Fast Lightoff Catalytic Converter for Reduced Combustion Emissions
SBIR Success Stories
Precision Combustion, Inc.
410 Sackett Point Road
North Haven, CT 06473
Telephone: 203-287-3700
http://www.precision - combustion, com
Environmental Problem
Mobile sources such as cars, trucks, and buses are
the primary contributors to air pollution and are a
major source of carbon dioxide (CO-,)-. Automotive
catalytic converters efficiently consume unburned hy-
drocarbons, carbon monoxide, and nitrogen oxides
(NOx), substantially cutting engine emissions, but
take time after engine start to heat up enough to
work. Before Precision Combustion Inc.'s (PCI) re-
search and development, approximately 80% of re-
maining automotive emissions occurred during the
startup period, before the main converter would heat
up enough to become effective and "lightoff." This
delay is common to all catalytic reactors.
SBIR Technology Solution
With support from EPA's Small Business Innovation
Research (SBIR) Program, PCI developed the Mi-
crolith® fast lightoff converter technology for auto-
motive applications, demonstrating fast lightoff
operation (including ultra low emission in an Escort
tested by Ford in 1993) among other features, and
making a pioneering contribution to industry auto-
motive fast lightoff technology. PCI's Microlith®
catalysts use wire mesh-type substrates, specialized
coatings, and unique reactor designs to achieve
quick lightoff though very high rates of heat and
mass transfer to and from a short contact time cat-
alytic surface. The resulting reactor is small and
lightweight, and begins to lightoff within a few sec-
onds. The improved mass transfer provides high
conversion efficiency, allowing substantial reduction
in converter volume, weight, and the amount of
precious metal required. The close coupling of cata-
lyst surface and inlet gas temperatures improves per-
formance while lengthening catalyst life.
Fast lightoff technology is now incorporated to vary-
ing degrees in most American automobiles and
other catalytic converter solutions, resulting in signif-
icant reduction in NOx, hydrocarbon, and CO
emissions. The project also led to multiple follow-on
breakthroughs and spinoff applications.
Commercialization Information
Following initial Phase I and II support from the
EPA's SBIR Program for fast lightoff catalytic convert-
ers, PCI received $3.5 million in Phase III support
from additional sources, including a direct EPA
Phase III award for $300,000 and funding from four
automotive engine manufacturers and two automo-
tive exhaust system manufacturers.
The technology also spun off to multiple follow-on
applications now comprising most of PCI's annual
revenues. PCI currently has 13 issued patents on the
technology, with others pending. The first spinoff
application was for specialty compact clean and effi-
cient burners, including for anode gas burners for
fuel cells and for infrared generators, producing
some $2.4 million in further development and an
ongoing sales and license revenue business.
The company was awarded a National Science
Foundation (NSF) SBIR Phase II grant for work on a
compact natural gas burner (with $2 million more to
date in Phase III revenues), and two Army SBIR
Phase II grants, for compact Jet Propellant 8 (JP8)
burners for Stirling engines (2007) (also with $2 mil-
lion to date in Phase III revenues) and for a cleaner
and more efficient military cookstove (2010).
(g)
Microlith Reactor prototypes and hot vibration
operation

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The technology also has been adapted successfully
for use by liquid fuel reforming technology for fuel
cells and other applications. PCI's Microlith® fuel-
flexible fuel processor is ultra-compact, fast lightoff,
highly efficient, and able to operate even with sul-
fur-containing J P8. For fuel cells, this offers fueling
with conventional fuels, without needing a hydro-
gen infrastructure. PCI has received four additional
SBIR Phase II grants for this work, with $12 million
to date in Phase III revenues.
Company History and Awards
Founded in 1986, PCI develops advanced catalytic
reactors and systems for energy sector applications,
including clean and efficient combustion, fuel re-
forming, air cleaning, and chemicals manufacture.
Partners include major industrial companies and
the U.S government. The company has received
multiple awards for its technology development, in-
cluding the EPA's Environmental Technology Inno-
vator Award in 1998, two Tibbetts awards for SBIR
excellence, two Dawnbreaker Profiles in Success
awards for commercialization achievement, two
Army SBIR Achievement Awards, and eight SBIR
success stories. PCI has 37 employees, working
together to make the world a better place.
SBIR Impact
Catalytic reactors with clean and efficient combustion are needed to miti-
gate emission of air pollutants and C02.
PCI developed a Microlith® catalytic reactor that enables ultra-compact,
high efficiency catalytic reactor solutions for a variety of clean energy appli-
cations.
EPA's SBIR Program provided early support to what is now an expanding
set of green energy solutions affecting multiple industries.
Including follow-on applications, PCI's revenues from technologies
developed with Phase III grant support exceed $20 million to date.
SBIR Success Stories

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