R & D Facilities

The world class Research & Development at Ecocat India Pvt Ltd is recognized by Government of India’s Department of Scientific & Industrial Research for its leading edge work. It works through two synchronous facilities for Mechanical and Chemical R&D to develop clean, green technologies that set global benchmarks in efficiency and cost effectiveness.

A dynamic team of engineers, post graduates, doctorates and post doctorates, well experienced in handling after treatment projects, works with latest analytical equipment for preparation, characterization and evaluation of materials. The research is driven by cost as well as stringent and dynamic legislative norms. Ecocat’s own R&D labs are supported by external emission laboratories for application engineering and long term development. The company also enjoys long term development co-operation with several high technology organisations and chemical manufacturers.

At Ecocat India, the primary focus of research comprises:

Three Way Catalyst (gasoline, LPG & CNG) washcoat optimised for OSC & endurance
Washcoat design & development and coating processes for Diesel emission after Treatment System DOC, DPF, SCR, ASC and their application specific variants
Customized washcoat chemistries and coating processes optimized for ceramic as well as metallic substrates
Coating process development for different substrate types
Efficient PGM usage for better effectiveness at lower costs
Coating Process technology for new products and improving Cost, Quality and Reliability

Mechanical R&D

Ecocat India’s Mechanical R&D Laboratory works with cutting edge design modelling and simulation software. Designs are conceptualised using 3D modelling software in conjunction with in-house developed simulation software for catalyst sizing.

Designs are optimised using 1D and 3D simulation software which evaluate the structural, flow and thermal performance of the entire exhaust after-treatment system. A prototype with the optimised design parameters is made on which further design validation tests are carried out.

Mechanical Tests

Exhaust manifold tests via partner(s)
Hot vibration tests via partner(s)
Radial compression test in house
Axial push-out test in house
Water shock test via partner(s)
Washcoat adhesion tests in house

Emission & Durability

Rapid engine aging via partner(s)
Several test vehicles in use for verifications and endurance tests

Emission Measurements

Engine dyno and CVS tests via partners
Synthetic gas simulation tests for petrol, diesel, CNG in house

Chemical R&D

Externally supported by emission laboratories and several advanced research institutes for application engineering and long term development, Ecocat India’s state-of-the-art Chemical R&D Laboratories focus on leading edge technologies.

Catalyst Performance Evaluation
Washcoat materials Characterization
Technology Transfer & validation
Washcoating Process Design & Development
Plant Support
New Washcoat Chemistry Design & Development
Chemical Kinetics Simulation

Materials Characterization Facilities

At Ecocat India, a special emphasis on the quality of the raw material used in our various products is the foundation of our proverbial quality and reliability. A wide range of tests and facilities are deployed for material characterization.

Materials Characterization Facilities

Equipment	Objective
XRF	Estimation of transition elements including PGM
ICP	Estimation of transition elements including PGM
Chemisorption Unit	Temperature programmed studies Specific Metal Surface Area Oxygen storage capacity NOX / Ammonia adsorption/desorption
Mass Spectrophotometer	Determination of components (mass balance)
Surface Area Analyzer & porosimeter	Washcoat Powder Surface Area & Pore Characterization
Optical microscope	Visual validation of washcoating uniformity
Laser Particle Size Analyzer	Estimation of particle size distribution
Thermal Analyzer	Determination of thermal stability of materials
Powder XRD	Crystallinity, crystallite size & phase determination of washcoat materials

Other characterization facilities such as SEM, AFM is outsourced

Catalyst Evaluation Facilities

Equipment	Objective
Performance Evaluation
Fully automatic Synthetic Gas test Bench	LOT & Conversion Efficiencies
FTIR Multi gas analyzer	Volumetric estimation multiple gases simultaneouses
Durability Studies
Catalytic converter accelerated Ageing System	A setup to study durability of catalytic converters (Thermal, Hydro-thermal, Oxidative & reductive)
Sulphur ageing system	A setup to study effect of sulfur poisoning on catalytic converters