Sie sind auf Seite 1von 4

See

discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/266485301

CATALYTIC CONVERTER BASED ON NON-


NOBLE MATERIAL

Article

CITATIONS READS

3 339

2 authors, including:

Pravin Rathod
Gujarat Technological University
21 PUBLICATIONS 42 CITATIONS

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

I working on GUJCOST project of performance improvement of Dry WEDM with ultrasonic vibration
since 2010. View project

All content following this page was uploaded by Pravin Rathod on 08 July 2015.

The user has requested enhancement of the downloaded file.


International Journal of Advanced Engineering Research and Studies E-ISSN22498974

Research Article
CATALYTIC CONVERTER BASED ON NON-NOBLE
MATERIAL
Chirag Amin1, Pravin P. Rathod2

Address for Correspondence


1
PG Student (ME Auto.), 2 Associate Professor
Mechanical Engineering Department, Govt. Engg. College, Bhuj. 370001,Kutch- Gujarat- India
ABSTRACT
Exhaust emissions of much concern are Hydrocarbon (HC), Carbon Monoxide (CO) and Nitrogen Oxide (NOx) from the
automotive vehicles. Catalytic converter oxidizes harmful CO and HC emission to CO2 and H2O in the exhaust system and
thus the emission is controlled. There are several types of problems associated with noble metal based catalytic converter.
These factors encourage for the possible application of non noble metal based material such as copper as a catalyst, which
may by proper improvements be able to show the desired activity and can also offer better durability characteristics due to its
poison resistant nature. This paper review most common technology available and its alternatives.
KEYWORDS: Catalytic converter; non-noble material.
I. INTRODUCTION spark-ignited (SI) engine, 5 to 15 percent of the
In internal combustion engines, the time available for exhaust gas is routed back to the intake as EGR. The
combustion is limited by the engines cycle to just a maximum quantity is limited by the requirement of
few milliseconds. There is incomplete combustion of the mixture to sustain a contiguous flame front during
the fuel and this leads to emissions of the partial the combustion event; excessive EGR in poorly set
oxidation product, carbon monoxide (CO), oxides of up applications can cause misfires and partial burns.
nitrogen (NOx) and a wide range of volatile organic B. Positive Crankcase Ventilation (PCV)
compounds (VOC), including hydrocarbons (HC), During normal compression stroke, a small amount
aromatics and oxygenated species. These emissions of gases in the combustion chamber escapes past the
are particularly high during both idling and piston. Approximately 70% of these "blow by" gases
deceleration, when insufficient air is taken in for are unburned fuel (HC) that can dilute and
complete combustion to occur. contaminate the engine oil, cause corrosion to critical
Carbon monoxide is a product of a partial parts, and contribute to sludge build up. At higher
combustion of hydrocarbons in fuel. It is always engine speeds, blow by gases increase crankcase
present when there is a lack of oxygen during pressure that can cause oil leakage from sealed
combustion and thus directly dependent on the engine surfaces.
applied engine air/fuel ratio. There are several paths The purpose of the Positive Crankcase Ventilation
that cause hydrocarbons in the exhaust. The most (PCV) system is to remove these harmful gases from
obvious is, as in the case of CO, a lack of oxygen the crankcase before damage occurs and combine
when the air/fuel mixture is rich. The other reasons them with the engine's normal incoming air/fuel
that can cause hydrocarbon emissions even with lean charge.
mixtures are crevices (piston top, threads around the C. Catalytic converters
spark plug), the quench layer (due to a lower In chemistry, a catalyst is a substance that causes or
temperature of the cylinders walls), porous deposits, accelerates a chemical reaction without itself being
and absorption by oil. NOx is formed during affected. Catalysts participate in the reactions, but are
combustion in the engine when oxygen reacts with neither reactants nor products of the reaction they
nitrogen because of a high combustion temperature. catalyze. A catalytic converter reduces temperature at
II. EXHAUST EMISSION CONTROL which CO & HC convert into CO2 and H2O.
TECHNIQUE Generally catalytic converters uses platinum group of
A. Exhaust gas recirculation (EGR) noble metals.
In internal combustion engines, exhaust gas III. HOW CATALYTIC CONVERTER WORKS?
recirculation (EGR) is a nitrogen oxide (NOx) In the catalytic converter, there are two different
emissions reduction technique used in petrol/gasoline types of catalyst at work, a reduction catalyst and
and diesel engines. EGR works by re-circulating a an oxidation catalyst. Both types consist of a ceramic
portion of an engine's exhaust gas back to the engine structure coated with a metal catalyst, usually
cylinders. In a gasoline engine, this inert exhaust platinum, rhodium and/or palladium. The idea is to
displaces the amount of combustible matter in the create a structure that exposes the maximum surface
cylinder. In a diesel engine, the exhaust gas replaces area of catalyst to the exhaust stream.
some of the excess oxygen in the pre-combustion The reduction catalyst is the first stage of the
mixture. Because NOx forms primarily when a catalytic converter. It uses platinum and rhodium to
mixture of nitrogen and oxygen is subjected to high help reduce the NOx emissions. When an NO or NO2
temperature, the lower combustion chamber molecule contacts the catalyst, the catalyst rips the
temperatures caused by EGR reduces the amount of nitrogen atom out of the molecule and holds on to it,
NOx the combustion generates. freeing the oxygen in the form of O2. The nitrogen
The exhaust gas, added to the fuel, oxygen, and atoms bond with other nitrogen atoms that are also
combustion products, increases the specific heat stuck to the catalyst, forming N2. For example:
capacity of the cylinder contents, which lowers the 2NO => N2 + O2 or 2NO2 => N2 + 2O2
adiabatic flame temperature. In a typical automotive

IJAERS/Vol. I/ Issue II/January-March, 2012/118-120


International Journal of Advanced Engineering Research and Studies E-ISSN22498974

Chemically heated catalyst;


Exhaust gas ignition;
Pre-heat burners;
The concept of using a catalyst near the engine
manifold or in the vicinity of the vehicle firewall to
reduce the heat-up time has been practiced.
Electrically heated catalyst are used to overcome the
The oxidation catalyst is the second stage of the cold temperatures during start up & provide heat to
catalytic converter. It reduces the unburned the exhaust gas or the catalytic surface using resistive
hydrocarbons and carbon monoxide by burning materials and a current/voltage source. Another
(oxidizing) them over a platinum and palladium approach investigated was the hydrocarbon
catalyst. This catalyst aids the reaction of the CO and adsorption trap in which the cold HCs are adsorbed
hydrocarbons with the remaining oxygen in the and retained, on an adsorbent, until the catalyst
exhaust gas. For example: reaches the light off temperature. All of these
2CO + O2 => 2CO2 approaches contain under floor catalysts of various
There are two main types of structures used in compositions. The chemically heated catalyst uses
catalytic converters -- honeycomb and ceramic beads. highly reactive specie, usually H2, which is generated
Most cars today use a honeycomb structure. in a device onboard, the vehicle. Since this reacts at
A. Types of converter room temperature over the catalyst, the heat of
a) Monolithic converters reaction warms up the catalyst to react during cold
The monolithic catalytic converter uses ceramic start. The exhaust gas igniters involve placing an
material made in a honeycomb pattern to control the ignition source (e.g. glow plug) in between two
exhaust gases flowing through it. The catalytic catalysts. During cold start, the engine is run rich and
elements in the ceramic are enclosed in stainless a small amount of air is injected to make the mixture
steel. When ceramic beads are used instead of a flammable. This is then ignited and heats the catalyst.
honeycomb structure, the unit is known as a pellet The pre-heat burner uses the gasoline fuel in a small
catalytic converter. burner placed in front of the catalyst. The burner is
b) Oxidation Converter / two-way catalytic turned on during cold start and the heat generated
converter warms up the catalyst. So, the catalyst is hot when
This type is also known as a two-way catalytic the cold exhaust from the manifold reaches the
converter, because it can only operate with catalyst.
hydrocarbons (unburned fuel) and carbon monoxide IV. WHY CATALYTIC CONVERTER
(caused by partially-burned fuel). Oxidation BASED ON NON-NOBLE MATERIAL?
converter elements are usually covered in platinum. Generally catalytic converter uses platinum group of
c) Reduction Converter / Three-way catalytic metals like Pt, Pd and Rh. These noble metals are
converter known to promote the oxidation processes. There are
Similar to the oxidation converter, the reduction several types of problems associated with noble metal
catalytic converter helps eliminate hydrocarbons and based catalytic converter. The failure of catalytic
carbon-monoxide emissions, plus oxides of nitrogen converter may be due to following factors:
emissions, or NOx. NOx emissions are produced in Converter meltdown
the engine combustion chamber when it reaches Carbon deposit
extremely high temperatures more than 2,500 degrees
Catalyst fracture
Fahrenheit, approximately.
Poisoning
d) Dual-Bed Converter
The converter becomes too hot and melts inside so
This is perhaps one of the most efficient converters.
that the small particles come apart on the inside. The
The dual-bed uses a combination of two-and three
broken pieces can move around and get in position to
way catalytic converters housed in a single unit. Both
plug up the flow of exhaust through converter. This
converters are connected through a chamber where
meltdown is caused by converter having too much
incoming emissions are mixed. An air line plugs into
work to do. There is too much HC or CO to clean up.
the mixing chamber to force air into the chamber to
The converter doesnt know how to stop; It keeps up
react with the combined emissions and help reduce
its reactions. The inside chamber of the catalytic
hydrocarbon and carbon-monoxide emissions.
converter gets coated with some contamination, like
B. Automobile exhaust catalysts
carbon, oil, coolant or other stuff, or they are just
Conversion efficiency of a catalytic converter is low
melted enough and reduce surface area. Poor engine
at low temperature and efficiency increases as
performance may happen as a result of a clogged or
exhaust temperature increase. It means that catalytic
choked converter. Symptoms of clogged converter
converter is less effective during cold starting, when
include loss of power at higher engine speeds, hard to
pollution constituents in the exhaust gas are
start, poor acceleration and fuel economy. A red hot
maximum. The technology race to develop suitable
converter indicates exposure to raw fuel causing the
methods to control cold start HCs included both
substrate to overheat. A critical review of all these
catalytic and some unique system approaches:
factors infers the following important facts: It is still
Close-coupled catalyst;
difficult to achieve long term durability of converter
Electrically heated catalyzed metal monolith; under the conditions of normal vehicle use.
Hydrocarbon trap;

IJAERS/Vol. I/ Issue II/January-March, 2012/118-120


International Journal of Advanced Engineering Research and Studies E-ISSN22498974

V. NON-NOBLE MATERIAL BASED were deposited on the top of piston and cylinder head
CATALYST surface, using standard electroplating process.
A. Iron-exchange zeolite Copper was coated by using a cyanide copper bath
Zeolite is crystalline, hydrated alumina silicates, which produces a coating of porous nature and a fine
formed in nature or can be synthesized. Zeolite is deposition of metal on surface.
formed of AlO4 and SiO4 bonded together via the Among the different catalysts investigated, copper
oxygen atoms and assembled in such a way as to was found very effective in reducing both HC and
constitute cavities, cages and channels, uniformly CO emissions, and brake thermal efficiency was also
penetrating the entire lattice volume and thus improved. At a high CR of 9:l and with a lean
generating a high internal surface area available for mixture (A/F=I5.7), copper catalyst increases the
adsorption and catalytic processes. The properties of absolute brake thermal efficiency from 17.7% to
zeolites or molecular sieves which make them 22.8%, decreases HC emissions from 3200 to 2300
particularly suitable for use as catalysts are their large ppm, and lowers CO emissions from 3.6 to 0.25% by
surface area, well defined and uniform pore structure, volume when compared to the normal engine
well defined crystal structure, temperature stability, (CR=7.4, A/F=13.2) at 2 kW, 3000 rpm.
easy ion-exchange method and reproducibility in VI. CONCLUSION
various forms. The iron-exchanged X-zeolite (FeX) This paper reviewed the most common existing
has been developed by ion-exchanging of 13X zeolite technologies available to reduce exhaust emission
in pelletted form (3.0 mm average diameter) with and catalytic exhaust after treatment. Methodologies
anhydrous Ferric chloride (FeCl3). The amount of the to increase temperature of catalytic converter during
metal salt used for ion-exchanging is 5% of the mass cold starting were also discussed. Finally, current
of X-zeolite. research going on to replace noble catalyst were
Randip K. Das et al. conducted experiment with the discussed.
exhaust of a stationary, 4-stroke, 3-cylinder, water- REFERENCES
cooled, SI engine with a total displacement volume of 1. Ronald M. Heck, Robert J. Farrauto, Automobile
exhaust catalysts, Applied Catalysis General, vol.
800 cc and coupled to a hydraulic dynamometer.
221, 2001, pp. 443457
Maximum conversion efficiencies of 55.8% and 2. Grigorios C. Koltsakis, Anastasios M. Stamatelos,
57.4% were recorded for NOx and CO, respectively. Catalytic automotive exhaust after treatment, Prog.
The catalyst also maintains its high performance Energy Combust. Sci., Vol. 23, pp. 1-39, 1997.
3. R.Murali Manohar et al. Bio-Diesel production and
through a wide range of temperatures.
Effect of Catalytic Converter on Emission performance
B. TiO2 & CoO with Bio-Diesel Blends, International Journal of
M A Kalam et al. presented characteristics of a new Engineering Science and Technology, Vol. 2(6), 2010,
catalytic converter (catco) to be used for natural gas pp. 2133-2139.
4. M A Kalam et al. Development and test of a new
fuelled engine. The catco were developed based on
catalytic converter for natural gas fuelled engine,
catalyst materials consisting of metal oxides such as Sadhana, Vol. 34, Part 3, June 2009, pp. 467481
titanium dioxide (TiO2) and cobalt oxide (CoO) with 5. Randip K. Das et al. Theoretical and experimental
wire mesh substrate. Both of the catalyst materials analysis of iron-exchanged X-zeolite catalyst for SI
engine emission control, Experimental Thermal and
(such as TiO2 and CoO) are inexpensive in
Fluid Science, vol. 19, 1999, pp. 214222
comparison with conventional catalysts (noble 6. John P.A. Neeft et al. Diesel particulate emission
metals) such as palladium or platinum. control, Fuel Processing Technology, 47, 1996, pp. 1-
The TiO2/CoO based catalytic converter and a new 69
7. Ramesh B. Poola et al. Devices to improve the
natural gas engine such as compressed natural gas
performance of a conventional two-stroke spark
(CNG) direct injection (DI) engine were developed ignition engine, ANL/ES/CP-15485 CONF-9504174-
under a research collaboration program. The original 1
engine manufacture catalytic converter (OEM catco) 8. Ashutosh Srivastava et al. Vehicular Emission Control
technique, ETWMT-09, indo-italian Conference on
was tested for comparison purposes. The OEM catco
emerging Trends in Waste management Technologies.
was based on noble metal catalyst with honeycomb Dec. 3.1.09.
ceramic substrate. It is experimentally found that the 9. Catalytic converter
conversion efficiencies of TiO2/CoO based catalytic 10. http://en.wikipedia.org/wiki/Catalytic_converter
11. Bharat stage emission standard
converter are 93%, 89% and 82% for NOx, CO and
12. http://en.wikipedia.org/wiki/Bharat_Stage_emission_sta
HC emissions respectively. It is calculated that the ndards
TiO2/CoO based catalytic converter reduces 24%, 13. Catalytic converter
41% and 40% higher NOx, CO and HC emissions in 14. http://auto.howstuffworks.com/catalytic-converter.htm
15. Catalyst Handbook (Johnson Matthey).
comparison to OEM catco respectively.
16. Hans Bode, Material Aspects in Automotive Catalytic
C. Copper as in-cylinder catalyst Converters, Wiley-VCH Verlag GmbH &Co., 2002.
In order to investigate the application of catalytic 17. A. Takigawa et al. Methane emission from automobile
combustion, Ramesh B. Poola et al. carried out equipped with threeway catalytic converter while
driving, Energy, vol. 30, 2005, pp. 461473.
experiment with various catalysts; such as copper,
18. M. Irani et al. Monolithic three way catalytic converter
chromium, and nickel, was coated on the combustion for automobile exhaust emission control, Iranian
chamber wall for determining their effect on engine journal of mechanical engineering, Vol. 2, No. 1, 2005,
performance, combustion, and emission IAChE.
characteristics. The effect of lean fuel-air mixture and
higher compression ratio was studied with the best
catalyst among all the catalyst tested. These catalysts

IJAERS/Vol. I/ Issue II/January-March, 2012/118-120

View publication stats

Das könnte Ihnen auch gefallen