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Risultati finali
This result concerns the development of a stable and reliable open-pore ceramic foam trap, with pore size optimised so as to enable good filtration efficiency (above 80%), good particulate penetration in the foam structure (which favours the catalyst-to-particulate contact) and acceptable pressure drop, which would otherwise result in a fuel penalty. Based on the foundry molten metal filter producing know-how, the manufacturing technique adopted for the production of the ceramic foams is based on the coating of open cell polyurethane foams by soaking them into ceramic slurry. Located in the exhaust line, the soot filter by trapping soot, could contribute to the reduction of emission of Diesel engine.
After characterisation and study of commercially available foams and literature review, ceramic foams were prepared. Definition of the composition, an optimisation of the slurry, mechanical tests, an optimisation of the open-pore structure were the different steps to the new recipe definition. Alumina and Mullite toughened by zirconia were the best compromise between mechanical and thermal properties. The common cell densities of the ceramic foam produced for the CATATRAP samples were 50 and 100ppi.
This result is the upgrading of the most promising catalytic foams to a prototype scale. The design of the prototype was accomplished to optimise filtration efficiency, pressure drop as well as mechanical and thermal resistance. Large scale foams were produced and mounted into an appropriate exhaust pipe at the optimal distance from the engine.
Since the main problem of the disk based prototype was the lack of the sufficient filtration area needed in order to keep the pressure drop at low levels, and since the diameter of the device could not be increased, it was necessary to completely change the design of the prototype. The idea is on the basis of the new geometry. In particular, the exhausts will have to pass through the foams in the radial direction of the trap instead of the axial one.
With this design the filtration area is increased of 75% compared to the previous design. Also the pressure drop should be reduced by a similar factor, to make the CATATRAP prototype competitive, in terms of pressure drop, to the state of the art wall flow monoliths.
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