NOx Monitoring From Mobile Sources Ceramatec, Inc. 2425 South 900 West West Valley, UT 84119-1517 (801) 972-2455 http://wmv.ceramatec.com/ EmiSense Technologies, LLC. 4205 West 1980 South Salt Lake City, UT 84104 (949) 502-8440 http://mvw.emisense.com Environmental Problem Nitrogen oxides (NOx), which are among the primary pollutants emitted from vehicle exhaust, cause signifi- cant environmental and human health issues. Ad- verse respiratory effects associated with NOx include airway inflammation in healthy people and increased respiratory symptoms in individuals with asthma. NOx exposure concentrations in vehicles and near roadways are appreciably higher than in other loca- tions and are of particular concern for susceptible in- dividuals, including children and the elderly. Monitoring the NOx concentration in exhaust streams is critical for the reduction of NOx emissions and compliance with EPA's clean air regulations. SBIR Technology Solution With support from EPA's Small Business Innovation Re- Search Program (SBIR), Ceramatec, Inc. has developed multiple types of sensors that can monitor the NOx concentration generated by combustion in diesel en- gines. These devices offer fast response and high sensi- tivity to NOx, low cross-sensitivity to other species, such as carbon monoxide (CO) and sulfur dioxide (S02), and can perform for extended periods in engine exhaust from mobile sources. These sensors will improve emis- sions monitoring and enforcement of emissions regula- tions for both on-road and off-road mobile sources. Many promising emissions-reduction devices have been developed in recent years, such as NOx ab- sorbers, selective catalytic converters (SCR), exhaust gas recirculation (ECR), and oxygen-enriched air injection (OEAI) technology. Information obtained by online NOx monitoring can be fed back into the process control system so that process variables can be optimized to re- duce pollution. Oram,iter's ceramic-based sensor suc- cessfully withstood high temperatures present in an engine exhaust stream (500-600° C). When measuring NOx concentrations, the sensor was not affected by the gas input nitric oxide (NO)/nitrogen dioxide (NO,) ratio; the sensor voltage was found to be proportional to the total NOx concentration. The sensor had no re- sponse to cross-sensitivity with carbon dioxide (C02) and water vapor, although cross-sensitivity to up to 1,500 ppm of CO and 15 ppm of SO, affected the baseline voltage of the sensor. The NOx sensor demon- strated sensitivity to NOx levels as low as 1 ppm. As a final step in Phase II, Ceramatec miniaturized the sen- sor into a smaller device that could be threaded into an exhaust port. Commercialization Information In November 2009, a new company, EmiSense Technologies, LLC, was formed to commercialize this efficient, durable, and cost-effective NOx sensor. Ceramatec is providing advanced diagnostic and an- alytical services to EmiSense. EmiSense is commercializing other advanced sen- sors, including electronic-field particulate matter (PM) sensors and oxygen or Lambda (air/fuel ratio) sensors, to promote clean emissions and help ad- dress the global challenges of fossil-fuel dependence and climate change. High-volume ceramic foundry services are provided to the company by CoorsTek (see below). EmiSense's intake high-speed oxygen sensors are used to manage exhaust gas recirculation for diesel, gasoline direct injection, homogeneous charge com- pression ignition, and other high-efficiency engines. The company's engine out oxygen, NOx, and PM sensors are used for closed-loop engine controls. Its after treatment oxygen, NOx, and PM sensors are used for on-board diagnostics emissions compliance and closed-loop controls of catalysis and particulate SBIR Success Stories Intake differentiators are • EmiSense products combine breakthrough technologies in both signal processing and technical ceramics. • Clean combustion is the most impactful near-term clean technology. Engine Out Oxygen, NOx, and PM (particulate matter) sensors used for closed-loop engine controls. Primary differentiators are speed, self-calibra- tion and self-diagnostics, and durability. Treatment Oxygen, NOx, and PM sensors used for on-board diagnostics (0BD) emissions compliance, and closed-loop controls of catalysis and particulate filter- ing. Primary differentiators are cost accuracy, and reliability. ESE31 GjEZHI gjg 0 EmiSense products include wideband oxygen sensors (Lambda, UEGO, WRAF), PM (particulate matter) sensors, and NO, sensors. For high-volume programs, the company also provides enabling components, including Application Specific Integrated Circuits (ASICs), modular electronic subsystems, and ceramic sensing elements. ------- filtering. The advantages offered by EmiSense's sensors include: • Superior response time • Automatic calibration for sensor drift compensation • Simplified, low-cost controller implementation • Simplified single-cell wideband sensors • Detailed sensor diagnostics • Individual-cylinder balancing • Misfire detection • Faster "light off" time • Improved resistance to thermal shock • Improved resistance to mechanical shock Company History Ceramatec was founded in 1 976 as a technology spin-off from the University of Utah. The com- pany specializes in the use of ceramics to de- velop cutting-edge technology. In its first 25 years, Ceramatec focused on sodium-sulfur bat- teries and their applications in industrial envi- ronments. Since 1990, the company also has focused on fuel cells, oxygen separation, new energy, and environmental technologies. In 2006, Ceramatec was a Utah Innovation Award Finalist for best NOx sensor. Because of the com- pany's success, the number of Ceramatec em- ployees has tripled during the past 7 years. In 2008, Ceramatec was acquired by CoorsTek, North America's largest supplier of technical ce- ramics, serving diverse industries, including au- tomotive, industrial, and semiconductor segments. EmiSense was formed in 2009 via a merger of as- sets, intellectual property, product lines, trade se- crets, and capital from CoorsTek, Inc. and Innovate! Technology, Inc. Prior to this merger, the EmiSense research team developed advanced emissions sen- sor technology as a part of Ceramatec, a CoorsTek R&D subsidiary. The new company integrates CoorsTek intellectual property and high-volume global manufacturing capacity with Innovatel's award-winning DirectDigital™ sensor technology and signal-processing patents. EmiSense develops smart sensors for clean emis- sions. Its products are critical enablers for next gen- eration, high-efficiency engines and generators, which help address the global challenges of fossil- fuel dependence and climate change. SBIR Impact Monitoring the NOx concentration in vehicle exhaust streams is critical for the reduction of NOx emissions and ensuing human health impacts as well as compliance with EPA's clean air regulations. Ceramatec, Inc.'s regular-sized and miniaturized ceramic-based sensors can monitor the NOx emissions generated by combustion in diesel engines. Ceramatec was a 2006 Utah Innovation Award Finalist for best NOx sensor, and the number of its employees has tripled in the past 7 years. | EmiSense Technologies, LLC was successfully launched to com- mercialize the NOx sensor supported by EPA's SBIR Program. SBIR Success Stories ------- |