CFD Analysis of Catalytic Converter to Increase

Filtration Efficiency and Achieve Limited Back

Pressure
Alok P Bendale1, Mohit Sharma2, Dr. Manavalla Sreekanth3,
1,2
Student, SMBS, VIT-Chennai
3
Assistant Professor SMBS, VIT-Chennai

Abstract: An catalytic converter is a exhaust discharge catalytic converters .In the thirties, automobile
control gadget that changes over harmful gases and manufacturers realized the need to treat the products of the
contaminations in exhaust gas from an IC engine into combustion process that occurred within the internal
less dangerous toxins by catalyzing a reduction reaction. combustion engines. The initial solution for this challenge
Catalytic converters are generally utilized with IC was the utilization of pellet catalytic converters. The pellets
engine powered by either gasoline or diesel including were spherical particles with diameters ranging from 2.5
lean-burn engines. The efficiency of catalytic converter mm to 5 mm and made of gamma-alumina. The pellets
depends upon the filtration efficiency and back were enclosed in a steel shell to form the catalytic converter
pressure. It is directly proportional to filtration and loaded with noble metals and stabilizers for exhaust
efficiency and inversely proportional to back pressure. emission treatment. This catalytic converter technology had
We are going to do CFD analysis of catalytic converter many disadvantages. Due to the design of these pellet
so as to increase filtration efficiency, achieve limited catalytic converters, a large pressure drop occurred across
back pressure and in turn decrease the fuel the converter which directly affected the performance of
consumption. Models with filter materials of fine grid the engine. Moreover, the risk of losing the catalyst was
size wire mesh packed inside the manifold develop more higher due to particle wear. These disadvantages
back pressure which causes more fuel utilization encouraged scientists and engineers to develop monolithic
because of lower volumetric efficiency. Utilization of catalytic converter found in vehicles today.
bigger grid size wire mesh results in less back pressure,
however the filtration efficiency is additionally reduced [II] Literature Review
which may not be adequate to meet the most stringent
The presence of catalytic converter in exhaust system of
emission standards endorsed. Through CFD
diesel engine increases the back pressure in engine. Due to
investigation, a trade off between these two parameters
increase in back pressure, the fuel consumption is higher in
namely, more filtration efficiency with restricted back
engine. Hence the flow phenomenon inside the catalytic
pressure is aimed at.
converter should be fully understood in order to consider
the current requirement of higher engine efficiency and
Keywords: CFD Analysis,, Catalytic converter, back
lower emission [6]. A CFD model has been developed
pressure, filtration efficiency, IC engines.
taking into consideration the thermal effects as temperature
affects fluid properties such as the density and viscosity
[I] Introduction
and is validated against both local temperature and velocity
Since their inception, automobiles have mostly been
experimental measurements. A controlled hot air
powered with an internal combustion engine. The
experimental setup is used to investigate the flow
combustion processes associated with those engines are
distribution under steady state conditions at the desired
responsible for releasing harmful emissions including
temperature and flow rate [10]. As temperature increases,
carbon monoxide (CO), unburnt hydrocarbons (HC) and
NOx conversion increases. Maximum NOx conversion is
nitrogen oxides (NOx) which have severe negative effects
0.9 at 900K. Maximum C3H6 conversion occurs is 0.9 at
on humans and the environment. This has led to the
900K. But there is a drastic change of conversion between
development of emission control systems to treat exhaust
600K and 700K. Maximum CO conversion is 0.4 at 900K.
gases and convert them to less harmful products called
Platinum is work in oxidation as well as in reduction
process, while Rhodium is worked in Reduction process
only. That is why we get more NOx conversion than CO
conversion. Because NOx conversion is higher in
Reduction Process and CO conversion is takes place in
oxidation process only [1]. On increasing temperature the
rate of surface reaction with the catalyst first increases and
then become stable. Increasing mass flow rate the pressure
drop increases linearly. Increasing substrate length
improves the performance of converter. On increasing flow
velocity pressure drop across the substrate and converter Construction
drastically increases. At high Reynolds number due to The catalytic converter consist of
turbulence flow uniformity affects and the turbulence can
be seen across the radial region and the outlet [5]. The
filtration efficiency and back pressure are interrelated. If
maximum filtration efficiency using very fine grid size wire
meshes, is achieved, the back pressure will also be
increased, which causes more fuel consumption. On the
other hand, if larger grid size wire meshes are used, back
pressure will be less, but the filtration efficiency will also
be reduced, which does not help in meeting the present
emission norms [3]. The opencell structures honeycombs,
at high flow rates, have higher mass transfer properties by
allowing more compact reactors, better conversion
efficiency with lower surface along with better porosity
[11]. The geometry of the element is made as tetrahedral
mesh, with a refined mesh near the wall. The model has
approximately 0.799 million tetrahedron fluid elements. Air
is used as fluid media, which is assumed to be steady and
compressible [9]. The inlet cone should be optimized to
avoid reverse flow observed in close coupled catcon near to
inlet cone. Also the geometry should be optimized to
increase uniformity index.

[III] Methodology

Fig. 1 Catalytic Converter Model

Fig. 2 Top View of Catalytic Beads and Wire Mesh

Selection of Filter Material

There are numerous kinds of filter materials are utilized in

internal combustion engine. They are Ceramic monolith,
ceramic foam, steel wire meshes, ceramic silicon fiber,
porous ceramic honey comb. Out of these filter materials,
steel wire mesh is chosen as filter material in light of the
fact that knitted steel wire mesh material is positioned first
for its collection efficiency of particulate issue. Alternate
purposes behind its choice are,
 Catalyst Table 1. Wire Mesh Specification

The flowing exhaust gas is allowed to move in every way Wire Mesh Size 1.61mm 1.01mm
inside the manifold. As the movement of exhaust gas isn't Wire Diameter 1.01mm 0.41mm
suddenly disturbed anyplace in its way, the back pressure is
constrained to least level. The porous nature of catalyst
beads additionally help the gas to flow over the bigger
surface region of the catalyst empowering better response
to occur for decreasing NOX as on account of SCR system.

1) Diesel Oxidation Catalyst

DOC is made as a flow through device that consists of

specially made catalytic beads and steel wire mesh material
which are coated with metal catalyst. As the hot gases
contact the catalyst and the coated wire mesh, most of the
exhaust pollutants such as CO, gaseous hydrocarbons,
Wire dia: 0.51mm Wire dia: 0.41mm
unburnt fuel and lube oil, toxic aldehydes etc. are oxidized
to CO2 and water, thus reducing harmful emissions. DOC Grid size: 1.61mm Grid size: 1.01mm
does not collect or burn the soot particles in diesel exhaust.
But it is accomplished by oxidizing the soluble organic Fig. 3 Wire Mesh
fraction of diesel PM.DOC can also produce sulphate
particles by oxidizing the SO2 present in the exhaust gas [IV] Physical Model
and thus increases the PM emission.
To meet the less ground clearance available in the
2) SCR Catalyst System present vehicles, the height of the manifold is
restricted to 110 mm. The cross section is made as
Presently, ammonia derived from urea is used to reduce rectangular of size 176 x 110 mm. In CFD, the system
NOX from diesel engines. This is achieved by allowing the consumes less memory space and less response time,
ammonia plus exhaust gas to flow over the platinum coated if the rectangular cross section is assumed. However,
ceramic substrates, and it has been proved as highly in actual practice, the rectangular corners are suitably
effective in reducing NOX in heavy duty applications [2]. rounded off which ensures the smooth flow of exhaust
Ammonia is produced on-board by rapid hydrolysis of gas with less turbulence near the wall sides.
nonhazardous form of urea solution. The problem with this
is, cost of on-board production of ammonia, cost of 1) Construction
additional on-board air supply equipments, and high cost of
The exhaust manifold designed for this study
rare metals like platinum etc. In this paper, rare earth metal
comprises two compartments. The first one is meant
catalyst is replaced by a specially prepared catalyst. This
for filtration and DOC catalyst. The second
catalyst selectively reacts with NO and NO2 species and
compartment is meant for filtration and SCR system.
effectively reduces them to form nitrogen and oxygen using
SCR technology. The upstream of the first compartment is filled with
steel wire meshes for about one-fourth of its length.
Filter Material
These wire meshes are placed vertically with their
Ceramic monolith, ceramic foam, steel wire meshes, surface being parallel to the flow of gas. Sufficient
ceramic silicon fiber, porous ceramic honey comb are the gaps are provided amongst the bunch of wire meshes
few types of filter materials reported in the literature. Out which make the gas to flow crosswise also for better
of these filter materials, steel wire mesh is selected as trap filtration and reduce back pressure. The downstream
material because knitted steel wire mesh material is ranked of first compartment is filled with catalyst beads and
first [4] for its collection efficiency of PM. The other steel wire meshes arranged in alternate layers. The
reasons for its selection are, beads are arranged horizontally in a single layer so
that the gas can enter at one end of the bead and come
a. Thermal stability during regeneration out in the opposite end. During its travel, the gas
b. Good mechanical properties follows the up and down movement and meets the
c. Long durability entire inner surface area of the catalyst. There are
d. Easy availability and less cost 1320 catalytic beads of size 16x16x16 mm placed in
e. Wire mesh Specifications each compartment. More contact surface area of the
catalytic beads enables the better catalytic reaction to
take place between the catalyst and the flowing
exhaust gas. The beads are designed so that the top
and bottom portions are open and the gas can go up Nitrogen will be the working fluid considered to be
and down to the next layer of beads through the steel operating at 3500 C and 1.35 bar.
wire mesh layers which are also horizontally placed.
5) Boundary Conditions
2) Working Principle
Boundary conditions are a set of properties or
In the first compartment the exhaust gas goes through conditions on surfaces of domains, and are required to
catalytic beads and steel wire mesh material which are fully define the flow simulation. The types of
covered with metal catalyst. As the hot gases contact boundary condition used are:
the catalyst and the covered wire mesh, a large portion
of the exhaust toxins, for example, CO, gaseous • Inlet
hydrocarbons, and unburnt fuel and lube oil,
• Outlet
poisonous aldehydes and so on are oxidized to CO2
and water, consequently diminishing harmful • Wall
emissions. In the second compartment ammonia in
addition to exhaust gas is gone through catalytic beads INLET: An inlet boundary condition is used where the
and steel wire mesh material which are covered with flow is predominantly directed into the domain. The
metal catalyst. Ammonia got from urea is utilized to inlet boundary condition is velocity inlet. Inlet
decrease NOx from diesel engines. Ammonia is velocity will be maintained at a slightly higher
created on-board by quick hydrolysis of non- value of 0.3 m/s. Fluid used – for simplicity of
hazardous type of urea solution. In second analysis a single gas entity is considered having
compartment the NOx are converted into nitrogen and nitrogen ideal gas.
oxygen. In the two compartments a part of the exhaust
gas goes through the wire mesh layers which trap a Turbulence – A high turbulence intensity of 10% will
part of the soot. The rest of the exhaust gas streams be flow will be assumed for the inlet while the
out to the neighboring bead set in a similar line-similar hydraulic diameter at the inlet will be considered to
to flow through substrate. The residue caught in the close the turbulence model equations.
wire mesh material is burnt by the NO2 that is created OUTLET: An outlet boundary condition is used where
by the upstream catalyst and consequently the filter is the flow is predominantly directed out of the domain.
regenerated ceaselessly. On the off chance that a The outlet will be considered as a pressure outlet at
circumstance happens where filter regeneration is zero gauge pressure.
halted and a saturation point happened with the
gathered residue, the wire meshes set over the WALL: Walls are solid (impermeable) boundaries to
catalytic beads won't connect as happened in the wall fluid flow. A zero velocity, no slip condition would be
flow filter. As the way of the gas isn't completely applied to all walls.
blocked, the back pressure created inside the catalytic
converter is especially constrained and no further Table 2. Wall Boundary Conditions
increment in back pressure can occur past certain
LOCATION TYPE
limit, regardless of the residue stacking over some
stretch of time. A compressed air cleaning process is Catalyst Bead Compartment Wall
recommended to clean the particulate matter Surfaces filter side compartment Wall
deposition on steel wire networks and catalytic beads. Top compartment Wall
In this procedure, two numbers of compressed air inlet
points are put in the middle of two compartments at
6) Governing Equation
diametrically opposite position.
For flow calculations the differential conservation
3) Grid Generation
equations are integrated over a given control volume.
The geometrical model of exhaust system is meshed in
 Continuity equation
ANSYS Fluent fluid flow. The total geometry is
exceptionally huge on account of the modelling of the
catalyst bead surfaces. In this way, just a quarter
section across a vertical plane slicing through the
geometry will be modeled. This is required to reduce
the complete cell check and subsequently the  Momentum equation
computational effort.

Computatioal Meshed Model

4) Material
 The Turbulence model used in this project work is k-ε
RNG turbulence model. It is appropriate to account for
high velocities and strong streamline curvature in the
flow domain. The differential transport equation for
the turbulence kinetic energy and turbulence
dissipation are given below.

 Turbulence Kinetic Energy

 Turbulence Dissipation
Fig.4 Stream Lines

Linearization: Implicit v/s Explicit

In both the segregated and coupled solution methods the

discrete, non-linear government equations are linearized to
deliver a system of equations for the dependent factors in
each computational cell. The resultant linear system is then
solved to yield an updated stream field solution. The way in
which the governing equations are linearized may take a
"explicit" or "implicit" from concerning the dependent
variable of interest. By implicit or explicit we implied the
following:

Implicit: For a given variable, the unknown value in each Fig.5 Vector Plot
cell is computed using a relation that includes both existing
and unknown values form neighboring cells. Therefore
each unknown will appear in more than one equation in the
system, and these equations must be solved simultaneously
to give the unknown quantities.

Explicit: For a given variable, the unknown value in each

cell is computed using a relation that includes only existing
values. Therefore each unknown will appear in only one
equation in the system and the equations for the unknown
value in each cell can be solved one at a time to give the
unknown quantities.

[V] Experimental Results

The essential point of this CFD examination is to limit back

pressure with maximum filtration efficiency of PM,
utilizing new catalyst for NOX reduction. At present, the Fig.6 Pressure Contour
wall flow ceramic substrate is utilized as filters which are
[VI] Conclusion
expensive and furthermore offer increasingly back pressure
resulting more fuel utilization. In the present study, steel The stream lines shown in the fig.4 implies that the
wire networks, one with platinum coating, with fine mesh maximum or almost all the amount of gas flowing through
size are utilized as filter materials. catalytic converter passes through the beads. Thus, it is
expected that the rate of reaction will increase and
subsequently increases the filtration efficiency.

The pressure contour shown in fig.5 implies that the

pressure is 267 Pa to 510 Pa from inlet to the catalytic bead
compartment. After leaving the catalytic compartment, due
to the backflow occurring before outlet, the pressure
increases up to 700Pa but at outlet (exit) it reduces up to Converters”, FFHMT, Paper No. 135, August 2017,
200Pa. Thus the 67 Pa pressure drop has been achieved. 135.1-135.7

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copper urea catalyst converter to check if the conversion 11, Nov 2017, 46-50
efficiency has been increased or not.
[12] A. Selamet, V. Kothamasua, J.M. Novak, R.A.
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