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The automotive catalytic converter, briefly called a catalyst, is one of several components of the car's exhaust system that reduces emissions of harmful gases released into the atmosphere by the engine, such as CO – carbon monoxide, HC – hydrocarbons, and NO – nitrogen oxide.
The action of the catalyst involves triggering a chemical reaction due to high temperature and the subsequent oxidation of these harmful gases, reducing their quantity and converting them into harmless ones by adding an oxygen molecule – CO2 – carbon dioxide, N2 – nitrogen, and H2O – water.
The catalyst generally consists of one or several ceramic or metal honeycombs enclosed in a metal exhaust can. To protect against shocks, vibrations, and for better contact between two parts, asbestos wool is used. Modern-generation catalysts are made of Al2O3-based ceramic (commercially known as cordierite), coated with a very thin fine layer of noble metals from the platinum group - Pt, Pd, Rh.
They also contain other rare and valuable metals like CeO2 and ZrO2, which help facilitate the chemical process. In some more specific cases (e.g., in more powerful gasoline engines or when there is little space very close to the engine), metal foil is used instead of a ceramic honeycomb.
This foil is made from stainless steel and is also coated with a fine layer of noble metals. In percentage terms, metal catalysts account for no more than 10% of the total production of catalysts.
Currently, catalysts are characterised by great diversity and complexity, but in general, they can be divided into several main types—oxidising and so-called three-way catalysts for gasoline engines. Oxidising catalysts are effective in purifying carbon monoxide and hydrocarbons but have a limited impact on nitrogen oxides.
They were used in the early years of catalyst adoption in the USA during the 1970s. Three-way catalysts are the most common in modern gasoline vehicles.
Their name comes from the three types of reactions they facilitate—the oxidation of CO, HC, and NO into CO2, H2O, and N2, respectively. These catalysts represent a closed system that includes a lambda probe (also known as an oxygen sensor), which regulates the amount of air needed for the engine to function properly.
Another type of catalysts includes NO-absorbing catalysts, particulate filters (DPF), and oxidising catalysts for diesel engines.
There is also a system known as "Selective Catalytic Reduction" for reducing the NO content in diesel engines of heavy and, more recently, passenger vehicles through the use of ammonia or ammonia precursors in an oxygen-rich environment. In the most modern diesel engines, there is a designated space (can) where additional burning of exhaust gases and injection of this ammonia are performed for further purification of the emitted gases, particulates, etc.—a process called "exhaust gas recirculation."