International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 5, Issue-11, Nov.

-2017
http://iraj.in
CFD ANALYSIS OF THREE WAY MONOLITHIC CATALYTIC
CONVERTER USING ANSYS 14.5R
1
YUGAL KISHORE, 2TUSHAR CHOUDHARY
1
Mechanical Engineering Department, RCET BHILAI
2
School of Mechanical and Building Sciences, VIT Bhopal University
E-mail: [email protected], [email protected]

Abstract - To reduce emission level monolithic three way catalytic convertor are widely been adopted in various
combustion engines. Designing any catalytic converter several factors need to be considered, however, it is a very complex
process involved in the optimization of different chemical and physical parameters. The catalytic performance of a converter
is readily been affected by various parameters such as cell densities, length, metal coverage, composition of fuel, etc. In this
article a 3D CFD analysis has been carried out using ANSYS Fluent 14.5R. The performances of convertor have been
studied on the basis of conversion efficiency. The governing equations are solved by using FLUENT solver, which further
coupled with surface reaction model. The flow characteristics across various section of the catalytic convertor are visualized
along with the simulation of heterogamous reaction within the convertor. The results are compared with the previous
experimental work of other and they present results are within acceptable limit.

Keywords - CFD, Monolithic three way catalytic convertor, Emission.

I. INTRODUCTION compact reactors, better conversion efficiency with

lower surface along with better porosity.
Catalytic converters are being widely used in Ozhan et al. [7] presents a novel approach for
automobile industry and have already been proved to examining the flow features within the automotive
be the most effective technical solution to reduce catalytic converter. The adopted methodology is a
harmful emissions from SI engines. A worldwide combination of physical and numerical multi-
demand for environmental protection has enforced resolution techniques, with the aim of reducing
more stringent emission legislations. According to computation cost Adaptive Mesh Refinement
existing experiences in the world [1], the main techniques has been optimized. It has been conclude
emission control technology for gasoline vehicles that by effective coupling of this technique significant
which can meet future severe emission standards like reduction fas been seen in the error of the numerical
Euro IV is still the three-way catalytic converter predictions
(TWC) plus electronic fuel injection (EFI) system. Yun [8] present 1-D transient emission analysis using
But the match of TWC with EFI and the optimum AMESim for LPG fueled vehicle in order to evaluate
design of the catalytic converter exhaust system optimum operating condition of a Secondary Air
should be more carefully refined. The main challenge Injection (SAI) system. [15] During simulation the
is how to reduce the hydrocarbon (HC) emitted from effect of SAI flow rate and supply time on CO, HC
vehicles during the cold start. According to vehicle and NOx emission has been analyzed and found that
driving cycle tests, approximately 80% of HC is significant reduction in species has been achieved for
emitted in the cold start phase due to a low the desired optimum operating condition.
temperature of the exhaust gas and monolith [2]. Symeon and Mantzaras [9] perform transient 2D
Therefore, how to increase HC conversion efficiency simulation in platinum-coated microchannel made of
during the cold start is the key to satisfy the stringent either ceramic or metallic walls. During simulation
regulations, and the temperature inside the monolith inlet pressure, wall thermal conductivity, heat
is the most important parameter to decrease the HC capacity are varied and comparative analysis has been
emission. Previous studies [4,5] mainly focus on the done between 100% CH4 and 90% CH4–10% H2 by
modeling of thermal and chemical behavior of the volume.
monolith, few of them on the measurement of the Kumar and Sandip [10] simulate laboratory-scale
temperature fields. catalytic converter using finite volume method. A
steady state analysis has been performed in order to
II. LITERATURE REVIEW analyze the fluid flow, heat and mass transfer and
heterogeneous chemical reactions.
Francesco et al. [6] perform comparative analysis
between Open-cell foams and Honey combs catalyst Santos and costa [11] evaluate the performance of
substrates using CFD and revealed that the open-cell mass transfer for automotive catalytic converters
structures honeycombs, at high flow rates, have operating under real conditions. By establishing a
higher mass transfer properties by allowing more new correlation for the mass transfers for 1D two
phase model experimentally. The experiments have

CFD Analysis of Three way Monolithic Catalytic Converter using ANSYS 14.5R

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International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 5, Issue-11, Nov.-2017
http://iraj.in
included measurements of conversion efficiencies for ( w) p
 div( wu)    div( gradw)  SMz
hydrocarbons, CO and NOx from ceramic and z z (7)
metallic three way catalytic converters.
Liu et al. [12] perform 3D modeling of methane Energy
ignition in a reverse flow catalytic convertor by
( i)
means of commercial CFD code FLUENT. The  div( iu)   pdivu  div(kgradT )    Si
applied methodology consists of pseudo- t
homogeneous and heterogeneous continuum models. (8)
At last it has been concluded that inlet temperature Surface Reaction Model - The heterogeneous reaction
and condition significantly affects the flow condition. is of the general form
Tsinoglou et al. [13] propose an alternative flow
Ng Ns Ng Ng
resistance computation, modeling method for the
prediction of transient flow fields in axi-symmetric g i .r Gi   si.r si   g i . r Gi   si' . r Si
'

converters time-efficiently. the proposed modeling i 1 i 1 i 1 i 1

has been verified by the CFD results. (9)

Kaiser and hobfeld [14] perform CFD simulation for where Gi and Si represent the gas species and the site
optimization of flow in order to prevent the converter species (adsorbed species), respectively. The rate of r
failure form high thermal and fluid dynamic loads. th forward reaction reads:
Ng gi , r
By means of optimized results, complexities of the si , r
flow condition are well understood. Rr  k f , r   Gi   Si wall
Kolrsakis and Stamatelos [15] gives a review of the i 1
wall (10)
catalytic system used in automobiles for emission The forward rate constant for r th reaction, kf,r is
control. The review covers the catalyst technology given by
appropriate in each case, the working principles and
performance uniqueness, durability characteristics s  E 
k ads
f r  As T exp  r 
and considerations regarding the interactions between  RT 
catalyst performance and engine management ……(11)
The rate coefficient for adsorption processes is
III. MATHEMATICAL MODEL calculated from the initial sticking coefficient S0, that
is the sticking probability at vanishing coverage:
The Navier–Stokes equations can be written in the 1 RT
most useful form for the development of the finite k ads
f k  Si
0

volume method:  2 M i
(12)
where t is the number of occupied adsorption sites of
Du p species i
    div( gradu)  SMx
Dt x (1)
IV. METHODOLOGY
Dv p For simulating the monolithic catalytic convertor
    div (  gradv)  SMy ANSYS 14.5 finite element control volume approach
Dt y (2) has been used. Where the CAD model of the catalytic
convertor is segmented into 105 order of nodes and
Dw p elements. In figure 1 the geometrical details are given
    div(  gradw)  SMz
Dt z (3) and the mesh model is presented in figure 2. The
details of boundary condtion have been shown in
Governing equations of the flow of a compressible figure 3. The operating parameters are tabulated in
Newtonian fluid table 1. The convergence of governing equation have
Continuity been shown in figure 3 with having iteration of 1123.

 div( u )  0
x (4)
x-momentum
(  u ) p
 div( uu)    div( gradu)  SMx
x x (5)

y-momentum
 (  v) p
 div(  vu )    div (  gradv )  S My
y y (6)
z-momentum
Figure 1 Model Geometry

CFD Analysis of Three way Monolithic Catalytic Converter using ANSYS 14.5R

47
International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 5, Issue-11, Nov.-2017
http://iraj.in
compared and the present FEV result shows good
trend and are within acceptable limit and the same
have been represented in figure 4-6.

Figure 2(a) Mesh Model

Figure 2 (b) Boundary condition

Figure 4 Conversion rate of carbon monoxide with respect to

inlet temperature

Figure 7 and 8 shows the pressure distribution across

the catalytic convertor. It have been seen that the
pressure significantly goes on decreases. From the
analysis it have been seen that the decline in pressure
is almost very less near the inlet section till 40mm
and across the substrate region significant drop in
pressure have been seen. While at the outlet section
again the rate drop in pressure decreases.

Figure 3 convergence

Parameter Value
Cells per square inch, CPSI 400
Substrate volume fraction 0.26
Washcoat volume fraction 0.12
Fluid volume fraction (OFA) 0.62
Hydraulic diameter, Dh, mm 1
Geometric surface area, GSA
m2/m3 2740
Active metal surface 27-28m2/g
Figure 5 Conversion rate of oxides of nitrogen with respect to
Ratio of active metal surface 70 inlet temperature
Ceria
Stablizedγ-
Wash coat Material alumina
Temperature range 100-600°C
1.35 m/s at
Velocity temperature dependent 25°C
Substrate material cordirite
Table 1 Physical Properties for simulation Ref.[16,17]

RESULT AND DISCUSSIONS

Validation
On simulating the monolithic catalytic convertor, the
conversion rate of carbon monoxide, oxide of Figure 6 Conversion rate of compounds of propane with
nitrogen and compounds of propane have been respect to inlet temperature

CFD Analysis of Three way Monolithic Catalytic Converter using ANSYS 14.5R

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International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 5, Issue-11, Nov.-2017
http://iraj.in
Figure 9 and 10 shows the velocity distribution across
the catalytic convertor. It have been seen that the
velocity distribution is not so uniform across the
various section of the catalytic convertor. From the
analysis it have been found that near the outlet
section higher level of velocity have been seen. While
at the substrate region the velocity distribution is at
lower level.

Figure 7shows the contour plot of static pressure distribution

Figure 11 shows the contour plot of velocity distribution

Figure 8 shows the pressure distribution across the catalytic

convertor

Figure 12 Turbulent intensity across the catalytic convertor

Figure 11 and 12 illustrates the turbulent intensity

across the catalytic convertor. It has been seen that
across the substrate wall significant turbulent
intensity has been seen. While at the outlet of
convertor high level of turbulence has been seen due
Figure 9 shows the contour plot of velocity distribution to bend converging section at the outlet.

CONCLUSION

In this article CFD analysis of an monolithic catalytic

convertor has been carried out and on the basis of it
various conclusions have been drawn.
 The rates of conversion of NO, CO, C3H6 are the
function of temperature.
 On increasing temperature the rate of surface
reaction with the catalyst first increases and then
become stable.
 The present proposed model has higher NOx
conversion rate as compared to other species.
Figure 10 velocity distribution across the catalytic convertor  Increasing mass flow rate the pressure drop

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 International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 5, Issue-11, Nov.-2017
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increases linearly. start period of CVS-75 mode” International Journal of
Automotive Technology June 2013, Volume 14, Issue 3, pp
 Increasing substrate length improves the 343-353
performance of converter. [9] Symeon Karagiannidis, John Mantzaras, “Numerical
 The order of conversion rate is as follows Investigation on the Hydrogen-Assisted Start-Up of
NO>C3H6>CO. Methane-Fueled, Catalytic Microreactors”, Flow,
Turbulence and Combustion September 2012, Volume 89,
 On increasing flow velocity pressure drop across Issue 2, pp 215-230
the substrate and converter drastically increases. [10] Ankan Kumar, Sandip Mazumder, “Toward simulation of
 Cell density of substrate plays crucial role in full-scale monolithic catalytic converters with complex
heterogeneous chemistry”,Computers & Chemical
flow uniformity. Engineering, Volume 34, Issue 2, 8 February 2010, Pages
 At high Reynolds number due to turbulence flow 135-145
uniformity affects and the turbulence can be seen [11] H. Santos, M. Costa,“Analysis of the mass transfer
across the radial region and the outlet. controlled regime in automotive catalytic
converters”,International Journal of Heat and Mass
 Porosity of substrate extensively gets affected at Transfer, Volume 51, Issues 1–2, January 2008, Pages 41-
high temperature and the rate of species 51
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Zheng, “Three dimensional modelling of methane ignition
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