Catalytic Converters: Design and Durability

I.D. #

98017

Duration

2 Days

The introduction of catalytic converters in 1975 has helped to breathe fresh air into the once-dismal arena of automotive emissions by reducing the hydrocarbons, carbon monoxide, and oxides of nitrogen by over 90%! This seminar explores the development of catalytic converters and the key inventions that made them viable, along with recent advances in converter technology required to meet stringent emissions regulations for both light-off and underbody converters. Applications of converter design to gasoline-powered cars, trucks and motorcycles will be presented. Also covered in this seminar are the durability and performance characteristics of both ceramic and metallic catalyst supports and certain design tools that help optimize the converter performance.

Attendees will receive a copy of Ron Heck's book, Catalytic Air Pollution Control: Commercial Technology.

Learning Objectives

By attending this seminar, you will be able to:

Describe why ceramics as structural materials behave differently than metals and how such differences affect product design and performance
Design catalytic converters that have adequate durability to meet performance and reliability requirements in the field
Work with advanced catalyst systems which help meet stringent emissions regulations e.g. LEV, ULEV, and SULEV
Examine field failures and conduct root cause analyses to help improve converter design

Who Should Attend

This course is designed for mechanical, metallurgical and chemical engineers, materials scientists, and chemists involved in heterogeneous catalysis, who are interested in handling, assembling, and failure analysis of catalytic converters.

Prerequisites

Participants should have a basic familiarity with automotive emissions for gasoline engines.

Seminar Content

DAY ONE (Instructor: Ron Heck)

Brief Historical Background
Fundamentals of Catalysis
- Definition of catalyst
- Characteristics of catalysis
- Catalytic reactions
- Catalyst preparation & characterization
- Catalyst durability
- Reaction controlling mechanisms
- Catalytic reactor design
Automotive Catalysis
- Historical background
- Engine emissions
- Three-way catalysis (TWC)
- Engine control - oxygen sensor
- Role of Ceria
- Catalyst monitoring (OBD)
- Palladium TWC technology
- Vehicle test procedures
Automotive Catalysis Advanced Technologies
- New standards
- Cold start technologies
- Close coupled catalyst
- Hydrocarbon traps
- Electrically heated catalysts
- Metallic honeycombs
- UEGO air/fuel sensor
- ULEV vehicle design
- SULEV/PZEV vehicle design
- Benefits of new high cell density
- Hybrids
Automotive Catalyst Durability Examples
- Engine aging protocols
- Sintering
- Masking
- Poisoning
- Attrition
Lean Burn Engines
- Background
- NO_x removal methods
- NO_x decomposition
- NO_xcatalytic reduction
- NO_x traps
- Selective removal with NH₃
Brief Summary
PremAir^Ž catalyst
- Reactions
- Applications
- Design parameters
- On-road experience
- Catalyst durability
- OBD requirements
- Credit potential

DAY TWO (Instructor: Suresh Gulati)

Brief Historical Background
Design of Catalyst Support
- Performance requirements
- Support material and structure
- Ceramic beads
- Ceramic honeycombs
- Geometric properties
- Physical properties
- Design parameters
- Substrate sizing
Substrate/Washcoat Interaction
- Washcoat distribution
- Composite properties
- High temperature behavior
- Comparison with substrate properties
Thin Wall Substrates
- Design options
- Properties and performance
- Effect of washcoat
- Packaging considerations
- Square vs. nonsquare cells
Packaging Design
- Isostatic strength of coated substrate
- Wiremesh and mat properties
- Durability requirements
- Canning techniques
- Inner vs. outer ribs
- Selection of mat and mount density
- Nonintumescent and hybrid mats
- Failure modes and prevention
- Advanced packaging designs
Thermal Shock Resistance
- Temperature gradients
- Thermal stresses
- Failure modes and prevention
- Thermal shock tests
- Thermal fatigue
Ceramic vs. Metallic Substrates
- Geometric properties
- High temperature strength and creep resistance
- Comparative performance
Applications
- Passenger car
- Gasoline truck
- Motorcycles

Instructor(s):

Suresh Gulati & Ronald Heck

Dr. Suresh Gulati was a Research Fellow in the Science and Technology Division of Corning Inc. where he specialized in the behavior of glass, glass-ceramics and ceramics subjected to mechanical and thermal loads, their fatigue and fracture properties and their long-term reliability. He is a member of American Men and Women of Science and Who's Who in Technology Today. Dr. Gulati is the author of over 200 publications in the area of ceramic catalyst supports, fiber optics, liquid crystal display glasses, cathode ray tubes, space windows, automotive windshields, and stepper lenses made from high purity fused silica. Before joining Corning, he held positions with Cornell University, the University of Colorado, and Continental Can Company. Dr. Gulati has a Ph.D. in applied mechanics from the University of Colorado, an M.S. in mechanical engineering from Illinois Tech and a B.S. in mechanical engineering from the University of Bombay, India.

Dr. Ron Heck is currently an independent consultant. Previously, he was a research manager responsible for developing catalyst technology for Engelhard Corporation's worldwide customers in automotive catalyst. He has worked on the development of catalytic processes in SCR NOx, NSCR NOx, automotive catalyst, diesel catalyst, PremAir^TM catalyst systems, hydrogenation technology, ozone abatement, volatile organic compound abatement, ammonia oxidation, chemical feedstock purification and chemical synthesis. He is a member of American Men and Women of Science and Who's Who in Technology Today. Dr. Heck is the author of over 80 publications in commercial applications of catalysts and holds 28 U.S. patents on catalytic processes. He is the co-author of the book with Dr. Farrauto entitled "Catalytic Air Pollution Control: Commercial Technology" and is the co-editor of the NewsBrief section of Applied Catalysis B: Environmental. Dr. Heck received his B.S. in chemical engineering and his Ph.D. from the University of Maryland.

Testimonial

"This is one of the best technical classes I've attended in a long time."
Mary Beth MacDonald
Design Release Engineer
GM Powertrain Division

"A very good seminar with relevant technology."
Donna Hale
Manager - Exhaust Core Engineering
DaimlerChrysler Corporation

"A comprehensive and concise introduction to the history and fundamentals of automotive catalyst technology."
Brian E. Mace
Senior Engineer
Honda R&D Americas, Inc.

Also available as an SAe-Learning program delivered on CD-ROMs!
Catalytic Converters: Design and Durability e-Seminar

Fees:

$1335

SAE Members*:

$1068 - $1202

* The appropriate SAE Member discount will be applied through the Registration process. Discounts vary according to level of membership: Elite Member 20%; Premium Member 15%; Classic Member 10%

CEU

1.3