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R-FOCAS™, a burner-based exhaust catalyst aging system, developed by Southwest Research Institute (SwRI), provides many advantages over engine-based aging methods. The illustration below shows major components of engine-based and burner-based aging.

Advantages of R-FOCAS Burner-Based Catalyst Aging

Burner-based catalyst aging allows independent control of thermal effects and effects caused by lubrication oil poisoning. Unlike engine-based aging, where oil consumption is inherent to engine operation and changes with engine wear, the R-FOCAS system consumes no oil during fuel-air combustion. Lube oil may be injected into the hot combustion products with a metering and measurement system. This process allows the user to age catalysts with or without oil poisoning effects.
 

Burner-based catalyst aging provides complete control of the aging process, including separation of thermal and oil poisoning aging effects.

Disadvantages of Engine-Based Catalyst Aging

Engine-based accelerated catalyst aging is limited to the maximum exhaust temperature the engine can reliably provide. The maximum temperature is typically lower than 900°C in the United States and as high as 940°C in Europe where expensive high-performance engines are used to generate exhaust. The rate of catalyst thermal aging is exponentially dependent on the exhaust gas temperature, and higher gas temperatures can dramatically shorten the time required to age catalysts.
 

Properties of R-FOCAS

R-FOCAS provides the user with complete flexibility and control over catalyst aging variables including:

• Exhaust mass flow rate from 20-90 g/s (40-160 SCFM)

• Exhaust air/fuel ratio (10:1 to 21:1) with closed-loop control

• Secondary air injection upstream of the test catalyst

• Catalyst inlet exhaust gas temperature up to 1,000°C

• Gasoline specification/composition

• Lube oil injection quantity, quality, and location into the hot exhaust stream

R-FOCAS users may perform full-size catalyst aging using preprogrammed EPA Strawman, RAT-A, and OPEST aging cycles. A cycle development tool included with the basic software also allows the user to easily create, store, and retrieve custom aging cycles. The system includes a complement of safety features designed to prevent damage of the test catalyst and to provide safe operation of the system. The LabVIEW^® based control system records data and displays graphical information as the aging cycle progresses.
 

Future Improvements of R-FOCAS

The current SwRI R-FOCAS system provides catalyst inlet temperatures as high as 1,000°C, providing a means of using accelerated aging cycles. Planned improvements will allow temperatures as high as 1,200°C. FOCAS provides an alternative means for simulating engine aging cycles, as well as exceeding the capabilities of an engine-based test system.

Availability of R-FOCAS Systems

R-FOCAS systems are available for purchase with or without the optional lube oil injection system. SwRI can provide R-FOCAS training at our facilities and/or at the client's facility. In addition, R-FOCAS systems are available for contract catalyst aging at SwRI's San Antonio, Texas, laboratories.

For more information about purchasing an R-FOCAS system, please contact Cynthia Webb by phone at (210) 522-5873, by fax at (210) 522-3950 or by e-mail at cwebb@swri.org.

For information about conducting a catalyst testing or aging program on an R-FOCAS system in our San Antonio, Texas, laboratories, please contact Martin Heimrich by phone at (210) 522-3022, by fax at (210) 522-3950 or by e-mail at mheimrich@swri.org.
 

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Southwest Research Institute® (SwRI®), headquartered in San Antonio, Texas, is a multidisciplinary, independent, nonprofit, applied engineering and physical sciences research and development organization with 11 technical divisions.

August 09, 2007