“Transforming Live, Inventing Future”

Project Report
on

“CATALYTIC

CONVERTER”

PRESENTED BY:

Donga Ravi V. (086346319502)

DEPARTMENT OF MECHANICAL ENGINEERING

LUKHDHIRJI ENGINEERING COLLEGE
MORVI - 363641
[YEAR - 2010]
 CERTIFICATE

This is to certify that the project entitled

“CATALYTIC CONVERTER” has been carried
out by the student under my guidance in
partial fulfillment of the Diploma
Engineering in Mechanical Engineering of
L.E. Collage during the academic Year 2010
(Semester-V) .

Presented By:-

Donga Ravi V. (086346319502)

Date:-

Place:- L.E. Collage, Morvi.

HEAD OF THE DEPARTMENT SUPERVISOR

 PROJECT APPROVAL SHEEET

Following student has done the appropriate

work related to the “CATALYTIC
CONVERTER” in partial fulfillment for the
award of Diploma of Engineering in
Mechanical Engineering of “L.E. College,
Morvi.” and is being submitted to “Gujarat
Technical University, Ahemdabad”

Presented By:

DONGA RAVI V. (086346319502)

Guided By:

J.M. SAGATHIA

Date:

Place:

L.E. College, Morvi.

 ACKNOWLEDGEMENT

I owe a great many thanks to a great many

people who helped and supported me during the
writing of this report.

My deepest thanks to Lecturer, Er. J.M.

Sagathia the Guide of the project for guiding and
correcting various documents of mine with
attention and care. He has taken pain to go
through the project and make necessary correction
as and when needed.

I express my thanks to the Head of the

Department Er. D.G. Panchal for extending his
support.

My deep sense of gratitude to Er. R.G. Chavda

support and guidance. Thanks and appreciation to
the helpful Friends in My Classroom and their
support.

I would also thank my Institution and my

faculty members without whom this project would
have been a distant reality. I also extend my
heartfelt thanks to my family and well wishers.

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 PREFACE

Catalytic converter is most effective device which

converts harmful gases due to engine exhaust into eco
friendly gases.

In this report, we have tried to bring into focus

imports of reducing air pollution and why catalytic
converter is necessary in automobile. We also tried to
bring advance technology found out now a day for
reducing air pollution.

By best effort, we try to focus necessity of subject.

We hope our report is one step ahead in this direction.

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CHAPTER 1: INTRODUCTION
1.1 INTRODUCTION
1.2 CATALYTIC CONVERTER AS A POLLUTION
CONTROL DEVICE
1.3 HOSTORY
1.4 POSITON OF CATALYTIC CONVERTER

CHAPTER 2: CONSTRUCTION
2.1 BASIC COMPONENT
2.2 COATING PROCESS
2.3 DETAILED COATING PROCESS
2.4 CATALYST MATERIAL
2.5 TYPES OF CATALYTIC CONVERTER

CHAPTER 3: WORKING
3.1 CONVERSION PROCESS
3.2 WAYS OF CONVERSION
3.3 FUEL AFFECTED IN PERFOMANCE OF CATALYTIC
CONVERTER
3.4 PRECAUTIONS
3.5 IMPROVEMENT

CHAPTER 4: NEW DEVELOPMENT

4.1 THIN WALL CERAMIC SUBSTRATES
4.2 ELECTRICALLY HEATED CONVERTER
4.3 PRE CONVERTER
4.4 QUESTION REGARDING CAT. CONV.

CHAPTER 5: NEWS
5.1 DIRECT FIT CONVERTER
5.2 CATALYTIC CONVERTER LAWS

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 » CHAPTER-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.

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.

♦ What is 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.

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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 Stempel's 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 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.

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.

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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.

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 » 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 encases 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. Monolithic catalytic converter substrates are shown in the picture above.

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 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 a catalyst
enriched slurry and then blowing out the slurry with air. 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 a catalyst
slurry and applying a vacuum at the other end of the monolith. This vacuum coating
method has been the focus of our research and is illustrated below.

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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.

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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
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.

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2.4 CATALYST MATERIALS:

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.

▪ Reduction converters: - it consists of platinum & rhodium.

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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.

♦ A three-way catalytic converter:

In a three-way catalytic converter, the converter is positioned in front of the

oxidation catalyst. A three-way catalytic converter reduces NOx emissions as well as
CO and HC. The three-way catalyst reduces NOx into nitrogen and oxygen

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♦ Ceramic honeycomb structure:

Ceramic Honeycomb

A ceramic honeycomb structure is provided with a plurality of open passages

extending there through in an axial direction thereof. The wall thickness of at least one
part of the open passages formed in an annular portion along an outer peripheral
surface of the structure is made larger than that of the other open passages formed in
the other portion than the annular portion, and the structure has excellent mechanical
strength and thermal shock strength.

A method for producing a ceramic honeycomb structure comprising applying a

coating material to an outer peripheral surface of the ceramic honeycomb body to form
an outer peripheral wall, the thickness of the coating material applied being determined
from the outer diameter of the ceramic honeycomb body and the drying shrinkage ratio
of the coating material, such that the outer diameter of the dried ceramic honeycomb
structure is within a target outer size ±1.4 mm.

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♦ 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:

2NO => N2 + O2 or 2NO2 => N2 + 2O2

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♦ The Oxidation Catalyst

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. Sometimes called an OxyCat when used on a diesel engine, it
works together with the DPF and EGR valve to remove the bulk of unburned
hydrocarbons, soot and NOx from diesel exhaust.

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

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(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.

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(2) Pellet Type:

# Pellet: It consists of a small aluminum oxide pellet of 1/8 to 1/10 of an inch in

diameter. They are coated with thin layers of platinum or palladium.

# 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.

# Drain plug: It permits removal of catalysts pellets with special requirement.

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 » CHAPTER-3 «

» WORKING «

3.1 CONVERSION PROCESS:

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).

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♦ 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).

» The main emissions of a car engine are:

► 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.

► Carbon monoxide (CO) - a poisonous gas that is colorless and odorless

► Hydrocarbons or volatile organic compounds (VOCs) – produced mostly from

unburned fuel that evaporates.

► 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.

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 3.2 WAYS OF CONVERSION:

# 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.

# 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 AFFECTED IN PERFORMANCE OF CATALYT

CONVERTER:

♦ 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., 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.

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♦ 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) – [(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.

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 –

1 part of Ethyl iodide (EI) – [(C2H5) 1] in 25 parts of gasoline.

1 part of Ethyl alcohol [C2H5OH] in 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.

♦ Leaded V/S 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 ). These particles when tested various acids (like stomach acids) have no
baked lead.

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 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.

More than half a liter of unleaded petrol is not petrol. It is actually a brew of
aromatics that replaced leads are Diethly benzene, Mesitylene, Toluene, Xylene and
Benzene. AI is declared carcinogeneous and will cause Leukemia and other cancer
related illness.

Dr. Warren, advisor to Government of USA had said “Don’t use it in any car
not fitted without catalytic converter. Don’t wash parts in it, if any gets on your skin ,
wash it off immediately, avoid fumes when refueling, Don’t remain near the exhaust
(when it is cold).

Prof. Maltoni and Morando Soffritti of Institute of Oncology at Bologna

said that exposure to Benzene, Toluene and Xylene caused cancerous tumors when
ingested or inhaled. Benzene acts on man’s tissues and organs.

Roger Perry, Prof. of environment control at Imperial collage conducted tests

which show that unleaded petrol can be directly linked to cancer.

Unleaded petrol costs more and creates more pollution as they have to make
aromatics as well. While filling , try to be in such a position that the breeze is blowing
away from you. Don’t let any to get on your skin. Aromatics will be absorbed your body
through the pores of your skin.

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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 with out rapid
acceleration. If the vehicle is continuously run with misfiring, it may cause
overheating of shell, carpet etc. resulting into fire.
So, don’t drive the vehicle with misfiring.

● Warning:- Avoid parking the vehicle over inflammable

materials, such as dry leaves, grass etc as the exhaust system
is not enough to initiate “fire”.

» Advantages:

» It gives more power

» It gives better performance
» It gives reduced fuel consumption

» Reducing amount of CO, HC and NOx, particulate

emission, it leads to pollution free environment. It
is having long life.

» It has to be replaced after 50,000 miles. Here no lead is

used so no TEL is formed, Which is very harmful to

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 health.

» 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.

♦ Difference between muffler and catalytic converter:

Muffler is less durable and corrosion occurs on outer skin. While in case of
catalytic converter outer skin is made of stainless steel, so it is more durable and
corrosion resistant.

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.

♦ Mini converter installation:

ON some 1977 and later vehicles Chrysler installed a small oxidation type
converter welded into the engine exhaust pipe about 6 to 12 inches from the exhaust
manifold. The device sometimes known as under hood converter begins the oxidation
of HC and Co compounds before they reach the main under floor unit. this result in a
more complete oxidation of harmful emission in the exhaust gas.

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.

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3.5 IMPROVEMENT:

# Chrysler’s Catalytic Air supply system:

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.

# Ford secondary air supply:

A ford catalytic converter does require secondary air supply. This
additional air contains the oxygen that will further oxidize the HC and Co compound
within the catalytic converter. The secondary air supply for the converter from Ford’s
Thermactor Air Injection System.

# General Motors secondary Air supply system:

General motors also use an air injection system to supply the necessary
oxygen to the catalytic converter in order for it to perform its function. In catalytic
system, pumped air enters to the exhaust pipe downstream from the exhaust manifold.

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Exp. On 2 – Wheeler (Max. Limit of CO 4.5% without cat. Con. Approx.)
(Max. Limit of CO 0.9% with cat. Conv. Approx.)

NAME OF CO% WITHOUT CO%WITH C.C. OF

VEHICALE CAT.CONV. CAT.CONV. VEHICLE(appr)
M-80 2.5 -- 74.0
Super 2.6 0.85 150
LML-Vespa 2.6 0.88 150
Chetak 2.6 0.87 150
Hero Honda 2.1 0.81 100
Suzuki Fiero -- 0.79 150
Hero Honda CBZ -- 0.8 150
HeroHonda Splendor 2.6 0.8 97.2
TVS Scooty 2.5 0.82 70
Bajaj Spirit 2.55 0.83 70
TVS XL Super 2.7 0.83 69.8

Exp. On 3 – Wheeler (Max. limit of CO 4.5% without cat. Conv. Approx.)

NAME OF CO% WITHOUT CO% WTTH C.C.OF

VEHICALE CAT.CONV. CAT. CONV. VEHICLE(appr.)
Bajaj Auto Rickshaw 2.6 YET NOT 150
FITTED
Atul Auto Rickshaw 2.75 150

Exp. On 4 – Wheeler (Max. Limit of CO 3.0% without Cat. Conv. Approx.)

(Max. Limit of Co 1.5% with Cat. Conv.)

NAME OF CO% WITHOUT CO% WITH C.C.OF

VEHICLE CAT. CONV. CAT.CONV. VEHICLE(appr.)
Maruti - 800 2.5 1.2 796
Esteem 2.6 1.15 1298
Fiat Uno 2.5 1.25 996
Maruti Zen 2.6 0.9 993
Maruti Van 2.7 1.17 796

NOTE: READING TAKEN ON NEPTUNE GAS ANALYZER

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 » CHAPTER-4 «

» NEW DEVELOPMENT «

4.1 Thin wall ceramic structures-

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.

4.2 Electrically heated catalyst (EHC)-

To reduce ‘cold start’ emission in first 2 minute of operation, when most of

automobile’s pollutants are emitted unconverted. Here metal monolith heats the cold
exhaust gases, pre converter accelerates exhaust gas conversion and then ceramic
main substrate begins conversion in less than 10 second engine ignitions.

4.3 Preconverter:

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 Another option for cold start control is a small converter placed very close to the
engine to accelerate exhaust gas converter.

4.4 SOME QUESTION REGARDING CATALYTIC CONVERTER:

● How do you know when a catalytic converter on your car is no longer

functioning properly?

Ans.

To understand why a catalytic converter fails, you need to know how it works. The
catalytic converter is part of the automobile exhaust system. It converts harmful
compounds in exhaust into harmless compounds. In a typical passenger car, the
catalytic converter, which resembles a muffler in shape, is between the engine and the
muffler. It’s on the underside of the car, usually underneath the passenger seat. Maybe
you have felt its warmth through the floor on a long trip.

Catalytic converters have been standard on U.S. automobiles since the mid-
1970s. The catalytic converter helped drive the push toward unleaded gasoline as well.
Leaded gasoline contaminates the catalyst used inside a catalytic converter, destroying
its usefulness and leading to a clogged converter.

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.

The catalysts include:

► Oxidation catalyst: Palladium (Pd) and platinum (Pt) metals in very small amounts (to
keep the catalytic converter price down) convert the hydrocarbons of unburned gasoline
and carbon monoxide to carbon dioxide and water.

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► Reduction catalyst: Palladium and rhodium (Rh) metals also in very small amounts
convert the nitrogen oxide to nitrogen and oxygen. Nitrogen oxide is a big contributor to
smog.

Many states and localities have legislated annual automobile emission testing
that checks the actual emission content. The exhaust emission test checks for the
absence of a converter or a malfunctioning one during an inspection. It’s illegal in some
states and localities to remove a factory-installed catalytic converter. A mechanic can
sometimes temporarily remove it and replace the catalytic converter with a test pipe, but
the rules on this can vary from place to place.

There are two ways a converter can fail:

(I) It can become clogged.

(II) It can become poisoned.

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.

A catalytic converter can also fail because of:

► Bad exhaust valves on the engine.

► Fouled plug causing unburned fuel to overheat the converter.

Sometimes you can tell that a converter is clogged because you don’t 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.

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 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.

Here is a safety reminder: Do not park your car over tall grass or piles of dry
leaves. Your car’s perfectly running catalytic converter gets very hot…enough to start
fires!

# Describe the causes of failure in catalytic converter:

Answer:

» 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.

» EXCESS FUEL OVERHEATING THE CATALYTIC CONVERTER

An engine that is performing at peak efficiency will burn all the fuel in the
combustion chamber during the combustion process. An engine that is not performing
properly, that is not burning all the fuel, will allow unburned or excess fuel to enter the
exhaust system. When this excess or unburned fuel contacts the hot core of the
converter it will ignite. This constant infusion of unburned fuel will cause temperature to
continuously rise above the designed operating temperature until the core of the
catalytic converter will actually melt. Possible causes for the excess fuel entering the
exhaust system are an incorrect fuel mixture, incorrect timing, corroded spark plugs,
worn and cracked ignition wires, improper fuel pressure, a faulty oxygen sensor,
sticking float, faulty fuel injector or a malfunctioning check valve.

» OIL OR ANTIFREEZE ENTERING EXHAUST

When oil or antifreeze enters the exhaust system and contacts the hot core of
the converter the oil and antifreeze will burn off leaving carbon deposits. The carbon
deposits will coat the core of the converter thus reducing the catalytic converter’s ability
to convert from harmful emission into harmless compounds. As the carbon deposits

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continue to accumulate, the pores in the ceramic catalyst will become restricted and
block exhaust flow through the exhaust system. The resulting increased backpressure
will result is a loss of power and overheated engine components. Possible causes are
worn piston rings, faulty valve seals or valve guides, blown head gasket or intake
gaskets, or warped engine components.

» MALFUNCTIONING OXYGEN SENSOR

The oxygen sensor measures the amount of oxygen present in the exhaust gas.
Depending on the voltage generated by the oxygen sensor, the engine management
system will change the air/fuel ratio to obtain the desired oxygen level present in the
exhaust gas. A malfunctioning oxygen sensor sending an erroneous reading to the
engine control system can causes a too rich or too lean condition. A rich condition will
cause a converter to overheat and melt down from the unburned fuel being ignited while
a lean condition can result in a misfire that can lead to the same result. Oxygen sensors
were out and need to be changed per your auto manufacturer’s time and mileage limits.

» BROKEN EXHAUST HANGERS OR MISALIGNED EXHAUST

An exhaust system that is misaligned or allowed to rattle will cause the fragile
ceramic catalyst inside the converter to break apart. When the core breaks or becomes
loose in the converter the brittle ceramic catalyst will continue to break up into smaller
pieces that will eventually block the flow of the exhaust. This increased backpressure
will lead to loss of power and heat build up.

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 » CHAPTER-5 «

» CATALYTIC CONVERTER NEWS «

5.1 Direct Fit Catalytic Converters

# Emission Control System

The purpose of the emission control system is just that; it controls the emissions
and exhaust from your vehicle. The idea is to turn the harmful gases your car
manufactures into harmless ones that don’t ruin the environment, or us. Some of the
problem gases are: hydrocarbons (unburned), carbon monoxide, carbon dioxide,
nitrogen oxides, sulfur dioxide, phosphorus lead and other metals.

To prevent the engine from polluting the environment with these gases, we
include a catalytic converter in our emission system. The catalytic converter is installed
in the exhaust line, between the exhaust manifold and the muffler, and makes use of
chemicals that act as a catalyst. Basically, the harmful gases enter the catalytic
converter, a kind of stainless steel container. The converter is lined with chemicals such
as aluminum oxide, platinum and palladium. These chemicals cause the carbon
monoxide and hydrocarbons to change into water vapor and carbon dioxide. Some
converters have a third lining of chemicals, platinum and rhodium, that reduce nitrogen
oxides (three-way, dual bed catalytic converter).

The reason that leaded gas cannot be used in an engine with a catalytic
converter is that the lead coat the chemicals in the chemical lining cant’s come in
contact with the pollutants.

One Step Closer to Ultra low-Emission Automobiles

A new application of a chemical process called sol-gel technology shows

promise for making automobile catalytic converters dramatically more efficient in
reducing harmful air pollution emissions by targeting the first minute-and-a-half in which
the car is running after a cold start, according to research presented at a meeting of the
American Chemical Society.

Most catalytic converters turn harmful combustion products such as

hydrocarbons, carbon monoxide, and nitrogen oxides into benign water, carbon dioxide,
and nitrogen. But during the first 90 seconds, while the catalytic converter has not

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reached optimum operating condition and maximum conversion efficiency, up to 70
percent of the total air pollutants discharged during a normal driving cycle are
exhausted to the atmosphere.

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.

# Suicides by Motor Vehicles

It has been suggested that the introduction of strict controls on exhaust
emissions may have a beneficial, decreasing, effect on the rate of suicides using this
method. This has been supported by a number of patient studies. In England and
Wales, in 1992, the suicide rate using MVEG dropped dramatically, from a high of 23.9
deaths per million in 1991 to 15.95 per million in 1992.

However, suicides from all other methods remained relatively constant around
53.0 deaths per million. At the same time the percentage of cars with catalytic
converters increased almost tenfold, from 0.4% in 1991 to 3.9% of the fleet in 1992.

As the alternative methods of suicide have remained little changed it appears

that there is little or no substitution occurring and that catalytic converter may be saving
lives.

# New China Auto Emissions Standards

To protect the environment, the Chinese government has tightened auto
emissions regulations and has encourages the increased practice of recycling
materials. Starting in 2000, to eliminate the use of leaded gasoline and to reduce
vehicle, catalytic converters will be installed in passenger cars and mini-buses. It will be
mandatory after this date that all vehicles be equipped with catalytic converters.

5.2 Catalytic Converter Laws:

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 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
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.

NOTE: Federal law prohibits removal or replacement of a properly functioning O.E.

converter.

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# When replacement of the converter is appropriate (as outlined above),
the E.P.A. further requires that:

1. It be installed in the same location as the original.

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.

4. It be properly connected to any existing air injection components on the vehicle.

5. It be installed with any other required converter for a particular application.

6. It be accompanied by a warranty information card to be completed by the installer.

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 REFERENCES

SERVICE MENUAL

● TATA ENGINEERING (GANESH), RAJKOT

● MARUTI ENGINEERING (PERFECT), RAJKOT
● VIKAS AUTO, RAJKOT

BOOKS

● AUTOMOTIVE MECHANICS
● INTERNAL COMBUSTION ENGINE. BY GANESHAN

WEB SITES

● WWW.HOWSTUFFWORKS.COM
● WWW.TATAENGINEERING.COM

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