Vehicle emissions trapping materials: Successes, challenges, and the path forward

Abstract The modern three-way catalyst (TWC) is very effective for treating the hydrocarbons (HCs), carbon monoxide (CO), and nitrogen oxides (NOx) from stoichiometric gasoline engines once the TWC has achieved its minimum operating temperature (e.g., 250 to 400 °C, depending on the gas species). Likewise, the diesel oxidation catalyst (DOC), selective catalytic reduction (SCR) catalyst with urea injection, and the diesel particulate filter (DPF) are effective for treating the HCs, CO, NOx, and particulate matter (PM) emissions from diesel engines once the catalysts are warmed up, although this can require a significant length of time (e.g., 1 to 3 min) because of the relatively low exhaust temperatures from diesel engines. For both types of engines, excess fueling is often used to accelerate the heating of the catalyst system after a cold start, although this decreases the fuel economy of the vehicle. Even with excess fueling, a high portion (up to 80%) of the total vehicle emissions is emitted during the cold start period (i.e., the period before the catalysts are functional). To treat the HC emissions during this cold start period, one approach is to employ a HC trap (HCT) that can adsorb the HC emissions at low temperatures and then oxidize the stored HCs to carbon dioxide (CO2) and water (H2O) at higher temperatures. To treat the NOx emissions during the cold start period, a passive NOx adsorber (PNA) can adsorb the NOx at low temperatures. For stoichiometric gasoline applications, the PNA can then reduce the stored NOx to nitrogen (N2) at higher temperatures. On diesel engines, the PNA can release the stored NOx back into the exhaust once the downstream urea/SCR system is operational. Some adsorber technologies have the capability of adsorbing HCs and NOx simultaneously. In this review, the HC trapping and passive NOx adsorbing technologies will be discussed in separate sections. This review will describe how the current trapping technologies can be applied in vehicle exhaust systems, the material properties required for efficient HCTs and PNAs, and the exhaust conditions that can inhibit/enhance their trapping properties. First, the performance of HCTs will be discussed in terms of their physical properties (e.g., pore size, acidity, presence of metal ions) and the trapping conditions (e.g., storage temperature, space velocity, and the presence of other exhaust species such as H2O and CO2). This will be followed by in-depth coverage of the reactions occurring during HC desorption. The second part of this review will focus on the composition of various PNA formulations, the effects of the trapping conditions (e.g., temperature, space velocity, the presence of other exhaust species such as CO2, H2O, CO, and C2H4), and the effects of sulfur poisoning on their trapping performance. The effect of hydrothermal aging and the regenerability of HCTs and PNAs will also be discussed. A significant amount of literature has emerged recently regarding HCTs and PNAs; this review is primarily focused on summarizing this literature and reconciling the differences presented.