Sebuah Kajian Pustaka: JEMMME (Journal of Energy, Mechanical, Material, and Manufacturing Engineering) Vol.6, No. 1, 2021 ISSN 2541-6332 | e-ISSN 2548-4281 Journal homepage: http://ejournal.umm.ac.id/index.php/JEMMME Mokhtar | A Honeycomb-Shaped Brass Plate Catalyst to Reduce Motor … 25 A Honeycomb-Shaped Brass Plate Catalyst to Reduce Motor Vehicle Emissions Ali Mokhtara, Ali Saifullahb, Andinusa Rahmandhikac a,b,cMechanical Engineering Department, Faculty of Engineering, Muhammadiyah Malang University Jl. Raya Tlogomas No. 246 Malang Telp. 0811360358, Email alimokhtar011@gmail.com, mokhtar@umm.ac.id Abstract The increasing number of motorized vehicles has a direct impact on exhaust gas air pollution. The air pollution in urban areas is dominated by motorized vehicle emissions, along with pollution problems. This study aims to reduce motor vehicle emissions by using a catalytic converter design made from a brass plate catalyst in the shape of a honeycomb. Honeycomb-shaped brass is suitable for catalysts in the catalytic converter. Besides being easy to obtain and cheap in price, the catalyst can reduce and oxidize exhaust gases well, making it suitable as a catalyst material. The method used in this research is the experimental method. It is started from the design of the catalytic converter house and determining the type of catalyst to the process of making the catalytic converter with a honeycomb-shaped brass plate. Then, testing to determine the emission of exhaust gases produced is required. The last step is to compare it without using a catalytic converter or standard conditions. From the results of the emission test, it was found that the use of a catalytic converter made from a brass plate catalyst in the shape of a honeycomb can reduce HC and CO emissions, while CO2 emissions has increased. A decrease in HC gas emissions by 19.1% for a single catalytic converter and 33.7% for a dual catalytic converter are better compared to without using a catalytic converter or standard conditions. Reduced CO gas emissions by 23.8% for a single catalytic converter and 43.1% for a dual catalytic converter are compared to without using a catalytic converter. Meanwhile, CO2 gas emissions increased by 60.7% for a single catalytic converter, and 81.6% for multiple catalytic converters are compared without using a catalytic converter. This is a result of the addition of oxygen to the oxidation process that running smoothly. Keywords: honeycomb-shaped brass plate, catalytic converter, emission 1. INTRODUCTION The catalytic converter is an exhaust emission control device installed in motorized vehicles [1]. The phenomenon of gas flow in the catalytic converter channel is difficult to observe, but it can be analyzed using FLUENT or ANSYS software. Simulations can be performed to determine the flow patterns that are formed in the channel. The more evenly the exhaust gas on the surface of the catalytic converter, the greater the emission reduction process [2]–[5]. The increase in the number of motorized vehicles will increase the use of fuel oil, especially in two-stroke engine vehicles, where the combustion process in these vehicles cannot be perfect compared to four-stroke engine vehicles. This will bring risks to the addition of toxic gases in the air, especially CO, HC, SO2 [6],[7]. Catalytic converters have become standard equipment for all motorized vehicles in the world. The catalyst will work effectively if the smoke gas can hit all surfaces of the catalyst and work between temperatures of 250o C to 300o C [8],[9]. The flow of flue gas through the horizontal hole catalyst without insulation shows good flow distribution results [8],[9]. Catalytic converter with aluminum catalyst shows poor results to reduce emissions http://ejournal.umm.ac.id/index.php/JEMMME mailto:alimokhtar011@gmail.com mailto:mokhtar@umm.ac.id JEMMME (Journal of Energy, Mechanical, Material, and Manufacturing Engineering) Vol.6, No. 1, 2021 doi: 10.22219/jemmme.v6i1.15532 Mokhtar | A Honeycomb-Shaped Brass Plate Catalyst to Reduce Motor … 26 [10]. Therefore, from the advantages and disadvantages of previous research, the present work was carried out by making a catalytic converter with a beehive-shaped brass plate as a catalyst. The problem in this study is how much emission levels are produced by motorized vehicles if they do not use a catalytic converter or in standard conditions. This value is then compared with the catalytic converter with a catalyst material from a honeycomb- shaped brass plate. The purpose of this study was to determine how much emissions a motorized vehicle would produce if it did not use a catalytic converter or standard conditions compared to using a catalytic converter with a catalyst material from a honeycomb- shaped brass plate, both single and multiple types. The honeycomb catalyst design model is as follows. Rumah Input Output Figure 1. Honeycomb catalyst design Incomplete combustion results in the formation of pollutant gas emissions such as HC, CO, NOx which are released by motor vehicles. In fact, there is no way that combustion can be 100% complete. Therefore, the catalytic converter needs to be installed in all motorized vehicles. The catalytic reduction reaction is principally to increase the reactance site of NO molecules (as in nickel or copper in CO) to form N2 and CO2 gases. NO can react with metal molecules to form oxides which then react with CO. Meanwhile, metal molecules that can be used as reducing catalysts are iron, nickel, copper, alloys, and oxides of these metals [11]–[13]. Figure 2. Exhaust gas design with Catalytic Converter (Heisler H, 1999) 2. METHODS A catalytic Converter (CC) is a tool to accelerate the combustion process of residual hydrocarbons (HC), carbon monoxide (CO), and nitrogen oxidation (NOx) which are still present in motor vehicle exhaust gases. When passing through the catalytic converter, the gas will undergo a chemical process (oxidized and reduced) due to the addition of oxygen and high temperatures. The combustion process of remaining hydrocarbons (HC), carbon monoxide (CO), and nitrogen oxides (NOx) which is still present in the exhaust gas when it passes through the catalyst will turn into stable compounds in the form of CO2, H2O, N2, and O2 [14],[15]. JEMMME (Journal of Energy, Mechanical, Material, and Manufacturing Engineering) Vol.6, No. 1, 2021 doi: 10.22219/jemmme.v6i1.15532 Mokhtar | A Honeycomb-Shaped Brass Plate Catalyst to Reduce Motor … 27 Hc Co No H2o Co2 N2 o2 Ke mufflerGas buang dari exhaust Rumah katalis Figure 3. Catalytic converter design model Exhaust gas emissions in the form of hazardous chemicals will be converted into harmless chemicals using a catalytic converter in the exhaust gas line [16], [17]. Among the catalysts used as catalytic converters, metals are the most effective materials as oxidation catalysts, including platinum, plutonium, palladium, copper, vanadium, iron, cobalt, nickel, manganese, chromium, and oxides of these metals [13]. The process of designing a catalyst in a catalytic converter requires special care to get maximum results, especially when the gas flow occurs in the catalyst. The more evenly the gas flow in the catalyst, the more optimal the reduction process will be so that the emissions released are reduced [2]. Figure 4. Materials, Assemblies, Testing Machines and Gas Analyzers Table 1. Experimental variable Catalytic Converter Fuel 1000 1500 2000 2500 3500 Standard Pertalite D111 D121 D131 D141 D151 D112 D122 D132 D142 D152 D113 D123 D133 D143 D153 D114 D124 D134 D144 D154 D115 D125 D135 D145 D155 Single CC Pertalite D211 D221 D231 D241 D251 D212 D222 D232 D242 D252 D213 D223 D233 D243 D253 D214 D224 D234 D244 D254 D215 D225 D235 D245 D255 Double CC Pertalite D311 D321 D331 D341 D351 D312 D322 D332 D342 D352 D313 D323 D333 D343 D353 D314 D324 D334 D344 D354 D315 D325 D335 D345 D355 JEMMME (Journal of Energy, Mechanical, Material, and Manufacturing Engineering) Vol.6, No. 1, 2021 doi: 10.22219/jemmme.v6i1.15532 Mokhtar | A Honeycomb-Shaped Brass Plate Catalyst to Reduce Motor … 28 The research method used is the experimental method. The first step is to conduct a motor vehicle emission test without using an ordinary catalytic converter, then conduct a motor vehicle emission test. The same step is carried out for the catalytic converter made of catalyst from a honeycomb-shaped brass plate. This catalyst has been recommended in previous studies. The design process is carried out before making the catalyst shape. The results of the catalyst molding are then tested for precision with the existing exhaust designs. The principle of this precision test is to show that the catalyst design is suitable for the exhaust shape that has been used. The final stage after a successful precision test is the installation of the latest catalyst model on the vehicle and testing its emissions. Emission testing is performed using an emission measuring device in the form of a gas analyzer. This tool serves to measure the level of exhaust gas emissions by inserting a gas detector pipe into the exhaust hole. The pipe will absorb the remaining combustion gas which is then read in the form of an analog value which shows the amount of emission content of the gas. The emission value is then printed out as desired. The initial way of making a catalyst is to cut the brass plate according to size, then assemble it according to the predetermined distance between the plates. Then, the whole assembly process is carried out using a welding machine as shown in Figure 4. 3. RESULT AND DISCUSSION From the test results obtained preliminary data for standard catalytic converters (shown in Table 2), with a single (Table 3) and double honeycomb-shaped brass plate as a catalyst (Table 4). The percentage of gas emission and reduction is shown in Table 5 and Table 6, respectively. Table 2. Experimental result of standard model Engine Speed (rpm) Data HC (ppm) CO (%) CO2 (%) O2 (%) T (oC) 1000 Average 782,8 4,16 4,96 8,43 247,22 1500 Average 678,2 4,28 6,12 7,83 261,4 2000 Average 525,8 4,54 7,12 5,58 272,94 2500 Average 461,4 4,72 7,92 4,916 297,48 3500 Average 414,2 5,12 8,8 4,604 316,1 Table 3. Experimental result of single catalytic converter model Engine Speed (rpm) Data HC (ppm) CO (%) CO2 (%) O2 (%) T (oC) 1000 Average 625,2 3,04 9,60 6,54 266,4 1500 Average 557,6 3,30 10,24 5,67 286,66 2000 Average 425,2 3,50 11,50 4,20 302,3 2500 Average 375,2 3,66 12,34 3,57 318,12 3500 Average 332,6 3,90 12,44 3,48 338,96 Table 4. Experimental result of double catalytic converter model Engine Speed (rpm) Data HC (ppm) CO (%) CO2 (%) O2 (%) T (oC) 1000 Average 538,80 2,14 11,74 4,39 284,56 1500 Average 444,80 2,36 12,14 3,72 302,36 2000 Average 335,00 2,66 12,76 2,84 314,78 2500 Average 307,00 2,84 13,36 2,53 333,74 3500 Average 270,20 2,98 13,40 2,28 352,64 JEMMME (Journal of Energy, Mechanical, Material, and Manufacturing Engineering) Vol.6, No. 1, 2021 doi: 10.22219/jemmme.v6i1.15532 Mokhtar | A Honeycomb-Shaped Brass Plate Catalyst to Reduce Motor … 29 𝑆𝑖𝑛𝑔𝑙𝑒 𝐶𝐶 𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 = (𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛 − 𝑆𝑖𝑛𝑔𝑙𝑒 𝐶𝐶 𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛) 𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛 × 100 % (1) 𝐷𝑜𝑢𝑏𝑙𝑒 𝐶𝐶 𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 = 𝐷𝑜𝑢𝑏𝑙𝑒 𝐶𝐶 𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛 × 100 % (2) Table 5. Percentage of data emissions CC Type HC (ppm) CO (%) CO2 (%) O2 (%) T (oC) Standard 572,48 4,56 6,98 6,27 279,028 Single CC 463,16 3,48 11,22 4,69 302,488 Double CC 379,16 2,60 12,68 3,15 317,616 Single CC emission percentage 19,10 23,75 -60,71 25,20 -8,41 Double CC emission percentage 33,77 43,12 -81,56 49,76 -13,83 𝑅𝑒𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑆𝑖𝑛𝑔𝑙𝑒 𝐶𝐶 𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 = 100 % − 𝑆𝑖𝑛𝑔𝑙𝑒 𝐶𝐶 𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 (3) 𝑅𝑒𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝐷𝑜𝑢𝑏𝑙𝑒 𝐶𝐶 𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 = 100 % − 𝐷𝑜𝑢𝑏𝑙𝑒 𝐶𝐶 𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 (4) Table 6. Percentage of emissions reduction CC Type HC (ppm) CO (%) CO2 (%) O2 (%) T (oC) % Reduction of Single CC emission 80,90 76,25 160,71 74,80 108,41 % Reduction of Double CC emission 66,23 56,88 181,56 50,24 113,83 Data were collected five times in each cycle, then averaged and plotted. The rotation variation is taken between 1000 rpm to 3500 rpm. The rotation data is taken with the assumption that the vehicle operates stationary at 1000 rpm and the maximum rotation is 3500 rpm. Figure 5. Comparison of HC emission to engine speed From the results of the emission test, it can be seen in Figure 5 that the standard model shows a high enough HC emission level with an average value of 572.48 ppm. The JEMMME (Journal of Energy, Mechanical, Material, and Manufacturing Engineering) Vol.6, No. 1, 2021 doi: 10.22219/jemmme.v6i1.15532 Mokhtar | A Honeycomb-Shaped Brass Plate Catalyst to Reduce Motor … 30 brass plate model in the form of a single honeycomb has decreased emission levels with an average value of 463.16 ppm. While the double honeycomb-shaped brass plate model has decreased with an average value of 379.16 ppm. This happens because the smoke gas that comes out through the catalytic converter undergoes a good reduction and oxidation process so that the HC emissions can decrease. The maximum level of HC reduction of 33.7% occurred in a double honeycomb-shaped brass plate catalyst. Based on the emission test results in Figure 6, it can be seen that the standard model shows a sufficiently large CO emission level with an average value of 4.56%. The largest decrease occurred in the brass plate model in the form of a single honeycomb with an average value of 3.48%. This happens because the fume gas that comes out through the catalytic converter undergoes a process of reduction and oxidation well so that CO emissions can decrease. For the double CC, the reduction level is still below the single CC due to in this model there are many obstacles when the exhaust gas comes out of the engine. Figure 6. Comparison of CO emission percentage to engine speed Figure 7. Comparison of CO2 emission percentage to engine speed From the emission test results in Figure 7, the average value of CO2 emission levels in the standard model is 6.98%. In the single honeycomb-shaped brass plate model, there is an increase with an average value of 11.22%. Meanwhile, the double JEMMME (Journal of Energy, Mechanical, Material, and Manufacturing Engineering) Vol.6, No. 1, 2021 doi: 10.22219/jemmme.v6i1.15532 Mokhtar | A Honeycomb-Shaped Brass Plate Catalyst to Reduce Motor … 31 honeycomb-shaped brass plate model has increased with an average value of 12.68%. This happens because the fume gas that comes out through the catalytic converter undergoes a process of reduction and oxidation well and the process of adding oxygen runs perfectly so that CO2 emissions can rise. The maximum CO2 increase level of 81.68% occurred in a double honeycomb-shaped brass plate catalyst. 4. CONCLUSION From the results, it can be concluded that the Catalytic Converter with a brass plate catalyst material in the shape of a honeycomb can significantly reduce emissions compared to the standard model or the model without a catalytic converter. The most significant emission reduction occurred for HC and CO, respectively 33.7% and 43.12%. 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