Catalytic converter From Wikipedia, the free encyclopedia Catalytic converter on a 1996Dodge Ram VanA catalytic converteris avehicle emissions control device which convertstoxicbyproducts ofcombustionin the exhaust of aninternal combustion engineto less toxic substances by way ofcatalysedchemical reactions. The specific reactions vary with the type of c atalyst installed. Most present-day vehicles that run ongasolineare fitted with a ―three way‖ converter, so named because it converts the three main pollutants in automobile exhaust. The three main pollutants arecarbon monoxide,unburned hydrocarbonandoxides of nitrogen.The first two are converted to two ne w molecules. This happens through an oxidizingreaction which converts carbon monoxide (CO) and unburned hydroc arbons (HC) toCO 2 and water vapor. The last pollutant is converted to three new molecules. This happens through a reductionreaction which convertsoxides of nitrogen(NO x ) to CO 2 ,nitrogen(N 2 ) andwater(H 2 O). [1] The first widespread introduction of catalytic converters was in the United Statesmarket, where 1975model yeargasoline-powered automobiles were so equipped to comply with tighteningU.S. Environmental Protection Agencyregulations on automobile exhaust emissions. [2][3][4][5] These were ―two-way‖ converters which combinedcarbon monoxide (CO) andunburned hydrocarbons(HC) to producecarbon dioxide(CO 2 ) andwater(H 2 O). Two-way catalytic converters of this type are now considered obsolete, having been supplanted except onlean burnengines by ―three-way‖ converters which also reduceoxides of nitrogen(NOx) . [2] Catalytic converters are still most commonly used inexhaust systemsinautomobiles,but are also used ongenerator sets,forklifts,mining equipment,trucks,buses,locomotives,motorcycles,airplanesand other engine-fitted devices. They are also used on some wood stoves to control emissions. [6] This is usually in response togovernment regulation,either through direct environmental regulation or through health and safety regulations.
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
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".[citation needed ] The cordieriteceramic 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.[citation needed ]
2. The washcoat. A 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).
[15]
3. 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 (see below) 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,[clarification
needed ]where its use is illegal because of the formation of dioxin.
[edit]Types
[edit]Two-way
A two-way (or "oxidation") catalytic converter has two simultaneous tasks:
1. Oxidation of carbon monoxide to carbon dioxide: 2CO + O2 → 2CO2
2. Oxidation of hydrocarbons (unburnt and partially burnt fuel) to carbon dioxide and water : CxH2x+2 +
[(3x+1)/2] O2 → xCO2 + (x+1) H2O (a combustion reaction)
This type of catalytic converter is widely used on diesel engines to reduce hydrocarbon and carbon monoxideemissions. 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.
[edit]Three-way
Since 1981, "three-way" (oxidation-reduction) catalytic converters have been used in vehicle emission control
systems in the United States and Canada; many other countries have also adopted stringent vehicle emission
regulations that in effect require three-way converters on gasoline-powered vehicles. The reduction and
oxidation catalysts are typically contained in a common housing, however in some instances they may be
housed separately. A three-way catalytic converter has three simultaneous tasks:
1. Reduction of nitrogen oxides to nitrogen and oxygen: 2NOx → xO2 + N2
2. Oxidation of carbon monoxide to carbon dioxide: 2CO + O2 → 2CO2
3. Oxidation of unburnt hydrocarbons (HC) to carbon dioxide and water : CxH2x+2 + [(3x+1)/2]O2 → xCO2 +
(x+1)H2O.
These three reactions occur most efficiently when the catalytic converter receives exhaust from an engine
running 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 liquefied petroleum gas (LPG)), natural gas and ethanol fuels is
each slightly different, requiring modified fuel system settings 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 for feedback mixture control were used.
Three-way catalysts are effective 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 efficiency 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 NOx 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 theconflicting requirements for effective NOx reduction and HC oxidation. The control system must prevent the
NOx reduction catalyst from becoming fully oxidized, yet replenish the oxygen storage material to maintain its
function as an oxidation catalyst.
Three-way catalytic converters can store oxygen from the exhaust gas stream, usually when the air-fuel
ratio goes lean.[16] When insufficient oxygen is available from the exhaust stream, the stored oxygen is released
and consumed (see cerium(IV) oxide ). A lack of sufficient oxygen occurs either when oxygen derived from
NOx reduction is unavailable or when certain maneuvers such as hard acceleration enrich the mixture beyond
the ability of the converter to supply oxygen.
[edit]Unwanted reactions
Unwanted reactions can occur in the three-way catalyst, such as the formation of odoriferous hydrogen
sulfide and ammonia. Formation of each can be limited by modifications to the washcoat and precious metals
used. It is difficult to eliminate these byproducts entirely. Sulfur-free or low-sulfur fuels eliminate or reduce
Although catalytic converters are effective at removing hydrocarbons and other harmful emissions, they do
not reduce the emission of carbon dioxide (CO2) produced when fossil fuels are burnt.[27]
Carbon dioxide produced from fossil fuels is one of the greenhouse gases indicated by
the Intergovernmental Panel on Climate Change (IPCC) to be the leading cause of global warming.[28]
The U.S. Environmental Protection Agency (EPA) has stated automobile emissions are a significant and
growing cause of global warming, because of their release of nitrous oxide(N2O), a greenhouse gas over
three hundred times more potent than carbon dioxide. The EPA states that motor vehicles contribute
approximately 8.2% of anthropogenic nitrous oxide emissions in 2008, from a high of 17.77% in 1998.
Nitrous oxide makes up 7.2% of greenhouse gases.[29]
An engine equipped with a three-way catalyst must run at the stoichiometric point, which means more fuelis consumed than in a lean-burn engine. This, in turn, means relatively more CO2 emissions from the
vehicle. Nevertheless, catalyst-equipped engines produce cleaner exhaust than lean-burn engines.
Catalytic converter production requires palladium or platinum; part of the world supply of these precious
metals is produced near Norilsk, Russia, where the industry (among others) has caused Norilsk to be
added to Time magazine's list of most-polluted places.[30]
[edit]Theft
Because of the external location and the use of valuable precious metalsincluding 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 removed with a
reciprocating saw.[31][32][33] Theft removal of the converter can often inadvertently damage the car's wiring or fuel
line resulting in dangerous consequences. Rises in metal costs in the U.S. during recent years have led to a
large increase in theft incidents of the converter ,[34] which can then cost well over $1,000 to replace.[35]
[edit]Diagnostics
Various jurisdictions now legislate on-board diagnostics to monitor the function and condition of the emissions-
control system, including the catalytic converter. On-board diagnostic systems take several forms.
Temperature sensors are used for two purposes. The first 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