
observed
The main function of an organic acid is to reduce the PGM: Pt(II, IV) 
Pt(0)
Citric acid has long been our principal choice, combining low cost and
increased activity

One or two acid groups bond to the Behaves as a negatively charged

surface, the remaining acid contributes particle, charge is spread over its
a surface negative charge. whole surface

Large decrease in IEP Moderate decrease in IEP

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation.
9
Introduction to Coating
Dosing – AID vs PC Process

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation.
10
Introduction: Cosmetic effects
Acid/Base, type of thickener

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation.
11
Washcoat application in manufacturing.

Showerhead

Headset

Substrate

Pallet

Vacuum Cone

12
Washcoat application

13
Washcoat application

14
Washcoat application

15
Washcoat application

16
Washcoat application

17
Washcoat application

18
Washcoat application

19
Washcoat application

20
Washcoat application

21
Washcoat application

22
Washcoat application

23
 Clean Air Technology organisation

Diesel
Gasoline

Light Duty (LDD) Heavy Duty (HDD)

Three way catalyst Gasoline Particulate Filter
(TWC) (GPF)

F)
CR

rap

C
RF

F
C
CS

DO

CS
R(

DO
C/S

SC

xT

SC
NO
AS

PGM
The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 24
Clean Air Technology organisation

Gasoline

Three way catalyst Gasoline Particulate Filter

(TWC) (GPF)

PGM Pd:Rh

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 25
Clean Air Technology organisation
Gasoline

• TWC Three Way Catalyst: oxidize pollutant from exhaust gases (CO,
HC & NOx).

• GPF – Gasoline Particulates Filter: filter soot emitted from the engine
+ additional conversion functionality – low loading of Pd & Rh.

Reduces NOx:
2 NO + 2 CO → N2 + 2 CO2
Carbon monoxide oxidation:
2 CO + O2 → 2 CO2
Hydrocarbons oxidation:
2 C2H6 + 7 O2 → 4 CO2 + 6 H2O
Filtration (GPF):
& [C] + NO2 → CO2 + NO

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 26
Clean Air Technology organisation

Diesel

Light Duty (LDD) Heavy Duty (HDD)

F)
CR

rap

C
RF

F
C
CS

DO

CS
R(

DO
C/S

SC

xT

SC
NO
AS

PGM (Pt:Pd)

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 27
Clean Air Technology
Diesel – Oxidation

• DOC – Diesel Oxidation Catalyst: designed to convert carbon

monoxide (CO) and hydrocarbons into carbon dioxide (CO2) and
water. Pt & Pd based. Low loadings for HDD slightly higher for LDD.

• CSF – Catalyst Soot Filter : filter soot emitted from the engine +
additional conversion functionality.

CO + ½ O2 = CO2
NO->NO2
[Hydrocarbons] + O2 = CO2 + H2O
& Filtration (CSF).

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 28
Clean Air Technology
Precious Group Metal (PGM)
Individual roles

DOC are composed of PGM metals (Pt,Pd) supported on a base support (typically alumina)

For Passive (low temperature) or Active (moderate to high temperature), the choice of active
metal is critical

Combine the two elements to get best of both characteristics

CONFIDENTIA
L

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions testing. These are indicative data and do not
represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation.
29
High Loaded Front Zone (Impreg) evolution
Process pass removal

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation.
30
HLFZ DOC shows vastly improved HC control
32gft-3 catalysts, 700°C 200h ageing

Volvo work has shown that the HLFZ initiates and maintains the exotherm
Currently this cannot be achieved to the same level of performance with a
highly zoned washcoated system
The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation.
31
Additional reactions with oxidation

This reaction also happens

• 2SO2 + O2  2SO3

And then this one

• SO3 + H2O  H2SO4

Sulphuric acid contributes to the total particulate matter (PM) of the

system, so…

High sulphur fuel, lots of sulphates floating about – can be a serious

issue

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation.
32
Clean Air Technology organisation
Diesel - Reduction

• NOx traps: high loaded in PGM, very complex product. Active at low T.

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 33
NOx Trap formulations
Current designs

WT NSC FT NSC
LT NSC

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 34
Clean Air Technology

Diesel - Reduction

• SCR (with urea): reduce Nitrogen oxides (NOx) into nitrogen and
water. JM manufactures SCR coatings with copper, iron and
vanadium based materials

• SCRF®: NOx/soot conversion/filtering. Warms up more quickly than

an SCR downstream of a CSF (due to its closer proximity to the
engine) enabling earlier NOx conversion. Cu based.

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 35
SCR NOx Reduction - Under Lean Conditions at high T

Urea solution @ 32% Ad Blue H2NCONH2 + H2O --> 2 NH3 + H2O

(NH2)2CO  HNCO + NH3 Pyrolysis at

120C

Hydrolysis at
HNCO + H2O  CO2 + NH3 160C

Minimum temperature for complete ammonia formation ~ 160 °C

Risk of polymerisation products below 180 °C

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform e
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legisl
SCR NOx Reduction - Under Lean Conditions

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform e
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legisl
Which SCR is best for which application?

SCR system properties:

Match the SCR properties with the correct DOC

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation.
38
Clean Air Technology organisation
Diesel – Oxidation again!

• ASC – Ammonia Slip Catalyst (always post SCR): Ammonia entering

the ASC is partially oxidized to NO. The freshly oxidized NO and NH 3
inside the ASC, not yet oxidized, can consequently react to N2
following the usual SCR reaction schemes.

New formulation are PtZ

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 39
Clean Air Technology organisation
Typical diesel exhaust system
NH3 N2

N2
NOx

-CO
-HC
-PM
-NOx
-NH3

HC+CO+NO

NO2+CO2

PM [C]

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 40
Filter Regeneration
Active or Passive

- Temperature raised by injecting

and burning fuel over catalyst
- Generate exotherm ~600-630oC

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions 41
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation.
 Clean Air Technology organisation

Diesel
Gasoline

Light Duty (LDD) Heavy Duty (HDD)

Three way catalyst Gasoline Particulate Filter
(TWC) (GPF)

F)
CR

rap

C
RF

F
C
CS

DO

CS
R(

DO
C/S

SC

xT

SC
NO
AS

PGM
The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 42
 Engine Operation
Why have a NOx Storage Catalyst
Gasoline vs Diesel engine operation
Pollutant conversion as a function of lambda

Diesel Operation
Diesel Operation

Rich Operation Stoichiometric Lean Operation Rich Operation Stoichiometric Lean Operation

Gasoline engine operates at around • In lean conditions (λ > 1.000): CO/HC

stoichiometric mixture with 0.997 < λ < oxidation
1.002:
• CO and HC oxidation • In rich conditions (λ < 1.000): NOx reduction
• NOx reduction
The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 43
Case study OM 654/ 656 engine: Euro6d and beyond
System design and operation strategy considerations
urea

NSC
SCR
SCRF® ASC

The Euro6d-full/7 system of choice is:

LNT+a-SCRF+SCR (optional) WT & FT-LNT Window

FT-LNT Extension
Window Extension

• The LNT handles low-temperature NOx

• From key-on/cold-start

• Urban/City NOx

• Via both storage and/or conversion

• The SCRF+SCR handles high-temperature NOx

• Motorway and rural driving

• Coverts all the NOx once it reaches ideal operating

temperatures
*SCR(F) windows dependent on system layout

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 44
 System Roadmaps and trends
NSC/LNT systems are in demand for the current and future legislation

Euro 6 b/c Euro 6d temp – RDE CF 2.1 Euro 6d final - RDE CF 1.5
Decreasing

LNT CSF LNT CSF

Decreasing Decreasing
DO SCR SCR DO SCR
CSF DOC CSF CSF
C ASC ASC C ASC

Decreasing
DO SCR SCR
SCR CSF LNT CSF LNT CSF
C ASC ASC

DO SCR SCR SCR

SCRF LNT SCRF LNT SCRF
C ASC ASC ASC

DO SCR
DCSC SCRF
C ASC

SCR ASC optional

SCR slice pre

SCR
or post SCRF
as an option

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 45
Case study with BMW: SCRF Improves NOx Conversion by Thermal Efficiency

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform e
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legisl
Clean Air Technology organisation

Formulation Code
Au:Pt:Pd:Rh

Part number –
random number

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 47
Clean Air Technology future strategy

• Metallic substrates

• Powder coating

• Switch to win gasoline businesses

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 48
Clean Air Sales 2017/2018 by sub-business

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 49
LDV Europe: tighter legislation adds value per vehicle

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 50
LDV China: tighter legislation doubles sales value
per vehicle

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 51
Global growth in vehicle production

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 52
HDD: tighter legislation triples sales value per
vehicle in China and India.

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 53
Global growth in vehicle production

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 54
Improvements in SRP

The data included herein were collected in a Johnson Matthey laboratory which has not been certified by the relevant authorities/agencies to perform emissions
testing. These are indicative data and do not represent a guarantee that the tested catalyst or emissions system will pass the relevant emissions legislation. 55
 EMEA CA Waste Washcoat Holding Forecast

1400 25 • Shipping licence – expected 1st wk Oct. No shipments in Sep. Apply for
next licence in Oct.
Re- £22m Skopje • Expect increase in Apr 2020 due to Brimsdown stock take shutdown.
• Need to actively manage generation.
gion
1200
20

1000 1022

Inventory Value (£m)

• MasterMelt (MRS) – increase capacity from average 45/month to
minimum 50/month. Need visibility on MRS shutdowns.
£14m 15 Royston • Site – Need to assign accountable individuals to manage this
Skopje
800 project/Wiped Film Evaporator (WFE) operation and drive IBC generation
reduction – crucial to meet target.
IBC Count

600 606 624

£9m 10

• Gauteng Refineries (GR) - to continue to accept 42 IBCs monthly in Q3

400 408 • Site - Generation to be sustained at no more than 20 IBCs/month.
396 Germiston
Roy- 291 • Germiston is looking for on-site processing to replace GR, to include into

ston 5
246
budget next year.

Germiston
200 208
125 142
20 20
0 0
9 9 9 9 9 0 0 0 0
r -1 n-1 g-1 t-1 c -1 b-2 r -2 n-2 g-2 Gliwice
• Need visibility of expected ramp up volumes for Gliwice and drop in
c volumes for other sites.
Ap Ju Au O D
e Fe Ap Ju Au

56
• In-house:
Flocculant Wet cake

Washcoat
feed

Centrifuge Boildown Effluent

(£50,000) 20
2208 MT 1800 MT tankers (Al)

• Axolot without dilution:

Flocculant Wet cake

Washcoat
feed -70 tankers
(£180,000)
Electrocoagulation Ion exchange Effluent
-280
tankers
1800 MT (£720,000)
2208 MT 7,200 MT diluted diluted

57
Thank you

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