Catalic Converter Report
Catalic Converter Report
TECHNICAL SEMINAR
On
CATALYTIC CONVERTER
Bachelor of Technology
In
MECHANICAL ENGINEERING
Submitted by
THADURI KIRAN KUMAR 19N85A0302
CERTIFICATE
-3-
Content:
Page no.:
1: INTRODUCTION
1.1 INTRODUCTION 6
1.2 CATALYTIC CONVERTER AS A POLLUTION
CONTROL DEVICE 6
1.3 HISTORY 7
1.4 POSITION OF CATALYTIC CONVERTER 8
2: CONSTRUCTION 9
2.1 BASIC COMPONENT 9
2.2 COATING PROCESS 9
2.3 DETAILED COATING PROCESS 10
2.4 CATALYST MATERIAL 12
2.5 TYPES OF CATALYTIC CONVERTER 13
i. The Reduction Catalyst 14
ii. The oxidation catalyst 15
3: WORKING
3.1 CONVERSION PROCESS 18
3.2 WAYS OF CONVERSION 20
3.3 FUEL AFFECTED IN PERFOMANCE OF CATALYTIC
CONVERTER 20
3.4 PRECAUTIONS 21
3.5 IMPROVEMENT 23
4: NEW DEVELOPMENT
4.1 THIN WALL CERAMIC SUBSTRATES 25
4.2 ELECTRICALLY HEATED CONVERTER 25
4.3 PRE CONVERTER 25
4.4 CATALYTIC CONVERTER LAWS. 26
-4-
List of figures
d) Catalyst materiel 12
-5-
1.INTRODUTION
1.1 INTRODUCTION
As we know, air pollution is big challenge for the world. Air pollution is not
national problem. An under developed country like India control of air pollution is very
necessary. Air pollution due to industrial west, automobile & by nature. But among that
air pollution due to automobile 70% of total air pollution. So now a day control of
automobile pollution & it’s bad effect is very necessary. We have several ways for
controlling automobile pollution, but most effective way is by using catalytic converter in
the automobile.
The catalytic converter does a great job at reducing the pollution, but it can still
be improved substantially. One of its biggest shortcomings is that it only works at a fairly
high temperature. When you start your car cold, the catalytic converter does almost
nothing to reduce the pollution in your exhaust.
As the name suggests, it basically converts harmful gases into harmless gases, which
are environment friendly, with the help of a catalyst.
Engine exhausts having harmful gases like CO, NOx & HC which are converted into
harmless gases like CO2, N2 & H2O respectively with the use of catalytic converter.
1.3 HISTORY:
-6-
In 1973, General Motors faced new air pollution regulations and needed a way to
make its cars conform to the stricter standards. Robert C. Stempel, who at the time was
a special assistant to the GM president, was assigned to oversee development of a
technology capable of addressing the problem. Under Stempel's guidance, GM built on
existing research to produce the first catalytic converter for use in an automobile.
In a study released on Nov. 28, 1973, the EPA determined "that lead from
automobile exhaust was posing a direct threat to public health."
Although catalytic converters were developed in the 1950s, the device couldn't be used
in vehicles because the lead in gasoline would render them useless.
A potential problem appears with the release of platinum group metals (PGMs)
from the converters into the environment. There is now convincing evidence for the
release of platinum group metals (PGMs) into the environment, possibly by abrasion of
the autocatalyst. As a result, PGMs are found to have increased in the environment. In
recent study, we found that PGMs have increased in road dust since 1984 and
particularly 1991.
-7-
1.4 POSITION OF CATALYTIC CONVERTER:
First of all catalytic converter was installed in under floor. This design needed
further improvement. so additional starter catalyst is installed in closed coupled position.
The catalytic converter usually looks like a muffler and is located underneath the
vehicle in the proximity of the passenger seat in most cars although some cars have
multiple converters. The purpose of a catalytic converter is to convert harmful
hydrocarbons, carbon monoxide, and nitrogen oxides into harmless compounds. The
catalysts inside the catalytic converter convert carbon monoxide and hydrocarbons into
carbon dioxide and water, and nitrogen oxides back into nitrogen and oxygen.
-8-
2.CONSTRUCTION
(2) Wash Coat: A coating that increases the effective surface area of the
substrates & facilitates the application of precious metal catalyst onto the surface of the
ceramic surface of the ceramic substrate.
(4) Mat: It provides thermal insulation & protects against mechanical shock &
chassis vibration.
(5) Can: A metal package that encases all the above components.
(6) Heat Shields: They are used to protect various parts surrounding the catalytic
converter, form thermal shocks.
Coating processes for catalytic converters present several challenges that have
been tackled in the visual analysis lab. Catalytic converter manufacturers complained
that quality control of catalyst coat thicknesses is difficult. In addition the coating liquid
often clogs several of the catalytic converter channels.
-9-
2.3 Detailed Coating Process:
A. MagnaFlow engineers its converters with maximum airflow in mind. The large
surface area of the honeycomb ceramic catalyst combines with a detailed coating
process to allow the most exhaust to flow through the converter. Innovative technology
allows each catalyst to both oxidize and reduce harmful emissions.
B. A ribbed body encases the ceramic to reduce expansion and distortion when the
converter reaches its high operating temperature. The ribs form channels that hold the
ceramic in proper alignment and protect the cushioning mat from direct exposure to
exhaust gases.
C. MagnaFlow converters have a smooth-flowing, 1/2" lap joint where the neck and
body connect. This joint prevents the neck from extending into the body, where it could
impede exhaust flow.
D. MagnaFlow maintains separate dies for several converter body sizes and
corresponding neck sizes. This process eliminates the need to adapt neck sizes to
make them fit on a single converter body size, which would increase back pressure and
decrease airflow and horsepower.
E. The ceramic catalysts are seam welded to a heavy-gauge, stainless steel converter
body. Furthermore, a stainless steel heat shield is seam welded to the inner converter
- 10 -
body. This style of welding forms a strong bond between the converter's components
and prevents the ceramics from shifting.
F. Ribbing on the shield offers a final layer of protection against heat damage while
reinforcing the structural stability of the entire converter.
- 11 -
2.4 CATALYST MATERIALS:
(d).catalyst meterial
▪ Oxidation converters: - 70% platinum & 30% palladium is not as efficient as platinum
but it is used to reduce overall cost of the unit.
- 12 -
2.5 TYPES OF CATALYTIC CONVERTER:
There are main types of structures used in catalytic converters. Honeycomb and
Ceramic beads. Most cars today use a honeycomb structure.
- 13 -
♦ The Reduction Catalyst
The section of a three-way catalytic converter that breaks NOx down into
harmless nitrogen and oxygen through a reduction reaction.
The reduction catalyst is the first stage of the catalytic converter. It uses platinum
and rhodium to help reduce the NOx emissions. When an No or NO2 molecule contacts
the catalyst, the catalyst rips the nitrogen atom out of the molecule and hold on to it,
freeing the oxygen in the form of O2. The nitrogen atoms bond with other nitrogen
atoms that are stuck to the catalyst, forming N2. For example:
- 14 -
♦ The Oxidation Catalyst
(g).oxidation catalyst
The oxidation catalyst is the second stage of the catalytic converter. It reduces
the unburned hydrocarbons and carbon monoxide by burning (oxidizing) them over a
platinum and palladium catalyst. This catalyst aids the reaction of the CO and
hydrocarbons with the remaining oxygen in the exhaust gas.
For example:
2CO + O2 => 2CO2
- 15 -
(1) Monolith:
# Shell: Manufactures make converter housing of sell of two stamed metal pieces
welded to gather to form a round or oval assembly.
# Monolith: It is made from ceramic matter. Honeycomb design has hundred of cellular
passages for the exhaust gases to floe through.
# Flow diffuser: It is situated between converter inlet & catalytic element. It is used to
obtain uniform flow of exhaust gases over the entire area. If it is not present them pellet
type gases will pass through the center of the element only.
- 16 -
(2) Pellet Type:
# Baffles: They direct the flow. First of all gases pass through the upper baffles. They
have to pass through the pellets & get out through lower baffles. Baffles support &
contains the bed.
# Insulation: Situated between inner 7 outer shells. It retarded the transfer of heat so no
heat shield is required here.
- 17 -
3.WORKING
Most modern cars are equipped with three-way catalytic converters. “Three-way”
refers to the three regulated emission it helps to reduce carbon monoxide, VOCs and
NOx molecules. The converter uses two different types of catalyst, a reduction catalyst
and an oxidization catalyst. Both types consist of a ceramic structure coated with a
metal catalyst, usually platinum, rhodium and palladium. The idea is to create a
structure that exposes the maximum surface area of catalyst to the exhaust stream,
while also minimizing the amount of catalyst required (they are very expensive).
- 18 -
♦ Pollutants Produced by a Car Engine:
In order to reduce emissions, modern car engines carefully control the amount of
fuel they burn. They try to keep the air-to-fuel ratio very close to the stoichiometric point,
which is the calculated ideal ratio of fuel. Theoretically, ratio the fuel will be burned
using all of the oxygen in the air. For gasoline, the stoichiometric ratio is about 14:7:1,
meaning that for each pound of gasoline, 14.7 pounds of air will be burned. Sometimes
the mixture can be lean (an air-to-fuel ratio higher than 14.7), and other times the
mixture can be rich (an air-to-fuel ratio lower than 14.7).
► Nitrogen gas (N2) - Air is 78%, nitrogen gas and most of this passes right
through the car engine.
► Carbon dioxide (CO2) - This is one product of combustion. The carbon in the fuel
bonds with the oxygen in the air.
► Water vapor (H2O) - This is another product of combustion. The hydrogen in the
fuel bonds with the oxygen in the air.
These emissions are mostly benign (although carbon dioxide emissions are believed to
contribute to global warming). But because the combustion process is never perfect,
some smaller amounts of more harmful emissions are also produced in car engines.
► Sunlight breaks these down to form oxidants, which react with oxides of
nitrogen to cause ground level ozone (O3), a major component of smog.
► Nitrogen oxides (NO and NO2, together called NOx) – contributes to smog and
acid rain, and causes irritation to human mucus membranes.
These are the main regulated emissions, and also the ones that catalytic
Converters are designed to reduce.
- 19 -
3.2 WAYS OF CONVERSION:
This type of converter either oxides or reduces but not both at one time, so
Most often not used now a days.
The primary technical barrier is emissions, learn burning CIDI engines have high
concentrations of O2, and so reduction of NOx, is not possible with a high standard
catalyst. So they have prepared a full size (110 cubic inch) converter & tested with a
CIDI engine on a dynamometer. Test results have demonstrated a NOx reduction of
40% more than double the reduction realized with commercially available catalysts.
♦ Unleaded Petrol:
- 20 -
Lead has been recognized as a health hazard. To reduce knocking (detonation)
and as an octane improve 1 part of Tetraethyl Lead (TEL) – [(C2H5) 4PB] is added in
1300 parts of gasoline. About 85% of lead entering the atmosphere comes from TEL.
Vehicles with catalytic converter must utilize and unleaded fuel. The lead itself
plates the catalyst to form a coating that prevents the exhaust gas pollution reacting and
therefore reacting with the catalyst.
Lead gradually gets accumulated in the body, after certain level it causes a
variety of heart, lungs, liver brain, etc.
It causes diseases like gastro intestinal damage, liver kidney damage, and
abnormality in fertility and pregnancy, mental development of children affected various
skin disease, etc.
Other sources of lead are Peuter (lead based alloy), lead solder in our cans of
precede food, lead pipes containing drinking water. Lead is removed otherwise catalytic
converter became clogged very quickly and stopped working. But unleaded petrol is
much more dangerous.
3.4 PRECAUTIONS:
- 21 -
If gases are too hot, by pass valve sends exhaust gases around the
Catalytic converter directly to the muffler.
(1) Failure to correct any of the conditions above will cause your new catalytic
converter to fail. The warranty of your new converter does not cover damage
described above. Tampering with or removing a catalytic converter from your
vehicle is illegal and can result in expensive fines.
(2) Use unleaded petrol only even one time leaded petrol will damage the catalytic
converter permanently.
(3) Consult an authorized service outlet at the earliest when, engine miss firing or
runs irregularly, following cold start, A significant loss of power is noticed.
» Advantages:
» Disadvantages:
» Cost is high.
» Volume required is high.
» Some amount of weight is added.
» There is over temperature problem.
» Heat shields required otherwise areas around it will be
severely due to thermal stresses.
» Catalytic material is lost.
» Unleaded fuel is required otherwise lead will be replace
the catalyst and so no reactions will be carried out
In case of catalytic converter, heat shields and interior insulation pads are
required due to high operating temperature. In case of muffler, no such requirement is
needed.
As shown in figure the oxidation reaction begins in the mini converter. As shown
her, oxygen along with HC and Co compounds pass into the mini converter where the
oxidized compounds pass into the main converter along with additional oxygen. The
main converter completes the oxidation HC and Co compounds and converts them into
harmless carbon dioxide and water.
3.5 IMPROVEMENT:
First of all Chrysler used its air injection system to supply the additional air
to catalytic converter. Afterwards it modifies it by addition of air switching valve and
coolant control engine vacuum switch. These units are control the air from the injection
pump during and after engine warm up. This assists in oxidation of HC and Co.
- 23 -
Exp. On 2 – Wheeler (Max. Limit of CO 4.5% without cat. Con. Approx.)
(Max. Limit of CO 0.9% with cat. Conv. Approx.)
- 24 -
4. NEW DEVELOPMENT
They are extruded from dense, high strength ceramic substrate without
sacrificing mechanical strength, total surface area remains same, back pressure
reduces, conversion efficiency increases and thermal expansion reduces.
4.3 Preconverter:
Another option for cold start control is a small converter placed very close to the
engine to accelerate exhaust gas converter.
- 25 -
4.4 Catalytic Converter Laws:
In 1986, the U.S. Environmental Protection Agency issued new guidelines for the
construction, efficiency and installation of aftermarket catalytic converters. All CleanAir
converters listed in this catalog have been designed, tested and manufactured to meet
this policy.
In addition, CleanAir converter listed in this catalog is appropriate for use under
the current requirements of the California Air Resources Board (C.A.R.B.).
2. A state or local inspection program has determined that the existing converter
need replacement.
3. Vehicles manufactured prior to 1996 must have more than 50,000 miles, and a
legitimate need for replacement must be established and documented.
4. In cases of OBD Il-equipped vehicles (1996 and later), the O.E. manufacturer's
8-year/80,000-mile warranty must have expired and a legitimate need for
replacement must have expired and a legitimate need for replacement must be
established and documented.
2. It be the same type as the original (i.e., two-way, three-way, three-way plus air/three-
way plus oxidation).
3. It be the proper model for the vehicle application as determined and specified by the
manufacturer.
- 26 -
REFERENCES
SERVICE MENUAL
BOOKS
● AUTOMOTIVE MECHANICS
● INTERNAL COMBUSTION ENGINE. BY GANESHAN
WEB SITES
● WWW.HOWSTUFFWORKS.COM
● WWW.TATAENGINEERING.COM
- 27 -