Precision Combustion, Inc. 410 Sackett Point Road, North Haven, CT06473 (203) 287-3700 http://vmw.precision-combustion.com DESCRIPTION OF THE TECHNOLOGY With support from the Environmental Protection Agency's (EPA) Small Business Innovation Research (SBIR) Pro- gram, Precision Combustion, Inc. (PCI) has developed the Microlith® Fast Lightoff Catalytic Converter that of- fers an economical approach to significantly reduce auto- motive combustion emissions and has found numerous additional applications where its unique operational char- acteristics offer reactor design advantage. PCI's Microlith® catalytic converter includes novel substrate geometry, which offers high mass and heat transfer, together with a complementary coating system. The resulting reactor is small and lightweight, and exhibits rapid thermal re- sponse. The improved mass transfer provides high con- version efficiency, allowing substantial reduction in con- verter volume, weight, and the amount of precious metal required. The high heat transfer and lower weight of the substrate provide very rapid thermal response, reaching inlet gas temperatures within 1 second. These attributes make the Microlith® substrate ideal for high-performance catalytic converter applications as well as for various burner and fuel reforming reactors used to create hydro- gen and/or syngas from hydrocarbon fuels. SIGNIFICANCE OF THE TECHNOLOGY Regulations governing automotive emissions in the United States are increasing in number and stringency, and there is a constant need for technological innovation to reduce emissions levels as more vehicles are produced with longer useful lifetime requirements. Current technology for auto emissions control consists primarily of ceramic-based cata- lytic converters in the exhaust system Although these catalytic converters are 95 percent effective once they reach operating temperature (after "lightoff"), they are ineffective during the first 1 to 2 minutes following en- gine startup. As a result, approximately 80 percent of au- tomotive hydrocarbon and carbon monoxide emissions are released during the initial period of a typical drive. Because PCI's Microlith® preconverter helps control these startup emissions when combined with a three-way main converter, it is capable of achieving an 80 percent reduc- tion in emissions of hydrocarbons and carbon monoxide,, and a 50 percent reduction of nitrogen oxide emissions compared to a conventional catalytic converter alone. As a lightoff converter, or preconverter, used in conjunc- tion with a conventional main converter, Microlith® sub- strate technology offers the potential for achieving Ultra Low Emission Vehicle (ULEV) performance using a de- vice one-fourth the volume of conventional advanced technology lightoff converters with much less catalyst used. PCI also has developed a smaller, less expensive lightoff converter that achieves Low Emission Vehicle perfor- mance as a stand-alone unit. The effectiveness and du- rability of the Microlith® catalytic converter have been demonstrated in prototype tests conducted at the Ford Motor Company (successfully demonstrated ULEV emis- sions from an Escort), other major auto manufacturers, and automotive suppliers. Comparative laboratory tests ~ The Microlith® Fast Lightoff Catalytic Converter, when used in conjunction with a conventional automo- tive main converter, is capable of achieving a greater than 80 percent reduction in emissions of hydro- carbons and carbon monoxide, and a 50 percent reduction of nitrogen oxide emissions. + The Microlith® is substantially smaller in volume and weight than conventional converters and requires considerably less precious metal. + The rapid thermal response characteristics as well as the small size and low weight of Microlith® sub- strate versus competing technologies are an important attribute to enable the development of on-board fuel reforming for automotive fuel cells. ~ Microlith®-based decomposition rectors enable the development and use of lower polluting aerospace propulsion. ------- PCI's automotive Microiith® converter and main converter assembled in an integrated can (left). A model of a stand-alone Microiith® automotive preconverter (right). PCI's Microiith® automotive preconverter undergoing a hot vibration test (100 Hz, 28 g, at 950°C for 150 hours). between conventional ceramic monolith and Microiith® sub- strates have shown that with a 20-fold reduction in con- verter volume, the Microiith® substrate delivers equiva- lent mass transfer-limited conversion. The Microiith® catalytic converter also reaches 350°C light off temperatures in less than l/20th the time required for a conventional auto- motive ceramicmonolith. PCI has found multiple uses for the Microiith® substrate. Catavltic converter applications include marine four- stroke engine, natural gas internal combustion engine, and small two-stroke utility engine emissions reduction. Department of Defense applications include use as in- frared signal generators for aerial target drones and for hydrogen peroxide decomposition for various mili- tary and propulsion applications. Participating in the genesis of the hydrogen economy, PCI has found increas- ing interest in Microlith*-based catalytic reactors for use in the various aspects of fuel reforming for fuel cells such as for catalytic partial oxidation, water gas shift, and pref- erential oxidation reactions, as well as for reformer start burners and fuel cell anode gas burners. COMMERCIALIZATION SUCCESS Award of the EPA SBIR contract helped PCI attract sub- stantial industrial investment that has advanced the Mi- croiith® technology along the path of large-scale pro- duction. Because of the value that Microiith®1 substrates have demonstrated as a platform technology, PCI has focused its commercialization efforts on tailoring the tech- nology for specific product application, manufacturing process development, and provision of prototype samples for testing to potential customers and partners. PCI has 13 issued patents on this technology and others pending. PCI already has received investment for spin-off applica- tions (e.g., industrial fume abatement, clean burners, fuel reformers, etc.) from private industry as well as the Na- tional Aeronautics and Space Administration, the U.S. Air Force, the U.S. Army, and the National Science Foun- dation. AWARDS AND COMPANY HISTORY In recognition of its significant achievement in developing the Microiith® Fast Lightoff Catalytic Converter and other innovative en- vironmental technologies, PCI received EPA's prestigious Environmental Technology Inno- ¦*=-- vator Award in March 1998. Later that year, PCI also was selected as a recipient of the Tibbetts Award from the Office of Technology, U.S. Small Business Ad- ministration, in recognition of its unique contributions as a "Small Business Innovation Research Model of Ex- cellence." PCI also was selected by Deloitte & Touche as a member of the Connecticut "Fast Fifty" in recogni- tion of its status as one of the fastest growing technology companies in that state during the years 1998-2001. EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is the feasibility study to determine the validity of the proposed concept and Phase II is the development of the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification (ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental Research, visit http://www.epa.gov/ncer/sbir. ------- |