SwRI: FOCAS Catalyst Aging System, a computer-controlled, gasoline-fueled burner system designed to simulate engine aging conditions

	A wide range of air-to-fuel ratios is possible with the FOCAS system specially-designed burner.

FOCAS^® is a computer-controlled, gasoline-fueled burner system designed to simulate engine aging conditions. Southwest Research Institute (SwRI) designed the system to accommodate full-sized catalyst systems and provide programmable aging cycles, allowing users to design and create aging cycles to meet specific needs.

FOCAS Features

• Temperature control (600 to 1,000°C catalyst inlet)*

• Flow control (50–130 g/sec)

• Wide-range, closed-loop air/fuel ratio control (0.75 < λ < 1.3)

• Capable of continuous operation at stoichiometric air/fuel ratios

• Programmable secondary air injection control

• Full FMEA (failure modes and effects analysis) safety monitoring and response

• Ability to add oil component to aging

*Temperature range is a function of total flow.

Engine-Based vs. Burner-Based Aging

Aging cycles developed on engine benches have been used to accelerate the thermal effects of catalyst aging from about 6 months of intensive driving to about 100 hours of simulated aging. With today's advanced emission solutions however, the catalysts are moving closer to the engine, resulting in increased operating temperatures that require increased total aging time. This increases both the cost and the risk of part failure because of stand malfunction or lack of control.

The classical approach to catalyst aging has been to use an engine-based aging stand. An alternative approach that can safely and efficiently reach higher temperatures can allow significant reductions in aging times.

The SwRI FOCAS catalyst aging system is a burner-based solution that allows the system to achieve operating temperatures of 1,000°C. Because FOCAS operates more efficiently than an engine-based system, aging costs can be reduced.

In an internal study, SwRI conducted research on 6 catalysts that showed burner-based aging provides results equivalent to engine-based aging (SAE 2003-01-0633). Three catalysts were aged using a gasoline-fueled engine, and 3 using the FOCAS gasoline-fueled burner. The engine was configured to run a standardized cycle, and FOCAS was programmed to run to the engine test cycle specifications. Aging was conducted using the same bed temperature, air/fuel ratios, and catalyst space velocity conditions in both systems.

Catalyst performance was measured at the beginning and end of the aging cycle and compared between the two methods. The FOCAS burner-based system produced thermal aging results equivalent to the engine aging cycle.

FOCAS Advantages

• Lower maintenance

• Higher efficiency system for fuel savings

• Fewer moving parts for reduced mechanical wear

• Power fault protection for operation during thunderstorms

• Wide-range lambda operation and control window

• Operation with or without lubricating oil (optional oil system add-on)

For more information about the FOCAS catalyst aging system capabilities at SwRI or how you can contract with SwRI, please contact Cynthia Webb at cwebb@swri.org or (210) 522-5873, or Bruce Bykowski at bbykowski@swri.org or (210) 522-2937.