EXPERIMENTAL INVESTIGATION ON 4 WAY CATALYTIC

CONVERTER COATED WITH CeO2, ZrO2AND ZEOLITE BY DIP

COATING TECHNIQUE

ABSTRACT
Automobile industry has a high impact on economy since with the demand for automobiles the fuel
consumption is also rises. The vehicles using less expensive fuel will have more utilization for daily needs.
It is projected that by 2030, 1300 million automobiles will be plying on roads. On proper combustion of
fuel CO2, H2O are generated which are less harm to engine and environment on low levels. But an
incomplete combustion may generate toxic pollutants like COx, NOx, HC which may cause a serious
threat to environment and human health. Amongst all NOx is the most predominant one

Hence throughout the world researches going to find the best methods to reduce this harmful gas level
from exhausts. A catalytic converter is an auxiliary equipment used in automobiles which will help to
reduce NOx and COx emissions by adsorption. But the coatings like Platinum and Rhodium metals on
monolith are a way too expensive as they are rare.

In this research an experimentational analysis done on alternative coatings. CeO2, ZrO2 are experimented
for NOx cut and control whereas Zeolites are used COx control.

KEYWORDS: CeO2, ZrO2, zeolite, Aluminum oxide (Alumina), polyvinyl alcohol(PVA), acetic acid,
distilled water, catalytic converter.

INTRODUCTION
depending upon the physical and chemical
The Toxic gases formation from automobile
property of pollutants, concentration of
vehicle exhaust depends on the combustion
pollutants and proportion of population
process air/fuel ratio, engine performance,
exposed. To controlling the formation of
compression ratio, temperature of flame and
pollutants it is necessary to properly maintain
function of carburetor etc., The types of
the vehicles and use a durable, economical, long
pollutants also depend upon the quality of fuels,
time stable and easily available catalyst in the
volatility and types of minerals and impurities
automobile catalytic converter system. The
present in the fuels. The major factors affect the
catalytic converter is a device it placed in the
automobile vehicles exhaust highly toxic to
vehicle exhaust pipe for converting HC, CO and
human health and living things. It also
NOx into less harmful gasses. In comparison
between urban area and rural area we have to
find out that urban area is highly affected by
automobile vehicles exhaust pollution. In the
vehicle source of automobile exhaust pollutants
control the certain emissionsstandard of tailpipe,
evaporative emissions controlling, increased
durability and application of computerized
diagnostic system. The older and heavy vehicles
emit more pollutants like HC, CO, NOx and
particulate matter per mile as comparison to new
and small-sized vehicles. Gases are brought in
from the ―input‖ pipe connected to the engine of
a vehicle. These are blown over the catalyst,
which causes a chemical reaction that breaks a
pollutant.
The less-harmful gases now travel through the
second pipe, or the ― output, that is connected to
a car’s tailpipe. Catalytic converter prototypes
were first designed in France at the end of the
19th century, when only a few thousand "oil
cars" were on the roads; these prototypes had
inert clay-based materials coated with Platinum,
Rhodium and Palladium and sealed into a
double metallic cylinder. A few decades later, a
catalytic converter was patented by Eugene
Houdry, a French mechanical engineer. Houdry
was an expert in catalytic oil refining, having
invented the catalytic cracking process that all
modern refining is based on today. Catalytic
converters were further developed by a series of
engineers including Carl D. Keith, John J.
Mooney, Antonio Elezar, and Phillip Messina at
Engelhard Corporation, creating the first
production catalytic converter in 1973.
TYPES OF CATALYTIC CONVERTERS
Two-way catalytic converter
A Two-way catalytic converter, simply called
as oxidation has two simultaneous tasks. One is
Oxidation of carbon monoxide to carbon
dioxide. Second is oxidation of hydrocarbons to
carbon dioxide and water, that means
incomplete combustion into a combustion
reaction. This type of catalytic converter is
widely used in diesel engines to reduce
hydrocarbon and carbon monoxide emissions.
They were also used on gasoline engines in
American and Canadian market automobiles
until 1981. Because of their inability to control
oxides of nitrogen, they were superseded by
three-way converters.
1) 2CO + O2 → 2CO2
2) CxH2x+2+[(3x+1)/2] O2→x CO2 + (x+1)H2 O
Three-way catalytic converter
Three-way catalytic converters have the
additional advantage of controlling the emission control were used.
of nitric oxide (NO) and nitrogen dioxide Three-way converters are effective when the
(NO2), which are precursors to acid rain and engine is operated within a narrow band of air-
smog. Three-way catalytic converters have been fuel ratios near the stoichiometric point. Total
used in vehicle emission control systems in the
conversion efficiency falls very rapidly when
United States and Canada, many other countries
the engine is operated outside of this band.
have also adopted stringent vehicle emission
Slightly lean of stoichiometric, the exhaust
regulations that in effect require three-way
gases from the engine contain excess oxygen,
converters on gasoline powered vehicles. The
the production of NOx by the engine increases,
reduction and oxidation catalysts are typically
and the efficiency of the catalyst at reducing
contained in a common housing.
NOx falls off rapidly.
1) 2CO + 2NO → 2CO2 + N2
2) HC + NO → CO2 + H2O + N2 The conversion of HC and CO is very efficient
3) 2H2 + 2NO → 2H2O + N2 due to the available oxygen, oxidizing to H2O
These three reactions occur most efficiently and CO2. Slightly rich of stoichiometric, the
when the catalytic converter receives exhaust production of CO and unburnt HC by the engine
from an engine running slightly above the starts to increase dramatically, available oxygen
stoichiometric point. For gasoline combustion, decreases, and the efficiency of the catalyst for
this ratio is between 14.6 and 14.8 parts air to oxidizing CO and HC decreases significantly,
one part fuel, by weight. especially as stored oxygen becomes depleted.
However, the efficiency of the catalyst at
The ratio for Autogas (or liquefied petroleum
reducing NOx is good, and the production of
gas LPG), natural gas, and ethanol fuels can
NOx by the engine decreases. To maintain
vary significantly for each, notably so with
catalyst efficiency, the air: fuel ratio must stay
oxygenated or alcohol based fuels, with e85
close to stoichiometric and not remain rich or
requiring approximately 34% more fuel,
lean for too long.
requiring modified fuel system tuning and
components when using those fuels. In general,
engines fitted 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 with feedback mixture
 Cerium oxide

Cerium oxide is an oxide of the rare earth metal

cerium. It is a pale yellow- white Powder with
the chemical formula CeO2, it enables the

METHODOLOGY
Main chemicals used in coating process

The cemicals used are (i) Cerium oxide (ii)

Zirconium dioxide (iii) Zeolite (iv) Aluminium removal of harmful NOX gases from the

oxide (v) Polyvinyl alcohol (vi) Acetic acid (vii) exhaust gases by oxidation to less harmful gases

Distilled water. We ended up taking Cerium like nitrogen.

oxide, Zirconium dioxide, Zeoloite and Zirconium dioxide

Aluminium oxide as research into three types of
Zirconium dioxide (ZrO2) is a white crystalline
catalysts and one type of support catalyst.
oxide of zirconium. ZrO2 its enables the
removal of harmful HC and CO gases from the
exhaust gases by reduction to less harmful gases
like carbon dioxide compared with CO and HC
Zeolite
For the control of the emission of the carbon
dioxide into the atmosphere we have chosen for
adsorption of Carbon Dioxide from the exhaust
of the gasoline vehicles using Zeolite.
Aluminum oxide
These materials are designed to provide a
high surface area to support thecatalyst wash
coat. The catalyst wash coat is a carrier for the
catalytic converter materials, which is used to
disperse the materials over a high surface area.
Titanium dioxide, aluminum oxide, silicon
dioxide, or a combination of silica and alumina
can be used.
Polyvinyl Alcohol
It maintains thermal stability.in order to
overcome such limitations we developed a
ceramic coated materials based composite
separator. The ceramic layers composed of
Al203 nano particles and polyvinyl alcohol
(PVA) support which was fabricated by ceramic
substrate. The resulted in excellent chemical
properties greatly strength and flexibility
characteristics.
Acetic acid
The acetic acid taken for this reason. It is
reaction is limited to the surface with the
formation of surface coordinated acetate under
both dry and humid conditions.
Distilled water
The distilled water basically contains nothing
in it. Water has all sorts of various minerals in
them. The presence of any contaminant could
vary the results in the test.
METHODS
Al2O3 Slurry Preparation for Wash Coating
Aluminum oxide (Alumina) was used as wash
coat material to increase the coating strength
to surface of Clay marbles or Pellets. Twenty-
five grams (25gm) of alumina was added into
five grams (5gm) of polyvinyl alcohol (PVA)
which is a water-soluble synthetic polymer
and are being used in papermaking, textiles,
and a variety of other coatings. 2ml acetic acid
with 50 ml of distilled water was added to get
aluminum oxide slurry. The slurry was then
stirred at 600 rpm for one hour.
The ceramic substrate was then coated with the
metal catalyst by dipping technique. Coated
substrates are calcined. In this process,
ceramic substrate was immersedinto prepared
catalyst slurry for the duration of 15·20
minutes. Then, the coated ceramic substrate
was removed from catalyst slurry. They were
dried in an oven at a temperature of120◦C for
2hours before being claimed in an oven.
Calcination is a process in which, amaterial
is heated to a high temperature without fusing,
so that hydrates, carbonates, or other
compounds are decomposed and the volatile
material is expelled. Calcination is done at a
temperature of 250C in oven for 30 min.
CeO2 Slurry Preparation for Oxidation
Coating
Cerium (IV) oxide is an oxide of the rare
earth metal cerium. It is a pale yellow-white
powder with the chemical formula CeO2. 10gm
of Cerium (IV) oxide was added into 2.5gm of
polyvinyl alcohol (PVA), which is a water-
soluble synthetic polymer and 2ml acetic acid
with 20 ml of distilled water to get Cerium (IV)
oxide slurry. The slurry was then stirred at
600rpm for one hour. After completing the
slurry preparation, wash coat coated ceramic
substrate was coated in the same way as above.
ZrO2 Slurry Preparation for Reduction
Coating
Zirconium dioxide (ZrO2) is a white crystalline
oxide of zirconium. 10gm of Zirconium dioxide
was added into 2.5gm of polyvinyl alcohol
(PVA), which is a water- soluble synthetic
polymer and 2ml acetic acid with 20 ml of
distilled water to get Zirconium dioxide slurry.
The slurry was then stirred at 600rpm for one
hour. After completing theslurry preparation,
ceramic substrate which are already coated with
wash coat are coated with the catalyst by the
coating process repeated as above.
Slurry Preparation for zeolite Coating
10gm of Zeolite was added into 2.5gm of
polyvinyl alcohol (PVA), which is a water-
soluble synthetic polymer and 2ml acetic acid
with 20 ml of distilled water to get Zeolite
slurry. The slurry was then stirred at 600rpm for
one hour. After completing the slurry
preparation, clay marbles substrate which are
already coated with wash coat are coated with
the catalyst by the coating process repeated as
above.
Human health effects on automobile
pollution
The automobile pollutants like CO, HC, NOX,
SOX and PM have bad effects on the human
health and environments. These pollutants are
directly affect on the respiratory tract and
cardiovascular systems of humans
Carbon Monoxide (CO)
It effects on the cardiovascular system, central
nervous system, headache, creating nausea and
judgment problem. The CO combines with
hemoglobin present in the blood cells and
converted into carboxy-hemoglobin which
reduces the oxygen carrying capacity of the
human beings. The effect of CO on human
health.
Hydrocarbon Compounds (HC)
HC caused respiratory tract illness and lung
cancer. The exposure of HC on the human body
to significant amounts of these chemical
compounds causes eye irritation, nausea and
dizziness. The long- t e r m exposure, in
addition to the carcinogenic effect, cancause
skin, liver, kidney and cataract damage.
Carbon Dioxide (CO)
CO2 caused suffocation, dizziness; destroy
central nervous system and death also.
Breathing becomes more difficult as carbon
dioxide levels rise. In closed areas, high levels
ofcarbon dioxide can lead to health complaints
such as headaches. If CO levels are high enough
therefore human or animals become
unconscious or die. Exposure to moderate and
highlevels of CO over long periods of time has
also been linked with the more risk of heart
disease.
It is also known as the greenhouse gas was
associated with global warming and increased
from the combustion of fossil fuels including
motor vehicle fuels. A high concentration of
CO2 can displace oxygen in the air. If the
less oxygen is available tobreathe, symptoms
such as rapid breathing, rapid heart rate,
clumsiness, emotional upsets and fatigue can during pregnancy and becomes a source of
result. exposure to the developing fetus. Young

Sulfur oxide (SO) children are mainly vulnerable to Pb poisoning

because they absorb 4–5 times as much ingested
The SO2 can affect the lung function and
Pb as adults from the given source.
irritate the mucous membranes of the
respiratory tract and foster the development of RESULTS
chronic respiratory diseases and particularly Reduction percentage of NOx
bronchitis. When it is breathed in irritates the
Case NOx (mg/km)
nose, throat and airways to cause coughing,
wheezing, shortness of breath, or a tight feeling Without catalytic 2400
around the chest. The most risk of developing converter
problems if they are exposed to sulfur dioxide
Modified catalytic 100
at people with asthma or similar conditions.
converter
Nitrogen oxide (NO)
B. S-VI 60
Nitrogen oxide can effect on the respiratory
system. It caused irritations on lungs, nose, Effective reduction 95.83%
eyes, and throat sections. NOx has direct and % (Comparison
indirect effects on the human health. It causes without and
breathing problems, headaches, chronically modified C. C)
reduced lung function, eye irritation, loss of
appetite and corroded teeth.
Lead (Pb)
Exposure to high levels of Pb may cause
anemia, weakness, and kidney and brain
damage. Very high Pb exposure can cause
death. Lead can cross the placental barrier,
which means pregnant women who are exposed
to lead also expose their unborn child. Lead can
damage a developing baby’s nervous system.
Human exposure is usually assessed through
the measurement of lead the young children are
particularly vulnerable to the toxic effects of
lead. Lead in the bone was released into blood
 converter

Reduction percentage of CO B. S-VI 60

Case CO (mg/km)
Effective reduction % 95.83%
Without catalytic 3000 (Comparison without
converter and modified C. C)

Modified catalytic 450

converter

B. S-VI 500

Effective reduction % 85%

(Comparison without
and modified C. C)

Reduction percentage of CO2

Case CO2 (mg/km)

Without catalytic 1600

converter

Modified catalytic 250

converter

Reduction percentage of HC B. S-VI 1000

Case HC (mg/km)
Effective reduction % 75%
Without catalytic 2400 (Comparison without
converter and modified C. C)

Modified catalytic 100

Comparison of effective reduction percentages CONCLUSION
Case Nox CO HC CO2 After various investigations on noble and non-
(mg/km) (mg/km) (mg/km) noble alloys and investigation on CeO2, ZrO2,

Without 2400 3000 3000 1600 Zeolite catalysts used in catalytic converter, we
concluded that CeO2, ZrO2, Zeolite performs
C. C
excellently compared as a noble catalyst. The
Modified 100 450 150 250 effect cerium oxide (CeO2) has 95.83%

C. C efficiency for reducing NOx emission as

compared to without catalytic converter to take
B. S-VI 60 500 170 1000 readings. The effect of Zirconium oxide (ZrO2)

Effective 95.83% 85% 95% 75% has 95% efficiency for reducing HC emission and

reduction 85% efficiency for reducing CO emission as

% compared to without catalytic converter. The

effect of Zeolite has 75% efficiency for reducing
CO2 a compared to B. S-VI. In the place of
ceramic substrate, we are using the stainless-steel
mesh to reducing the cost of catalytic converter
and possible to make the less wait new invention.