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Research and DevelopmentAuto Exhaust Catalysts R&D Dept.

Strengths of the Auto Exhaust Catalysts R&D Dept.

Based on the following perspectives, the Auto Exhaust Catalysts R&D Dept. engages in activities such as developing products, cultivating human resources, and cooperating with group companies/external organizations.

Development of materials/catalysts through a broad perspective from Åto m

Taking a theoretical approach by employing four components of thought

Example of actual materials/catalysts development using various perspectives fromÅto m

Cooperation as the BASF Group

Global support

  • We utilize the production and development centers of the BASF group to establish a global supply system.
  • We periodically hold technical meetings with BASF.

Organizations and Functions

We conduct business while cooperating and exchanging information with BASF and SMM.

Auto Exhaust Catalysts R&D Group

Design and development of exhaust gas catalysts for gasoline and diesel engines

In June 2016, in recognition of "development and commercialization of SCR catalyst systems," the group received the Technology Award from the Catalyst Manufacturers Association of Japan.

Advanced Technology Group

Conducts catalysts development, detailed analysis, and modeling for powder base

Fuel injection

Gas flow

Chemical reaction

Engine Laboratory Group

  • The Engine Laboratory Group uses actual engines and vehicles to test the durability and evaluate the performance of developed catalysts.
  • Main experimental facilities are a dynamometer for controlling engine load and various analytical instruments for measuring emissions. In terms of both quality and quantity, the experimental facilities owned by our company are at the same level of our customers in automotive manufacturing. We constantly install the optimal facilities in response to regulatory changes and customer needs.
  • Instead of simply conducting experiments, we constantly embrace challenges which include performing maintenance activities for keeping experimental facilities in optimal condition, thus ensuring the reliability of experimental data and increasing the efficiency of experiments through the effective use of equipment functions.
  • Furthermore, from the perspective of safety, we strive to enhance features including interlock devices and surveillance systems, thus ensuring the safety of our employees.

Dynamometer for large engines
(also supports engines of 10 liters and greater)

Gasoline durability

Chassis facilities

Engine Laboratory Facilities

[Gasoline Workbench]
[Diesel Workbench]

  • SOx meter, NH3 meter (can also measure N2O)
  • Micro tunnel (PM spectrometer)
  • Equipment for measuring the solid particle number (PN spectrometer)

[Analysis Equipment]

  • Catalyst activation testing equipment
    (model gas testing machine)
  • Physical property testing equipment
  • EPMA
  • SEM/EDX
  • STEM
  • XRD
  • TG/DTA
  • Other analysis equipment

Numazu Engine Laboratory

Development Examples

Diesel SCR Catalyst

Development example: Catalysts for purification of NOx emitted from a diesel internal combustion engine

We conduct integrated development from materials development to catalyst design and catalyzation activity (production technology).

For example, in the development of urea SCR (NOx selective catalysts reduction) catalysts, the BASF group developed a zeolite called Cu-CHA (patent pending) and catalyzed the material (coated a honeycomb carrier with a catalyst of the optimal composition). We then commercialized the development as a catalyst with high NOx purification performance. During the development process, we conducted review on the molecular level through HR-TEM microstructure analysis and first-principle calculation. This was done on the /Å and nano-scale.

BASF's originally-developed zeolite

CHA

HR-TEM photograph

Results of theoretical calculation for Cu-CHA

TWC Catalyst for Gasoline Engines

Development example: TWC catalysts for gasoline engines

As an example of TWC catalyst development, we are conducting review for the following types of conditions.

(1) Improvement of three-way performance

Three-way catalysts (TWC) purify the following three types of hazardous substances: CO, HC, and NOx. By analyzing elementary reactions for each different case of exhaust gas A/F (air-fuel ratio), we are working to improve activation in all areas.

Researching the unseen world at the elementary reaction level

(2) Improvement of rich performance

For the A/F discussed above, in order to heighten the exhaust gas purification performance in rich combustion conditions, we are working to accelerate hydrogen generation via CO/HC and water vapor.

(3) Acceleration of NO-CO reaction during lean control

For the A/F discussed above, in order to heighten the exhaust gas purification performance in lean combustion conditions, we are working to control the O2 gas concentration near precious metal.

Cooperation with External Organizations

Kusaka Laboratory, Waseda University

  • We conduct various joint research activities with the Kusaka Laboratory of Waseda University. We also give presentations at academic conferences.
  • This research focuses on the optimization of usage conditions for the DOC+CSF (catalyzation filter) exhaust gas processing system for diesel vehicles.

Nanoelectronics Research Institute, National Institute of Advanced Industrial Science and Technology (AIST)

  • We conduct various joint research activities with the Nanoelectronics Research Institute of AIST. We also give presentations at academic conferences.
  • This research focuses on the correlation between catalytic activity and the surface conductivity rate (calculated using EUPS) of catalyst material used in auto exhaust catalysts.

Note: EUPS = EUV photoelectron spectroscopy

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24th floor, World Trade Center Bldg. 2-4-1, Hamamatsu-cho, Minato-ku, Tokyo 105-6124
TEL : 81-3-3435-5490(Switchboard)  FAX : 81-3-3435-5484