[Kumar, 3(11): November, 2014] ISSN: 2277-9655

Scientific Journal Impact Factor: 3.449

(ISRA), Impact Factor: 2.114

IJESRT
INTERNATIONAL JOURNAL OF ENGINEERING SCIENCES & RESEARCH
TECHNOLOGY
Design and Analysis of Catalytic Converter Using Computational Fluid Dynamics (CFD)
K.Sathish Kumar*, V.Chandramohan
*1PG Scholar, Engineering Design, Department of Mechanical Engineering, Nandha Engineering
College, Erode, Tamil Nadu, India
2Assistant Professor, Department of Mechanical Engineering, Nandha Engineering College,
Erode, Tamil Nadu, India
Abstract
Now a days the global warming and air pollution are big issues in the world. The 70% of air pollution is due to
emissions from an internal combustion engine. The harmful gases like NOX, CO, unburned HC and particulate
matter increases the global warming, so catalytic converter plays an vital role in reducing harmful gases, but the
presence of catalytic converter increases the exhaust back pressure due to this the volumetric efficiency will
decrease and fuel consumption is higher. So analysis of catalytic converter is very important. The rare earth metals
now used as catalyst to reduce NOX are costly and rarely available. The scarcity and high demand of present
catalyst materials necessitate the need for finding out the alternatives. Among all other particulate filter materials,
knitted steel wire mesh material is Change and selected platinum, palladium, and rhodium coated on the surface of
ceramic honeycomb structures as filter materials in this paper. Through CFD analysis, various models with different
wire mesh grid shapes rectangular, circular, Diamond combinations were simulated using the appropriate boundary
conditions. The comparison of back pressure of different catalytic converter models is made in this paper.

Keywords: Catalytic converter, Mesh materials, Grid shapes, CFD..

Introduction
The fibre was washed thoroughly with water and control device which converts toxic by-products of
dried in an air oven at 800C for 6 h, before being combustion in the exhaust of an internal combustion
chopped into 6 mm length for fibre treatment and the engine to less toxic substances by way of catalyzed
preparation of the composites. Toluene- 2,4- chemical reactions. The specific reactions vary with
diisocyanate (TDI) and polypropylene glycol (PPG) the type of catalyst installed. Most present-day
of molecular weight 1000 were supplied by the vehicles that run on gasoline are fitted with a “three-
Aldrich Chemical Company, USA. Dibutyl tin way” converter, so named because it converts the
dilaurate was obtained from Scientific and Industrial three main pollutants in automobile exhaust: carbon
Supplies Corporation, Mumbai. Potassium monoxide, unburned hydrocarbon and oxides of
permanganate, sodium hydroxide and maleic nitrogen. The first two undergo catalytic combustion
anhydride used in the present study were of and the last is reduced back to nitrogen. The first
chemically pure grade [1]. The chopped fibres were widespread introduction of catalytic converters was
taken in a stainless steel vessel. A 10% solution of in the United States market, where 1975 model year
NaOH was added into the vessel and stirred well. gasoline-powered automobiles were equipped to
This was kept for 1 h with subsequentstirring. The comply with tightening U.S. Environmental
fibres were then washed thoroughly with water to Protection Agency regulations on automobile exhaust
remove the excess of NaOH sticking to the fibres. emissions. These were “two-way” converters which
Final washings were carried out with distilled water combined carbon monoxide (CO) and unburned
containing a little acid. The fibres were then air dried hydrocarbons (HC) to produce carbon dioxide (CO2)
[2]. Sugar cane biogases, the fibrous solid residue left and water (H2O). Two-way catalytic converters of
over after juice extraction from Sugar cane (S. this type are now considered obsolete, having been
Officinarum) – designated ‘‘B” – was supplied by the supplanted except on lean burn engines by “three-
Montebello distillery (Petit-Bourg, Guadeloupe). way” converters which also reduce oxides of nitrogen
Sugar cane bagasse fibers were obtained by milling (NOx).
using a A catalytic converter is a vehicle emissions
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[Kumar, 3(11): November, 2014] ISSN: 2277-9655
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Fig.1 Position of Catalytic Converter

Basic conversion of catalytic converter

3- Way converters working as two catalyst process:
1. Reduction and 2. Oxidation- and a sophisticated
oxygen storage/engine control system to convert
three harmful gasses- HC, CO and NOX. This is not Fig.4 Effect of Pollutants
an easy task: the catalyst chemistry required to clean Without the redox process to filter and change the
up NOX is most effective with a rich air/ fuel bias. To nitrogen oxides, carbon monoxides, and
operate properly, a three- way converter first must hydrocarbons into less harmful chemicals, the air
convert NOX (with a rich air/ fuel bias), then HC and quality (especially in large cities) would reach a
CO (with a lean bias). harmful level to the human being.

Nitrogen oxides- these compounds are in the same

family as nitrogen dioxide, nitric acid, nitrous oxide,
nitrates, and nitric oxide. When NOx is released into
the air, it reacts with organic compounds in the air
and sunlight, the result is smog. Smog is a pollutant
and has adverse effects on children's lungs.

Carbon monoxide- this form of CO2 is a harmful

variant of a naturally occurring gas. Odorless and
Fig.2 Basic Conversion of Catalytic Converter colorless, this gas does not have many useful
functions in everyday processes.
Dangers of pollutants
Hydrocarbons- inhaling hydrocarbons from
gasoline, household cleaners, propellants, kerosene
and other fuels can cause death in children. Further
complications can be central nervous system
impairments and cardiovascular problems.

Literature survey
A.K.M.Mohiuddin [1] et al, said that the purpose of
this paper is to present the results of an experimental
study of the performance and conversion efficiencies
of ceramic monolith three-way catalytic converters
(TWCC) employed in automotive exhaust lines for
the reduction of gasoline emissions. Two ceramic
converters of different cell density, substrate length,
and hydraulic channel diameter and wall thickness
Fig.3 Dangers of Pollutants were studied to investigate the effect of varying

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[Kumar, 3(11): November, 2014] ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
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key parameters on conversion efficiencies and NOx: Nitrogen compounds referred to as NOx have
pressure drop. The conversion efficiencies from caused many an emissions test failure. NOx
both converters were calculated and evaluated. emissions are basically Nitrogen molecules that have
combined with Oxygen and escape the engine
Thundil Karuppa Raj.R [2] et al, analyzed that the unburned. NOx emissions cause smog and acid rain.
design of catalytic converter has become critical
which requires a thorough understanding of fluid The compounds coating the inner structure of the cat
flow inside the catalytic converter. In this paper, an literally strip, ram together, and otherwise muscle
attempt has been made to study the effect of fluid these emissions into less harmful gases and water,
flow due to geometry changes using commercial leaving the stuff that comes out of your tailpipe in
CFD tool. The study has been conducted assuming much better shape.
the fluid to be air. The numerical results were used
determine the optimum geometry required to have a Overview of this project
uniform velocity profile at the inlet to the substrate. They are extruded from dense, high strength ceramic
substrate without sacrificing mechanical strength,
MingChen [3] et al, Analyzed that a modeling total surface area remains same, back pressure
approach to the design optimization of catalytic reduces, conversion efficiency increases and thermal
converters is presented. The first step of the expansion reduces.
optimization is the model-assisted sizing of catalysts. 1. Circular structure
The second step deals with the flow optimization of 2. Triangular Structure
the catalyst converter under the given geometric 3. Diamond type structure
restraints. The substrate is modeled as porous media,
where viscous and in it all resistances are specified via Methodology
empirical formula. With the help of the CFD tool, the Fig.5 shows the methodology which is used in this
flow in the converter can be optimized using analysis.
appropriate boundary layer control methods.

Problem finding
Once the catalytic converter reaches its operating
temperature (known as "light off temperature" and
usually between 400 and 600 degrees Fahrenheit) the
catalyst compound coating the inner ceramics start to
convert the three regulated harmful emissions into
less harmful emissions. The three harmful emissions
regulated by the EPA are Carbon monoxide (CO),
Hydrocarbons (or VOCs for Volatile Organic
Compounds), and Nitrogen compounds (NOx).

Carbon monoxide: Most of the used air leaving your

engine is Carbon dioxide or CO2. But since
combustion isn't always perfect or complete, some of
the Carbon molecules only pick up one oxygen
molecule to create carbon monoxide, a deadly,
odorless gas. The catalytic converter creates a
reaction between the CO and its surrounding air
particles to create CO2 and H2O (water).

Hydrocarbons: A Hydrocarbon is any compound

made of Carbon and Hydrogen that can be burned.
Hydrocarbon emissions cover a range of harmful
emissions, but they are all made up of unburned Fig.5 Methodology
Carbon and Hydrogen. Hydrocarbons are harmful Modeling
when breathed and contribute greatly to smog build The flow distribution across the monolith frontal area
up in urban areas. depends on the geometry of a specific design of inlet
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[Kumar, 3(11): November, 2014] ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 2.114

diffuser of drawings create modeling at done the

models were done. At first we are doing numerical
analysis of models being used in using experiments.
The data’s collected include,
Dimensions for flow full setup.
Scaling measure at reengineering.
Conversion data analysis in Inches in to
metric.
Dimensions for full assembly model
The details of the parameters are given in the
following
Table.1 Design parameters of catalytic converter

Fig.7 Isometric model of catalytic converter

The data’s regarding design parameters like Fig.8 Full assembly front view – pentagon type cross
width of the flow channel, catalyst thickness etc. are section
collected from the assembly.

Fig.6 Wire frame model of catalytic converter

Fig.9 Full assembly front view – circular type cross

section

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[Kumar, 3(11): November, 2014] ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 2.114

Fig.10 Full assembly front view – diamond type cross Fig.13 Boundary conditions
section
Meshing Analysis
The following mesh model has been created by using In our project how to model porous media in
ANSYS 14.5 software. FLUENT. Workshop models a catalytic convertor.
Nitrogen flows in though inlet with a uniform
velocity 22.6 m/s, passes through steel with paladiem
with rothiem coating is monolith substrate with
square shaped channels, and then exits through the
outlet. Substrate is impermeable in Y and Z
directions, which is modeled by specifying loss
coefficients 3 order higher than in X direction.

Results and discussions

Numerical results of circular cross section for CO2
Fig.14 shows the dynamic pressure distribution inside
Fig.11 Mesh model of catalytic converter the catalytic converter with circular cross section for
CO2 fluid flow. Maximum and minimum values of
dynamic pressure distribution is 1.08 Pa and 1.26×e4
Pa respectively

Fig.12 Mesh model of inner structure

Boundary conditions
The following boundary conditions have been given
to that catalytic converter.
Fig.14 Dynamic pressure
Fig.15 shows the wall temperature distributions
inside the catalytic converter with circular cross
section for CO2 fluid flow. Maximum and minimum

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[Kumar, 3(11): November, 2014] ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 2.114

values of wall temperature distributions is 0 K and

300 K respectively.

Fig.17 Dynamic pressure

Fig.15 Wall temperature
Fig.18 shows the wall temperature distributions
Fig.16 shows the velocity distributions inside the
inside the catalytic converter with circular cross
catalytic converter with circular cross section for CO2
section for CO fluid flow. Maximum and minimum
fluid flow. A maximum and minimum value of
values of wall temperature distributions is 0 K and
velocity distributions is 0 m/s and 1.20 m/s
300 K respectively.
respectively.

Fig.18 Wall temperature

Fig.19 shows the velocity distributions inside the
Fig.16 Velocity
catalytic converter with circular cross section for CO
fluid flow. A maximum and minimum value of
Numerical results of circular cross section for CO
velocity distributions is 4.70×e1 m/s and 1.38×e2 m/s
Fig.17 shows the dynamic pressure distribution inside
respectively.
the catalytic converter with circular cross section for
CO fluid flow. Maximum and minimum values of
dynamic pressure distribution is 3.62×e3 Pa and
8.89×e3 Pa respectively.

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[Kumar, 3(11): November, 2014] ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 2.114

square cross section for CO2 fluid flow. Maximum

and minimum values of wall temperature
distributions is 0 K and 300 K respectively.

Fig.22 shows the velocity distributions inside the

catalytic converter with square cross section for CO2
fluid flow. A maximum and minimum value of
velocity distributions is 0 m/s and 1.33×e2 m/s
respectively.

Fig.19 Velocity
Table.1 shows the Numerical result comparison of
circular cross section with different fluid flow
conditions.
Table.1 Numerical result comparison of circular cross
section

Fig.21 Wall temperature

Numerical results of square cross section for CO2

Fig.20 shows the dynamic pressure distribution inside
the catalytic converter with square cross section for
CO2 fluid flow. Maximum and minimum values of
dynamic pressure distribution is 7.17×e3 Pa and
1.26×e4 Pa respectively.

Fig.22 Velocity

Numerical results of square cross section for

CNO2
Fig.23 shows the dynamic pressure distribution inside
the catalytic converter with square cross section for
CNO2 fluid flow. Maximum and minimum values of
Fig.20 Dynamic pressure dynamic pressure distribution is 4.19×e3 Pa and
Fig.21 shows the wall temperature 9.95×e3 Pa respectively.
distributions inside the catalytic converter with

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[Kumar, 3(11): November, 2014] ISSN: 2277-9655
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Fig.23 Dynamic pressure

Fig.24 shows the wall temperature distributions
inside the catalytic converter with square cross
section for CNH2fluid flow. Maximum and minimum Fig.25 Velocity
values of wall temperature distributions is 0 K and
300 K respectively. Numerical results of square cross section for CO
Fig.26 shows the dynamic pressure distribution inside
the catalytic converter with square cross section for
CO fluid flow. Maximum and minimum values of
dynamic pressure distribution is 3.62×e3 Pa and
8.91×e3 Pa respectively.

Fig.24 Wall temperature

Fig.25 shows the velocity distributions inside the

catalytic converter with square cross section for
CNO2 fluid flow. A maximum and minimum value of
velocity distributions is 0 m/s and 1.33×e2 m/s
respectively. Fig.26 Dynamic pressure

Fig.27 shows the wall temperature distributions

inside the catalytic converter with square cross
section for CO fluid flow. Maximum and minimum
values of wall temperature distributions is 0 K and
300 K respectively.

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[Kumar, 3(11): November, 2014] ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
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Numerical results of diamond cross section for

CO2
Fig.29 shows the dynamic pressure distribution inside
the catalytic converter with diamond cross section for
CO2 fluid flow. Maximum and minimum values of
dynamic pressure distribution is 8.94×e3 Pa and
1.95×e4 Pa respectively.

Fig.30 shows the wall temperature distributions

inside the catalytic converter with diamond cross
section for CO2 fluid flow. Maximum and minimum
values of wall temperature distributions is 0 K and
300 K respectively.

Fig.27 Wall temperature

Fig.28 shows the velocity distributions inside the

catalytic converter with square cross section for CO
fluid flow. A maximum and minimum value of
velocity distributions is 0 m/s and 1.34×e2 m/s
respectively.

Fig.29 Dynamic pressure

Fig.28 Velocity
Table.2 shows the Numerical result comparison of
square cross section with different fluid flow
conditions.
Table.2 Numerical result comparison of square cross
section

Fig.30 Wall temperature

Fig.31 shows the velocity distributions inside the

catalytic converter with diamond cross section for
CO2 fluid flow. A maximum and minimum value of

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[Kumar, 3(11): November, 2014] ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 2.114

velocity distributions is 0 m/s and 1.33×e2 m/s

respectively.

Fig.33 Wall temperature

Fig.31Velocity
Fig.34 shows the velocity distributions inside the
Numerical results of diamond cross section for catalytic converter with diamond cross section for
CNO2 CNO2 fluid flow. A maximum and minimum value of
Fig.32 shows the dynamic pressure distribution inside velocity distributions is 0 m/s and 1.44×e2 m/s
the catalytic converter with diamond cross section for respectively.
CNO2fluid flow. Maximum and minimum values of
dynamic pressure distribution is 4.36×e3 Pa and
1.04×e4 Pa respectively.

Fig.34 Velocity
Numerical results of diamond cross section for CO
Fig.32 Dynamic pressure
Fig.35 shows the dynamic pressure distribution inside
the catalytic converter with diamond cross section for
Fig.33 shows the wall temperature distributions CO fluid flow. Maximum and minimum values of
inside the catalytic converter with square cross dynamic pressure distribution is 5.46×e3 Pa and
section for CNO2 fluid flow. Maximum and minimum 3.73×e4 Pa respectively.
values of wall temperature distributions is 0 K and
300 K respectively.

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[Kumar, 3(11): November, 2014] ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 2.114

Fig.35 Dynamic pressure Fig.37 Velocity

Table.3 shows the Numerical result comparison of
Fig.36 shows the wall temperature distributions diamond cross section with different fluid flow
inside the catalytic converter with diamond cross conditions.
section for CO fluid flow. Maximum and minimum Table.3 Numerical result comparison of diamond cross
values of wall temperature distributions is 0 K and section
300 K respectively.

Effects of dynamic pressure

Fig.38 to 40 shows the effect of dynamic pressure in
different cross section profile of the catalytic
converter under the CO2 fluid flow conditions.

Fig.36 Wall temperature

Fig.37 shows the velocity distributions inside the

catalytic converter with diamond cross section for
CO fluid flow. A maximum and minimum value of
velocity distributions is 0 m/s and 1.93×e2 m/s
respectively.

Fig.38 Effects of dynamic pressure in CO2 fluid flow for

different cross section

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[Kumar, 3(11): November, 2014] ISSN: 2277-9655
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(ISRA), Impact Factor: 2.114

Effects of velocity
Fig.42 to 44 shows the effect of velocity in different
cross section profile of the catalytic converter under
the CO2 fluid flow conditions.

Fig.39 Effects of dynamic pressure in CO fluid flow for

different cross section

Fig.42 Effects of velocity in CO2 fluid flow for different

cross section

Fig.40 Effects of dynamic pressure in CNO2 fluid flow for

different cross section

Effects of wall temperature

Fig.41 shows the effect of wall temperature in
different cross section profile of the catalytic
converter under the CO2, CO & CNO2 fluid flow
conditions.

Fig.43 Effects of velocity in CO fluid flow for different

cross section

Fig.41 Effects of wall temperature in different cross

section

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[3] Ming Chen, Karen Schirmer “A modeling

approach to the design optimization of catalytic
converters of I.C. Engines” PROCEEDINGS OF
ICEF03: 2003 Fall Technical Conference of the
ASME Internal Combustion Engine Division,
Pennsylvania, USA, September 7-10, 2003.

Fig.44 Effects of velocity in CNO2 fluid flow for different

cross section
Conclusions
Dynamic pressure
From the above numerical analysis results and
graphs we have concluded that the catalytic converter
with square cross section gives the minimum
dynamic pressure among the other two cross section
models(circular& Diamond).

Relative outer surface temperature

From the above numerical analysis results and graphs
we have concluded that the catalytic converter with
all cross section posses the same temperature
distribution towards the outside.

Velocity magnitude
From the above numerical analysis results and
graphs we have concluded that the catalytic converter
with square cross section gives the minimum velocity
magnitude among the other two cross section
models(circular& Diamond).

References
[1] A.K.M.Mohiuddin and Muhammad Nurhafez
“Experimental Analysis and Comparison of
Performance Characteristics of Catalytic
Converters Including Simulation”, Mechanical
Engineering Department, International Islamic
University, Malaysia. International Journal of
Mechanical and Materials Engineering (IJMME),
Vol.2 (2007), No.1, 1-7.
[2] Thundil Karuppa Raj.R and Ramsai.R “Numerical
Study of Fluid Flow And Effect of Inlet Pipe
Angle In Catalytic Converter Using CFD”, School
of Mechanical and Building Sciences, VIT
University, Vellore– 632 014, Tamil Nadu,
INDIA.
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