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INTRODUTION
1.1 INTRODUCTION
As everyone knows, air pollution is big challenge for the world. Air pollution is
not national problem. An under developed country like India control of air pollution is
very necessary. Air pollution due to industrial west, automobile & by nature. But
among that air pollution due to automobile 70% of total air pollution. So now a day
control of automobile pollution & it’s bad effect is very necessary. We have several
ways for controlling automobile pollution, but most effective way is by using catalytic
converter in the automobile.
The catalytic converter does a great job at reducing the pollution, but it can still
be improved substantially. One of its biggest shortcomings is that it only works at a
fairly high temperature. When you start your car cold, the catalytic converter does
almost nothing to reduce the pollution in your exhaust.
As the name suggests, it basically converts harmful gases into harmless gases,
which are environment friendly, with the help of a catalyst.
Engine exhausts having harmful gases like CO, NOx & HC which are converted
into harmless gases like CO2, N2 & H2O respectively with the use of catalytic
converter.
1.3 HISTORY
In 1973, General Motors faced new air pollution regulations and needed a way
to make its cars conform to the stricter standards. Robert C. Stempel, who at the time
was a special assistant to the GM president, was assigned to oversee development of a
technology capable of addressing the problem. Under Stempel's guidance, GM built on
existing research to produce the first catalytic converter for use in an automobile.
In a study released on Nov. 28, 1973, the EPA determined "that lead from
automobile exhaust was posing a direct threat to public health."
Although catalytic converters were developed in the 1950s, the device couldn't be used
in vehicles because the lead in gasoline would render them useless.
A potential problem appears with the release of platinum group metals (PGMs)
from the converters into the environment. There is now convincing evidence for the
release of platinum group metals (PGMs) into the environment, possibly by abrasion of
the autocatalyst. As a result, PGMs are found to have increased in the environment. In
recent study, we found that PGMs have increased in road dust since 1984 and
particularly 1991.
First of all catalytic converter was installed in under floor. This design needed
further improvement. So the 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) Wash Coat: A coating that increases the effective surface area of the
substrates & facilitates the application of precious metal catalyst onto the surface of the
ceramic surface of the ceramic substrate.
(4) Mat: It provides thermal insulation & protects against mechanical shock &
chassis vibration.
(5) Can: A metal package that encases all the above components.
(6) Heat Shields: They are used to protect various parts surrounding the catalytic
converter, form thermal shocks.
Coating processes for catalytic converters present several challenges that have
been tackled in the visual analysis lab. Catalytic converter manufacturers complained
that quality control of catalyst coat thicknesses is difficult. In addition the coating
liquid often clogs several of the catalytic converter channels.
B. A ribbed body encases the ceramic to reduce expansion and distortion when
the converter reaches its high operating temperature. The ribs form channels that hold
the ceramic in proper alignment and protect the cushioning mat from direct exposure to
exhaust gases.
C. MagnaFlow converters have a smooth-flowing, 1/2" lap joint where the neck
and body connect. This joint prevents the neck from extending into the body, where it
could impede exhaust flow.
D. MagnaFlow maintains separate dies for several converter body sizes and
corresponding neck sizes. This process eliminates the need to adapt neck sizes to make
them fit on a single converter body size, which would increase back pressure and
decrease airflow and horsepower.
E. The ceramic catalysts are seam welded to a heavy-gauge, stainless steel
converter body. Furthermore, a stainless steel heat shield is seam welded to the inner
converter 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.
There are main types of structures used in catalytic converters. Honeycomb and
Ceramic beads. Most cars today use a honeycomb structure.
Ceramic Honeycomb
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:
For example:
(1) Monolith:
# Shell: Manufactures make converter housing of sell of two stamped 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 then pellet
type gases will pass through the center of the element only.
# 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.
WORKING
Most modern cars are equipped with three-way catalytic converters. “Three-
way” refers to the three regulated emission it helps to reduce carbon monoxide, VOCs
and NOx molecules. The converter uses two different types of catalyst, a reduction
catalyst and an oxidization catalyst. Both types consist of a ceramic structure coated
with a metal catalyst, usually platinum, rhodium and palladium. The idea is to create a
structure that exposes the maximum surface area of catalyst to the exhaust stream,
while also minimizing the amount of catalyst required (they are very expensive).
In order to reduce emissions, modern car engines carefully control the amount of
fuel they burn. They try to keep the air-to-fuel ratio very close to the stoichiometric
point, which is the calculated ideal ratio of fuel. Theoretically, ratio the fuel will be
burned using all of the oxygen in the air. For gasoline, the stoichiometric ratio is about
14:7:1, meaning that for each pound of gasoline, 14.7 pounds of air will be burned.
Sometimes the mixture can be lean (an air-to-fuel ratio higher than 14.7), and other
times the mixture can be rich (an air-to-fuel ratio lower than 14.7).
Nitrogen gas (N2) - Air is 78%, nitrogen gas and most of this passes right
through the car engine.
Carbon dioxide (CO2) - This is one product of combustion. The carbon in the
fuel bonds with the oxygen in the air.
Water vapor (H2O) - This is another product of combustion. The hydrogen in the
fuel bonds with the oxygen in the air.
These emissions are mostly benign (although carbon dioxide emissions are believed to
contribute to global warming). But because the combustion process is never perfect,
some smaller amounts of more harmful emissions are also produced in car engines.
Sunlight breaks these down to form oxidants, which react with oxides of
nitrogen to cause ground level ozone (O3), a major component of smog.
Nitrogen oxides (NO and NO2, together called NOx) – contributes to smog and
acid rain, and causes irritation to human mucus membranes.
These are the main regulated emissions, and also the ones that catalytic
converters are designed to reduce.
This type of converter either oxides or reduces but not both at one time, so most
often not used now a days.
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
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.
Unleaded Petrol
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.
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.
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.
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).
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.
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.
Advantages
Cost is high.
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.
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.
3.5 IMPROVEMENT:
First of all Chrysler used its air injection system to supply the additional air to
catalytic converter. Afterwards it modifies it by addition of air switching valve and
coolant control engine vacuum switch. These units are control the air from the injection
pump during and after engine warm up. This assists in oxidation of HC and Co.
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.
Exp. On 2 – Wheeler (Max. Limit of CO 4.5% without cat. Con. Approx.)
» CHAPTER-4 «
» NEW DEVELOPMENT «
4.3 Preconverter:
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:
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.
► 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.
► 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 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.
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.
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:
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 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.
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.
» CHAPTER-5 «
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.
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.
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.
In 1986, the U.S. Environmental Protection Agency issued new guidelines for the
construction, efficiency and installation of aftermarket catalytic converters. All
CleanAir converters listed in this catalog have been designed, tested and manufactured
to meet this policy.
In addition, CleanAir converter listed in this catalog is appropriate for use under the
current requirements of the California Air Resources Board (C.A.R.B.).
2. A state or local inspection program has determined that the existing converter
need replacement.
3. Vehicles manufactured prior to 1996 must have more than 50,000 miles, and a
4. In cases of OBD Il-equipped vehicles (1996 and later), the O.E. manufacturer's
2. It be the same type as the original (i.e., two-way, three-way, three-way plus air/three-
3. It be the proper model for the vehicle application as determined and specified by the
manufacturer.
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