NOx-Trap Catalyst Development for Mitsubishi 1.8L GDI™ Application

A new single-brick Ba + alkali metals NOx-Trap catalyst has been developed to replace a two-brick NOx-Trap system containing a downstream three-way catalyst. Major development efforts include: 1) platinum group metals selection for higher HC oxidation with potassium-containing washcoat, 2) alumina and ceria selection, and Rh architecture design for more efficient NOx reduction and 3) NiO to suppress H₂S odor. Mitsubishi Motors' 1.8L GDI™ with this Delphi new NOx-Trap catalyst with H₂S control achieves J-LEV standard with less cost and lower backpressure compared to the previous model. It is further discovered that incorporation of NiO into the NOx-Trap washcoat is effective for H₂S control during sulfur purge but has a negative impact on thermal durability and sulfur resistance. Further study to improve this trade-off has been made and preliminary results of an advanced washcoat design are presented in this paper. Details will be reported in a future publication.