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1 History
The catalytic converter was invented by Eugene Houdry,
a French mechanical engineer and expert in catalytic oil
rening[6] who lived in the U.S. around 1950. When
the results of early studies of smog in Los Angeles were
published, Houdry became concerned about the role of
smoke stack exhaust and automobile exhaust in air pollution and founded a company, Oxy-Catalyst. Houdry rst
developed catalytic converters for smoke stacks called
cats for short. Then he developed catalytic converters
for warehouse fork lifts that used low grade non-leaded
gasoline.[7] Then in the mid-1950s he began research to
develop catalytic converters for gasoline engines used on
cars. He was awarded United States Patent 2742437 for
his work.[8]
Widespread adoption of catalytic converters didn't occur
until more stringent emission control regulations forced
the removal of the anti-knock agent tetraethyllead, from
most gasoline, because lead was a 'catalyst poison' and
would deactivate the converter by forming a coating on
the catalysts surface, eectively disabling it.[9]
A catalytic converter is a vehicle emissions control device that converts toxic pollutants in exhaust gas to less
toxic pollutants by catalyzing a redox reaction (oxidation
or reduction). Catalytic converters are used in internal
combustion engines fueled by either petrol (gasoline) or
dieselincluding lean burn engines.
TYPES
3 Types
3.1 Two-way
A two-way (or oxidation) catalytic converter has two
simultaneous tasks:
1. Oxidation of carbon monoxide to carbon dioxide:
2CO + O2 2CO2
Ceramic-core converter
2. The washcoat. A washcoat is a carrier for the catalytic materials and is used to disperse the materials
over a large surface area. Aluminum oxide, titanium
dioxide, silicon dioxide, or a mixture of silica and
alumina can be used. The catalytic materials are suspended in the washcoat prior to applying to the core.
Washcoat materials are selected to form a rough, irregular surface, which greatly increases the surface
area compared to the smooth surface of the bare
substrate. This in turn maximizes the catalytically
active surface available to react with the engine exhaust. The coat must retain its surface area and prevent sintering of the catalytic metal particles even at
high temperatures (1000 C).[16]
3.2 Three-way
Three-way catalytic converters (TWC) have the additional advantage of controlling the emission of nitrogen
oxides (NO), in particular nitrous oxide, a greenhouse
gas over three hundred times more potent than carbon
dioxide,[17] a precursor to acid rain and currently the
most ozone-depleting substance.[18] Technological improvements including three-way catalytic converters have
led to motor vehicle nitrous oxide emissions in the US
falling to 8.2% of anthropogenic nitrous oxide emissions
in 2008, from a high of 17.77% in 1998.
3.3
Diesel engines
slightly above the stoichiometric point. This point is between 14.6 and 14.8 parts air to 1 part fuel, by weight, for
gasoline. The ratio for Autogas (or liqueed petroleum
gas (LPG)), natural gas and ethanol fuels is each slightly
dierent, requiring modied fuel system settings when
using those fuels. In general, engines tted with 3-way
catalytic converters are equipped with a computerized
closed-loop feedback fuel injection system using one or
more oxygen sensors, though early in the deployment of
three-way converters, carburetors equipped for feedback
mixture control were used.
Three-way catalysts are eective when the engine is operated within a narrow band of air-fuel ratios near stoichiometry, such that the exhaust gas oscillates between
rich (excess fuel) and lean (excess oxygen) conditions.
However, conversion eciency falls very rapidly when
the engine is operated outside of that band of air-fuel ratios. Under lean engine operation, there is excess oxygen and the reduction of NO is not favored. Under rich
conditions, the excess fuel consumes all of the available
oxygen prior to the catalyst, thus only stored oxygen is
available for the oxidation function. Closed-loop control
systems are necessary because of the conicting requirements for eective NO reduction and HC oxidation. The
control system must prevent the NO reduction catalyst
from becoming fully oxidized, yet replenish the oxygen
storage material to maintain its function as an oxidation
catalyst.
they eectively have to be equipped with a 2-Way catalytic converter and a diesel particulate lter. Note that
this applies only to the diesel engine used in the vehicle.
As long as the engine was manufactured before 1 January
2007, the vehicle is not required to have the DPF system.
This led to an inventory runup by engine manufacturers
in late 2006 so they could continue selling pre-DPF vehicles well into 2007.[21] During the re-generation cycle,
most systems require the engine to consume several gallons of fuel in a relatively short amount of time in order
to generate the high temperatures necessary for the cycle
to complete. This has been shown to adversely aect the
overall fuel economy of vehicles equipped with DPF systems, especially in vehicles that are driven mostly in city
conditions where frequent acceleration requires a larger
amount of fuel to be burned and therefore more soot to
collect in the exhaust system.
3.4
Installation
REGULATIONS
5 Damage
Catalyst poisoning occurs when the catalytic converter is
exposed to exhaust containing substances that coat the
working surfaces, encapsulating the catalyst so that it cannot contact and treat the exhaust. The most-notable contaminant is lead, so vehicles equipped with catalytic converters can be run only on unleaded fuels. Other common catalyst poisons include fuel sulfur, manganese (originating primarily from the gasoline additive MMT), and
silicone, which can enter the exhaust stream if the engine has a leak that allows coolant into the combustion
chamber. Phosphorus is another catalyst contaminant.
Although phosphorus is no longer used in gasoline, it (and
zinc, another low-level catalyst contaminant) was until recently widely used in engine oil antiwear additives such as
zinc dithiophosphate (ZDDP). Beginning in 2004, a limit
of phosphorus concentration in engine oils was adopted
in the API SM and ILSAC GF-4 specications.
7.1
Warm-up period
Negative aspects
5
In the United States, for example, it is a violation of Section 203(a)(3)(A) of the 1990 Clean Air Act for a vehicle
repair shop to remove a converter from a vehicle, or cause
a converter to be removed from a vehicle, except in order to replace it with another converter.,[26] and Section
203(a)(3)(B) makes it illegal for any person to sell or to
install any part that would bypass, defeat, or render inoperative any emission control system, device, or design element. Vehicles without functioning catalytic converters
generally fail emission inspections. The automotive aftermarket supplies high-ow converters for vehicles with
upgraded engines, or whose owners prefer an exhaust system with larger-than-stock capacity.[27]
8 Theft
Because of the external location and the use of valuable
precious metals including platinum, palladium, rhodium,
and gold, converters are a target for thieves. The problem is especially common among late-model trucks and
SUVs, because of their high ground clearance and easily removed bolt-on catalytic converters. Welded-in converters are also at risk of theft, as they can be easily cut
12
REFERENCES
o.[31][32][33] Thieves techniques for fast removal of a used for the same reasons and in the same manner as an
converter, for instance using a portable reciprocating saw, oxygen sensor: the only dierence is the substance being
can often damage other components of the car. Damage monitored.
to components like wiring, or a fuel line, can have dangerous consequences. Rises in metal costs in the U.S.
during recent years have led to a large increase in con- 10 As a metaphor
verter theft.[34] A catalytic converter can cost well over
$1,000 to replace.[35]
In his book Immigration Wars: Forging an American Solution, governor Jeb Bush uses the device as a
metaphor, comparing skilled worker immigration into the
United States of America to a catalytic converter. He
9 Diagnostics
says,'We cannot put aside this powerful catalytic converter for continued progress.'
Various jurisdictions now legislate on-board diagnostics
to monitor the function and condition of the emissionscontrol system, including the catalytic converter. On11 See also
board diagnostic systems take several forms.
Temperature sensors are used for two purposes. The rst
is as a warning system, typically on two-way catalytic converters such as are still sometimes used on LPG forklifts.
The function of the sensor is to warn of catalytic converter temperature above the safe limit of 750 C (1,380
F). More-recent catalytic-converter designs are not as
susceptible to temperature damage and can withstand sustained temperatures of 900 C (1,650 F). Temperature
sensors are also used to monitor catalyst functioning: usually two sensors will be tted, with one before the catalyst and one after to monitor the temperature rise over the
catalytic-converter core.
The oxygen sensor is the basis of the closed-loop control
system on a spark-ignited rich-burn engine; however, it is
also used for diagnostics. In vehicles with OBD II, a second oxygen sensor is tted after the catalytic converter
to monitor the O2 levels. The O2 levels are monitored
to see the eciency of the burn process. The on-board
computer makes comparisons between the readings of the
two sensors. The readings are taken by voltage measurements. If both sensors show the same output or the rear
O2 is switching, the computer recognizes that the catalytic converter either is not functioning or has been removed, and will operate a malfunction indicator lamp and
aect engine performance. Simple oxygen sensor simulators have been developed to circumvent this problem
by simulating the change across the catalytic converter
with plans and pre-assembled devices available on the Internet. Although these are not legal for on-road use, they
have been used with mixed results.[36] Similar devices apply an oset to the sensor signals, allowing the engine to
run a more fuel-economical lean burn that may, however,
damage the engine or the catalytic converter.[37]
NO sensors are extremely expensive and are in general
used only when a compression-ignition engine is tted
with a selective catalytic-reduction (SCR) converter, or
a NO absorber catalyst in a feedback system. When tted to an SCR system, there may be one or two sensors.
When one sensor is tted it will be pre-catalyst; when two
are tted, the second one will be post-catalyst. They are
Catalytic heater
Cerium(III) oxide
NOx adsorber
Roadway air dispersion modeling
12 References
[1] Palucka, Tim (Winter 2004). Doing the Impossible. Invention & Technology 19 (3). Archived from the original
on 3 December 2008. Retrieved 14 December 2011.
[2] Petersen Publishing (1975). The Catalytic Converter.
In Erwin M. Rosen. The Petersen Automotive Troubleshooting & Repair Manual. New York, NY: Grosset
& Dunlap. p. 493. ISBN 0-448-11946-3. For years,
the exhaust system (...) remained virtually unchanged until 1975 when a strange new component was added. Its
called a catalytic converter(...)
[3] General Motors Believes it has an Answer to the Automotive Air Pollution Problem. The Blade: Toledo, Ohio.
12 September 1974. Retrieved 14 December 2011.
[4] Catalytic Converter Heads Auto Fuel Economy Eorts.
The Milwaukee Sentinel. 11 November 1974. Retrieved
14 December 2011.
[5] Choosing the Right Wood Stove. Burn Wise. US EPA.
Retrieved 2 January 2012.
[6] Csere, Csaba (January 1988). 10 Best Engineering
Breakthroughs. Car and Driver 33 (7): 63.
[7] Exhaust Gas Made Safe. Popular Mechanics, September
1951, p. 134, bottom of page
[8] His Smoke Eating Cats Now Attack Trac Smog. Popular Science, June 1955, pp. 83-85/244.
[9] Sta writer (undated). Eugene Houdry. Chemical Heritage Foundation. Retrieved 7 January 2011.
[10] (registration required) Carl D. Keith, a Father of the Catalytic Converter, Dies at 88. The New York Times. 15
November 2008.
[11] Sta writer (undated). Engelhard Corporation. referenceforbusiness.com. Retrieved 7 January 2011.
[12] Robert N. Carter, Lance L. Smith, Hasan Karim, Marco
Castaldi, Shah Etemad, George Muench, R. Samuel
Boorse, Paul Menacherry and William C. Pfeerle
(1998). Catalytic Combustion Technology Development
for Gas Turbine Engine Applications. MRS Proceedings,
549, 93 doi:10.1557/PROC-549-93
[13] Worthy, Sharon. Bio-Medicine: Connecticut chemist receives award for cleaner air technology. 23 June 2003.
Retrieved 11 December 2012.
[14] Pischinger, Univ.-Prof. Dr.-Ing. Stephan (2011). Verbrennungsmotoren Band 2 (24 ed.). Aachen, Germany:
Lehrstuhl Fr Verbrennungskraftmachinen. p. 335.
[15] Pischinger, Univ.-Prof. Dr.-Ing. Stephan (2011). Verbrennungsmotoren Band 2 (24 ed.). Aachen, Germany:
Lehrstuhl Fr Verbrennungskraftmachinen. p. 335.
[34] Johnson, Alex (12 February 2008). Stolen in 60 Seconds: The Treasure in Your Car As Precious Metals Prices Soar, Catalytic Converters Are Targets for
Thieves. MSNBC. Retrieved 7 January 2011.
13 Further reading
Keith, C. D., et al. U.S. Patent 3,441,381: Apparatus for purifying exhaust gases of an internal combustion engine. 29 April 1969
Lachman, I. M. et al. U.S. Patent 3,885,977:
Anisotropic Cordierite Monolith (Ceramic substrate). 5 November 1973
Charles H. Bailey. U.S. Patent 4,094,645: Combination muer and catalytic converter having low
backpressure. 13 June 1978
Charles H. Bailey. U.S. Patent 4,250,146: '"Caseless monolithic catalytic converter. 10 February
1981
Srinivasan Gopalakrishnan. GB 2397782: Process
And Synthesizer For Molecular Engineering of Materials. 13 March 2002
14
14
External links
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15
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