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College of Engineering,
Karvenagar, Pune
CERTIFICATE
Date :
Place :PUNE
Guide
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Tackling Cold Start Problem in Catalytic Converter 2019
ACKNOWLEDGEMENT
I take this opportunity here to thank all those who had helped us in making this
seminar.
First of all, I express our deep gratitude to our seminar guide Prof. S. R. Dhok for his
valuable support, help & guidance from time to time during the project work. I am
also grateful to our Head of Department, Dr. P. S. Purandare for giving us this
opportunity to present this seminar.
Last but not the least; I would like to thank our entire teaching staff who assisted me
directly or indirectly throughout the duration of this time period.
Gautami Deshpande
T150450836
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Tackling Cold Start Problem in Catalytic Converter 2019
LIST OF FIGURES
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Tackling Cold Start Problem in Catalytic Converter 2019
INDEX
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Tackling Cold Start Problem in Catalytic Converter 2019
ABSTRACT:
As we know, we live in an era of industrialization. We are constantly surrounded by
various machines. All the machines which operate using non-renewable energy
resources are expected tp emit CO2 and H2O after the complete reaction. But, in
reality, all the reactions leave poisonous gases such as Carbon Monoxide(CO), Oxides
of Nitrogen and Hydrocarbons as effluents. These are proved to be very harmful for
the living body. Hence we need to rectify the above mentioned gases into less harmful
Catalytic convertors are being used for the same purpose since many years.
New modifications are being made in the catalytic convertors for the sake of complete
elimination of the effluents. Hence we try to eliminate the problems faced by Cat-cons
such as back pressure, durabily and cold starting. Problem of back pressure can be
starting play a major role in the industries and hence needs to be solved.
Cold start problem of the catalytic converter can be solved by using PCM and
This further increase the capacity, durability and efficiency of the catalytic converter
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Tackling Cold Start Problem in Catalytic Converter 2019
The converter uses simple oxidation and reduction reactions to convert the
unwanted fumes. Recall that oxidation is the loss of electrons and that reduction is the
gaining of electrons. The precious metals mentioned earlier promote the transfer of
electrons and, in turn, the conversion of toxic fumes.
There are two types of "systems" running in a catalytic converter, "lean" and
"rich." When the system is running "lean," there is more oxygen than required, and
the reactions therefore favor the oxidation of carbon monoxide and hydrocarbons (at
the expense of the reduction of nitrogen oxides). On the contrary, when the system is
running "rich," there is more fuel than needed, and the reactions favor the reduction of
nitrogen oxides into elemental nitrogen and oxygen (at the expense of the two
oxidation reactions). With a constant imbalance of the reactions, the system never
achieves 100% efficiency.
Note: converters can store "extra" oxygen in the exhaust stream for later use.
This storage usually occurs when the system is running lean; the gas is released when
there is not enough oxygen in the exhaust stream. The released oxygen compensates
for the lack of oxygen derived from NOx reduction, or when there is hard acceleration
and the air-to-fuel ratio system becomes rich faster than the catalytic converter can
adapt to it. In addition, the release of the stored oxygen stimulates the oxidation
processes of CO and CxH.
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Tackling Cold Start Problem in Catalytic Converter 2019
1.1.2 Construction
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Tackling Cold Start Problem in Catalytic Converter 2019
The catalyst core, or substrate. For automotive catalytic converters, the core is
usually a ceramic monolith with a honeycomb structure. Metallic foil monoliths made
of FeCrAl are used in some applications. This is partially a cost issue. Ceramic cores
are inexpensive when manufactured in large quantities. Metallic cores are less
expensive to build in small production runs, and are used in sportscars where low
back pressure and reliability under continuous high load is required. Either material is
designed to provide a high surface area to support the catalyst washcoat, and therefore
is often called a “catalyst support”. The cordierite ceramic substrate used in most
catalytic converters was invented by Rodney Bagley, Irwin Lachman and Ronald
Lewis at Corning Glass, for which they were inducted into the National Inventors Hall
of Fame in 2002.
The washcoat is a carrier for the catalytic materials and is used to disperse the
materials over a high 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).
The catalyst itself is most often a precious metal. Platinum is the most active catalyst
and is widely used, but is not suitable for all applications because of unwanted
additional reactions and high cost. Palladium and rhodium are two other precious
metals used. Rhodium is used as a reduction catalyst, palladium is used as an
oxidation catalyst, and platinum is used both for reduction and oxidation. Cerium,
iron, manganese and nickel are also used, although each has its own limitations.
Nickel is not legal for use in the European Union (because of its reaction with carbon
monoxide into nickel tetracarbonyl). Copper can be used everywhere except North
America, where its use is illegal because of the formation of dioxin.
Substrate: It is defined as the base material on which the catalyst wash coat is
provided
Three basic types of substrates which are widely used:
Ceramic Monolith
Metallic Wiremesh
Pellet Type
1. Ceramic Foam
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Tackling Cold Start Problem in Catalytic Converter 2019
Unlike standard, honeycomb type catalytic substrates, ceramic foam based systems
homogenize the flow as well as the thermal and chemical loads inside the converter.
The flow of exhaust gases inside the foam is turbulent, leading to improved heat and
mass transfer characterized by significantly higher sherwood and nusselt numbers
compared to the laminar flow inside honeycomb substrate channels. The ceramic
foams developed represent a promising concept, since they redistribute the flow of
exhaust gases thus enhancing turbulence and the mixing of species, without increasing
flow resistance to prohibitive levels. They can initiate, facilitate or balance complete
oxidation of unburnt HCs and CO, oxidize a substantial fraction of particulates while
generating required reactants for the following aftertreatment step. The turbulent flow
inside the ceramic foams permits short overall lengths for high conversion rates. The
relatively low material and manufacturing costs are an additional important aspect. In
urea based SCR (Selective Catalytic Reaction) nitrogen oxide reducing systems, the
evaporative characteristics of the liquid reactant and the mixing of NH3 with NOx are
improved by the turbulent flow through the ceramic foam based catalytic converter.
2. Metallic Substrate
Material like stainless steel is used to manufacture a wire mesh with required
cell density as a substrate.
This substrate is further treated so as to impregnate the catalyst onto it for the
required reactions to take place.
3. Zeolite Pellets
Zeolite has received captivating attention as an environmental catalyst due to
its capability in filtration, refining and separation of chemical species. Porous alumina
structure of interconnecting channels provides the advantages by promoting radial
mixing and enhancing turbulence. Existing PGM (Platinum Group Metal) catalysts,
which are commonly used in honeycomb structure of conventional catalytic
converters, are highly expensive.
This project develops a Porous Alumina-Zeolite (PAZ) filter and investigates
its influence on hydrocarbon (HC) emission from a spark ignition engine. This filter
employs polymeric sponge method to obtain porous structure with a composition of
90 vol. % alumina and 10 vol. % of zeolite. The filter is tested in the exhaust system
of 1300 cc engine at different speeds from 1400 rpm to 3200 rpm. The emission is
measured and compared with conventional catalytic converters. Further experiment is
conducted by installing both commercial catalytic converter and PAZ filter and in
their reverse position. Analysis shows reduction of emission level up to 20 % is
obtained between 1400 rpm to 2200 rpm for PAZ and a combined system of both
PAZ and catalytic converter. The results exhibits the potential of PAZ filters as a HC
trap especially in a cold start region in which the catalyst in catalytic converter has not
been fully activated yet.
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1. Cerium Oxide
It is used as an oxygen storing compound. It liberates of absorbs O2 during the
air-fuel perpetuations. It was found to have the proper redox response, there it is the
most commonly used O2 storage compound in modern day catalytic converters.
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Step I: Soaking of 13x zeolite sieves in silver nitrate and copper nitrate solution as per
specified ratio of zeolite and solution (being 20:3)
Step II: Dried pallets are then heated in electric furnace to 6000C which oxidises
nitrate from zeolite surface to form Ag and Cu coated 13x zeolite .
We have tested catalytic converter at 20:3 ratio which gives best result at
various operating conditions.
4. Ammonia
Use of urea spray: By using urea spray selective catalytic reduction of
oxides of nitrogen take place. In automotive industries the solution
known as ADBLUE is used which is 32.67% urea by weight
4NH3+4NO+O2 4N2+6H2O
6NO2+8NH3 7N2+12H2O
The steel can is exposed to high temperatures because of the heat generated
within the converter. It is necessary to select steels that have low thermal expansion
coefficient and excellent creep resistance to maintain the holding force
The holding force can decrease if the steel shell expands too much or if the steel
undergoes permanent deformation. Ferrite stainless steels 409 and 439 are commonly
used for catalytic converter cans. The thermal expansion of this steel is 30% lower
than 300 series stainless steels.
2. Literature review
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Two-way catalytic converter was mainly used before 1981. After which they
were replaced by three-way catalytic converters due to their lack to control nitrogen
oxides.
The major issue in three-way catalytic converters is that the reduction of NOx
fails under lean conditions, while the oxidation of CO and HC remains incomplete in
rich conditions.
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2.2.1Back Pressure
The classic symptoms of too much backpressure include things like a lack of
high speed power, poor fuel economy and even overheating. Anything that backs up
exhaust pressure into the engine will also back up heat. About a third of the heat
produced by combustion goes out the tailpipe as waste heat, so if the heat can't escape
it can overload the cooling system and make the engine run hotter than normal,
especially at highway speeds.
If there is a complete blockage in the exhaust, the engine may start and idle
fine for a minute or two, then die as backpressure builds up and strangles the engine.
In some instances, backpressure may buildup to such a degree that it blow out a pipe
connector or the converter shell. That makes diagnosis a lot easier, but in most cases
you may not be sure if there is an exhaust restriction or not. So in these instances, you
need to measure backpressure.
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2.2.2Warm-up Delay
Vehicles fitted with catalytic converters emit most of their total pollution
during the first five minutes of engine operation; for example, before the catalytic
converter has warmed up sufficiently to be fully effective.
2.2.2.1Light-off Temperature
Automotive catalytic converters are quite efficient once they reach operating
temperature, typically destroying over 98% of the incoming hydrocarbons (HCs) and
carbon monoxide (CO). However, up to 80% of the emissions during the Federal Test
Procedure occur during the first few minutes when the engine is running rich, the
oxygen sensor is not yet operational, and the catalytic converter has not reached its
light-off temperature. Thus, to significantly reduce automotive emissions of HCs and
CO, a method must be found which will reduce the emissions during the cold start
period.
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c. Thermal insulation
The concern over cold-start emissions has led to significant activity by auto
manufacturers and suppliers in developing new emissions treatment techniques.
Leading approaches include quick-heat of the catalyst electrically [Laing, 1994;
Socha et al., 1994] or with a catalyzed-fuel burner [Oser et al., 1994]. These
techniques typically require a minimum of 1 kW to 2 kW of power for 1 0 to 30
seconds in order to reduce (but not totally eliminate) the cold-start emissions. In
addition to significant added cost and complexity, these systems also undergo
repeated and severe thermal gradients. It is anticipated that these gradients may lead
to a reduction in system durability at a time when warranty periods are being
extended. Electrically heated catalyst systems also put the battery through repeated
deep-discharge cycles and stress the alternators.
This can involve double-walled insulating pipe leading from the manifold to
the catalyst, as well as hightemperature refractory insulation around the catalyst itself.
Sufficient insulation around the catalyst can maintain its temperature above lightoff
for several hours after the engine is shut off. Any trip initiated within this time then
would start with virtually no cold-start emissions. As with electrically heated and
fuel-fired catalysts, some vehicles may require air-injection to fully catalyze the fuel-
rich mixture typically present in the first few minutes of engine operation.
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3. CASE STUDY
This approach involves introducing a very small amount of hydrogen gas into the
vacuum insulation. This can be accomplished by mounting a small metal hydride with
an electric resistance heater to the cold side of the vacuum insulation. The pressure of
the hydrogen is a predictable function of the hydride temperature, and the gas is
readily reabsorbed whenever the hydride is allowed to cool. By controlling the
temperature of the hydride, the thermal conductance of the insulation can be
continuously adjusted between a minimum value determined by the construction of
the insulation and a maximum value bounded roughly by the thermal conductance of
the hydrogen gas. This variable-conductance insulation (VCI) was applied to
automotive catalytic converter thermal management. The first two catalytic converter
test articles (TA-CC1 and TA-CC2) contained cordierite converter monoliths without
precious-metal loading and were used only to verify thermal performance modeling.
A standard laboratory heat-retention test involved heating the converter to 650°C with
an electric air heater and monitoring the converter cooldown. The time to reach a
conservative light-off temperature of 350°C was used to evaluate heat-retention
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Fig 8: Comparison between different methods like PCM, VCI, and conventional converter
4. REFERENCES:
[1] Taylor K.C., “Automotive Catalytic Converters”, Catalysis Science & Technology
Springer Verlag, Berlin, Vol 5 pp. 120 – 170 (1983)
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