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A PROJECT REPORT
Submitted by:
CHRISTO T JOSEPH
REG NO: 13771FDAE0077
DIPLOMA
IN
AUTOMOBILE ENGINEERING
July 2016
CATALYTIC CONVERTER
A Project report submitted for the partial fulfillment of the Diploma in automobile
engineering.
2013 2016
By
CHRISTO T JOSEPH
REG NO: 13771FDAE0077
External Guide
Dr. Ajay Kumar
Head of the department
Dept. of Automobile engineering
College of engineering Kidangoor
Kidangoor P.O, Kottayam, Kerala - 686572
GUIDES CERTIFICATE
I hereby certify that the research work embodied in the dissertation entitled catalytic
converter has been under taken and completed by CHRISTO T JOSEPH under my guidance
and supervision. I also certify that he has fulfilled all the requirements under the covenant
governing the submission of dissertation for award of DIPLOMA IN AUTOMOBILE
ENGINEERING.
Place: Pala
Date: 12 July 2016
DECLARATION
I hereby declare that the research work embodied in the dissertation entitled
CATALYTIC CONVERTER has been carried out by me, under the guidance and
supervision of Dr. Ajay Kumar, head of Automobile Dept. College of engineering kidangoor.
I also declare that this dissertation has not been submitted for the award of Diploma in
Automobile Engineering.
Place: Pala
Date: 12 July 2016
CHRISTO T JOSEPH
REG NO: 13771FDAED0077
ABSTRACT
Catalytic converter is most effective device which converts harmful gases due to
engine exhaust into eco friendly gases. In this report, I have tried to bring into the importance
of reducing air pollution and why catalytic converter is necessary in automobile. Also the
principles of the catalytic converter and explains its workings. And I tried to bring in advance
technology found out now a day for reducing air pollution. By best effort, I tried to focus on
the necessity of subject. I hope my report is one step ahead in this direction.
CONTENTS
CHAPTER
TITLE
PAGE
NO:
1
Introduction
1.1 Introduction
1.3 History
1.4 position of catalytic converter
2
CONSTRUCTION
2.1 Basic components
2.2 Coating process
2.3 Detailed coating process
2.4 Catalyst materials
2.5 Types of catalytic converter
2.5.1 Three way catalytic converter
2.5.2 Ceramic Honeycomb type
2.5.3 Monolith
2.5.4 Pellet type
Working
3.1 conversion process
3.1.1 Pollutants released by a car engine
3.2 Ways of conversion
3.3 Fuel effects in performance of catalytic converter
3.3.1 Compression ignition direct injection
3.3.2 Unleaded petrol
3.3.3 Leaded versus unleaded
CHAPTER
TITLE
PAGE NO:
3.4 precautions
3.5 Advantages
3.6 Disadvantages
3.7 Improvements
3.7.1 Chryslers Catalytic Air supply system
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New developments
4.1 Improvements in latest catalytic devices
4.1.1 Thin wall ceramic substrates
4.4.2 Electrically heated converter
4.4.3 Pre converter
4.2 Catalytic Converter troubleshooting
4.3 Reasons of catalytic converter failures
4.3.1 Clogged or poisoned cat-con
4.3.2 Bad exhaust valves
4.3.3 Out of tune engine
4.3.4 Excess fuel overheating the cat-con
4.3.5 Malfunctioning oxygen sensor
4.3.6 Oil or antifreeze entering the exhaust
Conclusion
References
CHAPTER 1
INTRODUCTION
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 happens due to industrial waste, automobile & by nature. But among that air
pollution due to automobile contributes to 70% of total air pollution. So now a day control of
automobile pollution & its 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
1.2 Catalytic Converter as a Pollution Controller Device
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.
1.2.1 Catalytic converter
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
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 Stempels guidance, GM built on existing research to
produce the first catalytic converter for use in an automobile. Catalytic converters were first
installed in vehicles made in 1975 in response to EPA regulations passed two years earlier
tightening auto emissions and requiring a gradual decrease in the lead content of all gasoline.
In a study released on Nov. 28, 1973, the EPA determined that lead from automobile
vehicles was posing a direct threat to public health Although catalytic converters were
developed in the 1950s, the device couldnt be used in vehicles because the lead in gasoline
would render them useless.
Since the introduction of stringent emission regulations in the US in the 1970s, car
manufacturers have modified their exhaust systems to incorporate catalytic converters for the
removal of Nox, CO and hydro carbons. All new cars registered throughout the European
Union from 1st January 1993 have to be fitted with catalytic converters. Platinum, palladium
and rhodium are the main active components.
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.
1.4 Position of Catalytic Converter in an Exhaust System
First, all catalytic converters were 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.
CHAPTER 2
CONSTRUCTION
2.1 Basic Components
(1) Substrate: is ceramic honeycomb like structure with thousands of parallel channels that
provide a large surface area for the engine exhaust.
(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.
(3) Catalyst: Precious metal catalyst-the heart of catalytic converter, applied to wash coated
ceramic substrate.
(4) Mat: It provides thermal insulation & protects against mechanical shock & chassis
vibration.
(5) Can: A metal package that encase all the above components.
(6) Heat Shields: They are used to protect various parts surrounding the catalytic converter,
form thermal shocks.
2.2 Coating Process
Catalytic converters are used in automobile and industries for pollution abatement. They
usually consist of cordierite ceramic extruded to form a structure of honeycomb-like cells that
extend as channels along the catalytic converter length. A paint-like liquid containing the
precious metal catalyst is coated on the channel walls. During operation, exhaust gases are
conveyed with low pressure drop through the catalytic converter. The pollutant gases are
removed by catalytic activity in the catalyst coating.
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. Usually, the monoliths are sprayed with a non-viscous
solution containing dissolved catalyst. Sometimes the monoliths are coated by dipping into
catalyst enriched slurry and then blowing out the slurry with air.
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The air clears the channels leaving a layer of deposited slurry solids on the channel walls. A
solid coat of catalyst, called the washcoat, is left after the liquid components dries out. A
third method is to suck the slurry through the monoliths by lowering one end of the monolith
into catalyst slurry and applying a vacuum at the other end.
2.3 Detailed Coating Process
(1) 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.
(2) 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.
(3) 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.
(4). 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.
(5) 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 body. This
style of welding forms a strong bond between the converters components and prevents the
ceramics from shifting.
(6) Ribbing on the shield offers a final layer of protection against heat damage while
reinforcing the structural stability of the entire converter.
2.4 Catalyst material
A catalytic is a substance that causes chemical reaction without being changed by the
reaction. Noble metals are used as catalysts. A catalytic is a substance that causes chemical
reaction without being changed by the reaction. Noble metals are used as catalysts.
Oxidation converters: - 70% platinum & 30% palladium is not as efficient as platinum but it
is used to reduce overall cost of the unit.
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(2) An oxidation catalyst is a flow through exhaust device that contains a honeycomb structure
covered with a layer of chemical catalyst. This layer contains small amounts of precious metal-usually
platinum or palladium-that interact with and oxidize pollutants in the exhaust stream (CO and
unburned HCs), thereby reducing poisonous emissions.
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:
CO + O2 => 2CO2
CHAPTER 3
WORKING
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.
(1) Carbon monoxide (CO) a poisonous gas that is colorless and odorless.
(2) Hydrocarbons or volatile organic compounds (VOCs) produced mostly from unburned
fuel that evaporates.
(3) Sunlight breaks these down to form oxidants, which react with oxides of nitrogen to cause
ground level ozone (O3), a major component of smog.
(4) 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.
3.2 Ways of conversion
(1) 2-way pellets (bead) type
This type of converter either oxides or reduces but not both at one time, so most often not
used now a days.
(2) 3-ways / dual / hybrid type
First of all exhaust gases passes through TWC where it reduces Nox & partly oxidizes
HC/CO. Then pump provides sufficient air form oxidation Purpose. Then it passes through
COC, where final oxidation of HC/CO. Then Pump provides sufficient air from oxidation
purpose. Then it passes through COC, where final oxidation of HC/Co takes place.
3.3 Fuel effects in performance of catalytic converter
3.3.1 Compression ignition direct injection(CIDI)
CIDI engines have highest thermal efficiency of any proven automobile power plant.
Which increases fuel economy up to 35% . They are expected to deliver a fuel economy of up
to 80mpg in vehicles being developed under partnership for a new generation of vehicles
(PNGV) the joint venture of automobile giants like Chrysler corp., ford motor co.,
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Lawrence Livermore national lab, loss Alamos national lab, dark ridge national, and Sandia
national lab. 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.
3.3.2 Unleaded Petrol
Lead has been recognized as a health hazard. To reduce knocking (detonation) and as an
octane improve 1 part of Tetraethyl Lead (TEL)
PB] 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.
Manufacturers prevent the use of leaded fuel in a vehicle by the design of the filler tube
leading down to the fuel tank. There is a special filler tube which has restriction placed at its
opening which prevents the entry of large leaded fuel delivery nozzles at gasoline pumps.
Lead gradually gets accumulated in the body, after certain level it causes a variety of heart,
lungs, liver brain, etc.
As an alternative to TEL as octane improver, either of the following can be added part of
Ethyl iodide (EI) [(C2H5) 1] in 25 parts of gasoline.
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.
3.3.3 Leaded versus Unleaded
Lead is there to enable higher octane petrol for better efficiency. Lead when burnt in
engine is subjected to 2000-3000 degrees and is actually baked like a house brick which
when emitted from exhaust fall to the ground within 10-12 feet ( heavier than air ).
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These particles when tested various acids (like stomach acids) have no baked lead. 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.
More than half a liter of unleaded petrol is not petrol. It is actually a brew of aromatics that
replaced leads are Diethyl benzene, Mesitylene, Toluene, Xylene and Benzene. AI is declared
carcinogeneous and will cause Leukemia and other cancer related illness.
3.4 Precautions
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.
(4)In the event of above symptoms, drive a car low speed without rapid acceleration. If the
vehicle is continuously run with misfiring, it may cause overheating of shell, carpet etc.
resulting into fire. So, dont drive the vehicle with misfiring.
3.5 Advantages
(1) It gives more power
(2)It gives better performance
(3) It gives reduced fuel consumption
(4) Reducing amount of CO, HC and Nox, particulate emission, it leads to pollution free
environment.
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CHAPTER 4
NEW DEVELOPMENTS
After the engine exhaust gases pass through the catalytic converter, the gases go through the
muffler or mufflers, depending on the make of the automobile and rarely have a problem with
being clogged or plugged during its lifetime. The inside of the catalytic converter is a
honeycomb set of passageways or small ceramic beds with catalysts. A chemical reaction
takes place to make the pollutants less harmful. There are many passages for the exhaust
gases to flow, less allow for the maximum amount of surface area for the hot gases to pass.
4.3 Reasons of catalytic converter failures
4.3.1 Clogged or poisoned catalytic converter
There really is no inspection port for the consumer or mechanical to see an actual clog
in a converter. Often, the only way to tell if a catalytic converter is malfunctioning (plugged)
is to remove it and check the change in engine performance. When a clogged converter is
suspected, some mechanics temporarily remove the O2 sensor from the exhaust pipe ahead of
the catalytic converter and look for a change in performance.
A catalytic converter relies on receiving the proper mix of exhaust gases at the proper
temperature. Any additives or malfunctions that cause the mixture or the temperature of the
exhaust gases to change reduce the effectiveness and life of the catalytic converter. Leaded
gasoline and the over-use of certain fuel additives can shorten the life of a catalytic converter.
4.3.2 Bad exhaust valves
Sometimes you can tell that a converter is clogged because you dont go any faster
when you push the gas pedal. Also, there usually is a noticeable drop in gas mileage
associated with a clogged catalytic converter. A partially clogged converter often acts like an
engine governor. Limiting the actual RPMs to a fast idle. A totally clogged converter causes
the engine to quit after a few minutes because of all the increased exhaust back pressure. The
catalytic converter, like the rest of the emission system, typically has a warranty length that
exceeds the term of the warranty for the rest of a typical U.S. automobile.
4.3.3 Out of tune engine
Anytime an engine is running out of tune due to improper air/fuel mixture, misfiring
cylinders, faulty engine sensors, incorrect ignitions timing, etc., damage to the catalytic
converter will be incurred. Proper and regular servicing per the auto manufacturers
recommendations are necessary to prevent premature catalytic converter failure.
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CHAPTER 5
CATALYTIC CONVERTER NEWS
15
This brief window of pollution emission has been targeted as the point of attack by Chaitanya
Narula and his colleagues in the chemistry department of the Ford Motor Company Research
Laboratory in Dearborn, MI, to meet upcoming goals for ultra low automobile emissions.
5.3 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.).
E.P.A. guidelines state that replacement converters may be installed only in the following
situations:
(1) The vehicle is missing a converter
(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
year/80,000-mile warranty must have expired and a legitimate need for
(5) Replacement must have expired and a legitimate need for replacement must be
established and documented.
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