ISS PRESENTATION ON CATALYTIC CONVERTERS

SUBMITED BYGAURAV PAHUJA 10-MEU-027

INDEX
What is catalytic converter? Need for catalytic converter Structure of catalytic converter Types of catalytic converters Working Factors affecting catalytic converter efficiency Advantages and disadvantages of using catalytic converters Ongoing research in the field of catalytic converters

WHAT IS CATALYTIC CONVERTER?

A catalytic converter is an after treatment device used to reduce exhaust emissions outside of the engine. This device is installed in the exhaust system between the exhaust manifold and the muffler, and usually is positioned beneath the passenger compartment.

 Most catalytic converters are constructed of a ceramic material in a honeycomb shape with square openings for the exhaust gases. The substrate is contained within a round or oval shell made by welding together two stamped pieces of aluminum or stainless steel. The converter contains small amounts of rhodium, palladium, and platinum. These elements acts as catalysts. A catalyst is a substance that accelerates a chemical reaction by lowering the energy needed for it to proceed. The catalyst is not consumed in the reaction and so functions indefinitely unless degraded by heat, age, contaminants, or other factors.

FIG.1 Catalytic converters used in cars (westerman.com)

 Lead was a major gasoline additive. The additive TEL( tetraethyl lead) was effectively used to increase the gasoline octane number, which allowed for higher compression ratios and more efficient engines. However, the resulting lead in the engine exhaust was a highly poisonous pollutant. Hence, need for catalytic converters. Also, during the combustion in the engine cylinder, compounds like CO, HC, SO2, NOX and some amounts of phosphorous are produced which leads to more emissions from the exhaust. Hence, the need for catalytic converters.

NEED FOR CATALYTIC CONVERTER

STRUCTURE OF CATALYTIC CONVERTER

Catalytic converter is basically a stainless steel container mounted somewhere along the exhaust pipe of the engine. Inside the container, is a porous ceramic structure through which the exhaust gas flows. This ceramic is a single honeycomb structure with many flow passages. Some converters use loose granular ceramic with the gas passing between the packed spheres. The surfaces of the ceramic passages contains small embedded particles of catalytic material that promote the oxidation reactions in the exhaust gas as it passes.

 Alumina is the base ceramic material used for most catalytic converters. Alumina can withstand the high temperatures, it remains chemically neutral, it has very low thermal expansion, and it does not thermally degrade with age. The catalyst materials most used are platinum, palladium, and rhodium.

Fig.2-Honeycomb structure of the ceramic material inside the catalytic converter( bikechatforums.com)

TYPES OF CATALYTIC CONVERTERS

There are 2 types of catalytic converters used in all the modern automobiles namely 2 WAY CATALYTIC CONVERTER- A 2 WAY catalytic converter has two simultaneous tasks ie. Oxidation of CO to CO2 and oxidation of hydrocarbons (unburnt and partially burnt fuel) to CO2 and H20. The chemical reactions taking place inside the 2WAY catalytic converter are as follows-

2CO + O2 2CO2 CxH2x+2 + [(3x+1)/2] O2 xCO2 + (x+1) H2O This type of catalytic converter is widely used on diesel engines to reduce carbon monoxide and hydrocarbon emissions. They were also used on gasoline engines in American and Canadian automobile market until 1981. Because of their inability to control oxides of nitrogen, they were superseded by 3 WAY converters.

Fig.3-2 WAY catalytic converter (google.com)

 3 WAY catalytic converters- 3 WAY catalytic converters have the additional advantage of controlling the emission of NOX. Since 1981, these converters have been used in vehicle emission control systems in the United States and Canada. Infact many other countries have also adopted stringent vehicle emission regulations that in effect require 3 WAY catalytic converters on gasoline powered vehicles. A 3 WAY converter has three simultaneous tasks ie reduction of NOX to N2 and O2,oxidation of CO to CO2 and oxidation of HC to CO2 and H20.

The chemical reactions taking place are as follows2NOx xO2 + N2 2CO + O2 2CO2 CxH2x+2 + [(3x+1)/2]O2 xCO2 + (x+1)H2O.

Fig.4- 3 WAY catalytic converter (google.com)

 3-WAY+AIR CATALYTIC CONVERTER- The 3way +air converter performs the same functions as the 3-way converters but has secondary air pumped into the middle of the converter between two separate catalyst coated ceramic substrates. The addition of air improves the oxidation capabilities of the converter.

 DIESEL OXIDATION CATALYST- This is the most commonly used catalytic converter for the CI engines. This catalyst uses O2 in the exhaust gas stream to convert CO to CO2 and HC to H2O and CO2. These catalysts are not active for NOX reduction because any reductant pressure would react first with the high conc. Of O2 in diesel exhaust gas. Reduction of NOX emissions from the CI engines is effective by the addition of the exhaust gas to the incoming air charge, known as EXHAUST GAS RECIRCULATION or EGR.

Fig.5-Catalytic conversion of carbon monoxides and hydrocarbons (nett technologies inc)

 MONOLITHIC CATALYTIC CONVERTER- Catalytic converter with

a catalyst-coated, ceramic honeycomb monolith (monolith is a large block of stone or anything that resembles one in appearance, intractability, etc) through which the exhaust gases pass. The catalytic converter contains a palladium-impregnated ceramic honeycomb monolith then a platinum and rhodiumimpregnated ceramic honeycomb monolith. The exhaust gas flow contacts the palladium-impregnated monolith then contacts the platinum and rhodiumimpregnated monolith. The operating temperature of a cat is between 350 to 400 degrees Celsius which causes a chemical reaction to occur as the exhaust gases flow through the coated monolith. The harmful gases are oxidised and converted.

WORKING
The working of the catalytic converter is divided into 3 stages as explained below REDUCTION CATALYST- It is the first stage of the catalytic converter. It uses platinum and rhodium to reduce the NOX emissions. When an NO or NO2 molecule contacts the catalyst, the catalyst rips the nitrogen atom out of the molecule and holds on to it, freeing the oxygen in the form of O2. The nitrogen atoms bond with other nitrogen atoms that are also stuck to the catalyst, forming N2.

The reactions take place as follows2NO => N2 + O2 or 2NO2 => N2 + 2O2 2NO => N2 + O2 or 2NO2 => N2 + 2O2 OXIDATION CATALYST- It is the second stage of the catalytic converter. It reduces the unburnt hydrocarbons and CO by oxidizing them over a platinum or palladium catalyst. This catalyst aids the reaction of the CO and hydrocarbons with the remaining oxygen in the exhaust gas. The reaction take place as follows2CO + O2 => 2CO2

 CONTROL SYSTEM- The third stage of the conversion is control system that monitors the exhaust stream and uses this information to control the fuel injection system. There is an O2 sensor mounted upstream of the catalytic converter, meaning it is closer to the engine than the converter. The sensor tells the engine computer how much oxygen is in the exhaust. The engine computer can increase or decrease the amount of oxygen in the exhaust by adjusting the air-to-fuel ratio.

FACTORS AFFECTING CATALYTIC CONVERTER EFFICIENCY

Factors affecting catalytic converter efficiency are explained as below TEMPERATURE- The efficiency of the catalytic converter is very much dependent on temperature. When a converter in good working order is operated at a fully warmed temperature of 400C or above, it will remove 98-99% of CO, 95% of NOX and more than 95% of HC from exhaust flow emissions.

Fig.6- Efficiency vs. temperature plot (V.Ganesan, internal combustion engines)

 EQUAVALENCE RATIO- It is also necessary for the engine to be operating at the proper equavalence ratio to get high converter efficiency. Effective control of HC and CO occurs with stoichiometric or lean mixtures while control of NOX requires near stoichiometric conditions.

Fig.7- Efficiency vs. equivalence ratio plot ( V.Ganesan, internal combustion engines)

 LEAD CONTAMINATION- Lead has a major impact on the catalytic converter efficiency. Infact, a small amount of lead on a catalyst site can reduce the HC emission reduction by a factor of 2 or 3. Small amounts of lead impurities are found in some fuels, and 10 to 30% of this ends up on the catalytic converter. Up until the early 1990s leaded gasoline was quite common and the leaded gasoline cannot be used in engines equipped with catalytic converters. Use of leaded gasoline filled two times would completely poison a converter and make it totally useless. To reduce the chances of accidentally using leaded gasoline with a catalytic converter, the fuel pump nozzle size and the diameter of the fuel tank inlet are made smaller for unleaded gasoline.

Fig.8- Efficiency vs. lead contaminant on catalyst (V.Ganesan, internal combustion engines)

ADVANTAGES
Main advantage of using the catalytic converter is that it cuts down pollution, hence lesser amount of harmful gases in the atmosphere. The introduction of catalytic converters has led to the introduction of unleaded gasoline, since catalytic converters do not work with leaded gasoline. It has caused atmospheric levels of lead particulates to drop.

DISADVANTAGES
They are very expensive to get replaced. CO2 is the product of the reaction that takes place inside the converter, so widespread use of catalytic converters has also contributed to increased atmosphere levels of CO2 which is a greenhouse gas.

ONGOING RESEARCH IN THIS FIELD

Improving the effectiveness of catalytic converters via reduction of cold start emissions.