A catalytic converter is an emissions control device that converts toxic pollutants, present in automotive exhaust gas, to non-toxic pollutants by catalysing the required chemical reactions. Since 1981, due to the increasingly stringent legislation on vehicle emissions, the "three-way" catalytic converters have been introduced to gasoline engine vehicles. The utilization of PGMs in catalysts fabrication for automotive emission control devices -mainly Platinum, Rhodium and Palladium- has been the prime driving force for market demand growth in the recent years and no alternative materials exhibiting similar efficiency in toxic pollutants abatement have ever been introduced to the market. It is worth noting that 40% of Pt, 81% of Rh and 67% of Pd demand is allocated to autocatalysts fabrication. In 2015, PGMs supply was below demand by about 20 tonnes and it is forecasted to grow in the coming years due to the increasingly stringent legislation on automotive emissions and also, the current irreplaceability of PGMs in autocatalysts. According to the International Trade Centre, in 2015 the European autocatalysts market used 43 tonnes of Pt, worth €1.4 billion, for autocatalysts that classifies Europe as the world’s largest consumer of PGMs. At the same time, European primary PGMs production is insignificant; about 70% of the global production (160 tonnes) comes from South Africa and Russia.
The PROMETHEUS project represents a disruptive innovation aiming to demonstrate and for the first time introduce to the market a novel eco-friendly nano-structured automotive catalyst substituting at least 50% (the substitution of PGMs has been proven to be up to 85%), of the PGMs, while keeping the same performance and reducing production cost and European PMGs expenses/imports and reliance on PGM producers. Five overall objectives set and achieved are:
1. The development of a single catalytic washcoat powder containing Palladium, Rhodium, and Copper nanoparticles.
2. Production of more than 110 pieces of full scale PROMETHEUS catalyst prototypes
3. Full scale demonstration of PROMETHEUS catalyst.
4. Preparing for Market Replication. A full EC Homologation Approval Campaign has been designed and it is under way including 12 cars of all Euro Standards and sizes.
5. An exploitation and business plan has been set up. Two separate routes for the commercialization are being followed: a) Introduction to the Market as a Replacement Catalyst and b) Meet Car Manufacturer's criteria in order to be considered as an Original Equipment (OEM)
