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Optimization of catalytic converter related to flow improvements, cost and conversion of pollutants using computational model and computational fluid dynamics (CFD) are described in this paper. A computational model is developed for predicting the performance of Pd/Rh catalytic converter at wide range of operating conditions. An experimental investigation was done on Pd/Rh catalytic converter for validating the model. Optimization of the catalytic converter was carried out based on three parameters namely catalytic converter length, cell densities and typical metal loading. The cell densities varied from 200 cpi to 1200 cpi. The length of the catalytic converter varied from 70 mm to 180 mm. About 8 patterns were studied on Pd/Rh catalytic converter. The predicted patterns show that about 48 percent precious metal can be saved by proposed metal loading patterns.

Current generation of metal monolith using binary catalysts Pt/Rh (5:1) is simulated for transient temperature and conversion inside a catalytic converter during warm-up. A new concept in mass transfer on a catalytic combustion is introduced in this model for improving accuracy is known as Reynolds analogy. Design parameters and operating conditions are investigated for its influence on solid temperature and conversion of species. New patterns of precious metal loading have been investigated for metal savings and maximum conversion efficiency. Satisfactory validation of computed data was observed.

Performance of a Current generation catalytic converter using Pd/Rh (10:1) as binary catalyst impeded on an ultra thin ceramic substrate and alumina wash coat is modeled for performance prediction and parametric optimization. Kinetic rates for the catalyst are reduced after conducting series of experiments on a passenger car engine. A new concept in mass transfer coefficient is introduced for improving accuracy of the model prediction. In order to take care of the precious metal resources and to become independent of precious metal price fluctuation, a new pattern of loading of precious metal is suggested for optimum performance and metal savings about 46 percent was observed. Experimental investigations were carried out to validate the established kinetic rates over a wide range operation of the engine and for the model validation. Satisfactory agreements are observed for the model prediction and experimental results.

The investigations relating to the evaluation of an automobile catalytic converter are reported in this paper. These investigations are aimed at arriving at a data that would pave the way for the optimization of a catalytic converter by experimental and computer simulation at steady and transient operating conditions The converter used in the present study contains Pd, Rh binary catalyst (10:1) impregnated on ultra thin ceramic substrate. Characterization of catalytic converter was done for its compositions using Inductively Coupled Argon Plasma (ICAP) and Scanning Electron Microscope (SEM). The necessary instrumentation developed, which include pre and post converter emissions, backpressure and exhaust gas temperature are described for both steady and transient conditions. The experimental setup has been designed for assessing the performance of a catalytic converter on a passenger car at different operating conditions.