Benefits of nCATfiber technology

A reduction in catalysts means that catalytic devices can be manufactured and sold for less, while maintaining their pollution-reducing properties. When used to treat engine exhaust, nCATfiber technology uses approximately 75% less catalyst material than conventional catalytic converter technology. Catalysts are very costly, at an average of $1,000 per troy ounce, and can be cost prohibitive.

In all applications, nCATfiber has a high temperature tolerance. One of the main reasons a catalytic converter fails is due to a process called agglomeration. Agglomeration occurs at high temperatures, approximately 650º C, and causes the catalyst particles to “clump together” and become partially useless. nCATfiber uses a technology to separate the catalyst particles so agglomeration does not occur at high temperatures. Furthermore, ceramic fibers can withstand temperatures over 1000º C while maintaining the same properties.

nCATfiber material can be used in several beneficial ways. It can be applied to rigid support structures or mixed with ceramic microfibers to form a composite material. We work with customers to understand specific applications and to design the optimal format to use nCATfiber materials.

nCATfiber materials, when mixed with ceramic microfibers, has a texture very similar to a ball of cotton, so the material is flexible. It can withstand vibrations, system shocks and can be formed into any desired shape or size. nCATfiber products can fit inside mufflers, exhaust pipes, or even inside of catalytic converters. Rigid catalytic converters fail under mechanical shock (vibrations, dropping, etc.) and under sudden high temperatures (possible in all internal combustion engines). The advantages of nCATfiber catalytic products are the ability to absorb thermal shock and to operate consistently through sudden high temperature spikes.

nCATfiber products are made from ceramic nanofibers, which are extremely small in diameter. When small ceramic nanofibers contain catalyst material, the catalyst reactive surface area is maximized and the product size decreases. For example, the amount of nCATfiber product needed for a 6.5 HP lawn mower engine is approximately the size of three cotton balls. When compared to other widely adopted catalytic devices with the same catalysis efficiency, the nCATfiber product is much smaller and lighter.

nCATfiber products can be “stacked” in layers, with each layer containing different catalyst materials. This is beneficial because chemical reactions can require more than one catalyst in order to achieve a desired reaction. nCATfiber products are custom made for every application so they work to their fullest potential.