Old IMCO

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Presentation Presentation OutlineOutline

I.I. IMCO’s Line & UMICOREIMCO’s Line & UMICOREII.II. Emissions BasicsEmissions BasicsIII.III. Catalytic Converter ComponentsCatalytic Converter ComponentsIV.IV. OpportunitiesOpportunitiesV.V. Fit IssuesFit IssuesVI.VI. AssemblyAssemblyVII.VII. Q & AQ & A

2002 - IMCO begins Manufacturing Catalytic Converters and 2002 - IMCO begins Manufacturing Catalytic Converters and partner with UMICOREpartner with UMICORE

2003 – IMCO dedicates R&D area for development of2003 – IMCO dedicates R&D area for development ofdirect fit catalytic converters direct fit catalytic converters

2006 – IMCO and Maremont combine R&D efforts for 2006 – IMCO and Maremont combine R&D efforts for

development of all catalytic convertersdevelopment of all catalytic converters

2007 – IMCO partners with Delphi (UMICORE) and Johnson Matthey2007 – IMCO partners with Delphi (UMICORE) and Johnson Matthey for the production of catalytic converter bricks for the production of catalytic converter bricks

IMCO’s IMCO’s Converter HistoryConverter History

UMICOREUMICORE• Leader in Global Metals Leader in Global Metals

& Materials& Materials• 1968 – began catalyst 1968 – began catalyst

researchresearch• World Wide Supplier World Wide Supplier

of Catalystof Catalyst• ≈ ≈ 95% OEM95% OEM• Unsurpassed R&D Unsurpassed R&D

and Technologyand Technology• Acquired Delphi Acquired Delphi

Catalyst October 2007Catalyst October 2007

Delphi CatalystDelphi CatalystNOW UMICORENOW UMICORE• Pioneered the Pioneered the

converter industry in converter industry in the 1970sthe 1970s

• Expertise in hot end Expertise in hot end exhaust after treatment exhaust after treatment and engine control and engine control systemssystems

• Division of General Division of General Motors until 1999Motors until 1999

Johnson Johnson MattheyMatthey

• Manufactured first Manufactured first catalyst for vehicle catalyst for vehicle pollution in 1974pollution in 1974

• Began supplying Began supplying catalysts for catalysts for commercial pollution commercial pollution control in 1960’scontrol in 1960’s

• Has Supplied 1 out of Has Supplied 1 out of 3 auto catalysts ever 3 auto catalysts ever mademade

This Means You GetThis Means You Get

OEM Technology onOEM Technology on

EVERY EVERY Brick!!Brick!!

IMCO IMCO Product LineProduct Line

EPA EPA Aftermarket Aftermarket RegulationsRegulations

Over 100 Universal Converter OptionsOver 100 Universal Converter Options• Certifications Certifications

4.0L 4,250lbs. to 7.5L 10,000lbs.4.0L 4,250lbs. to 7.5L 10,000lbs.• Standard Oval, Wide Oval and 4” Round Ceramic Standard Oval, Wide Oval and 4” Round Ceramic • Various Configurations – air, no air, O2 boss, etcVarious Configurations – air, no air, O2 boss, etc• Metallic Pre CatsMetallic Pre Cats• EPA OBD II CompliantEPA OBD II Compliant

Over 550 Direct Fit ConvertersOver 550 Direct Fit Converters

IMCO’s Product IMCO’s Product LineLine

• 75-100 New Direct Fits Converters75-100 New Direct Fits Converters• California OBD II CertificationsCalifornia OBD II Certifications• 10-20 New Universal Converters10-20 New Universal Converters• The Heavy Loaded XL Catalytic ConverterThe Heavy Loaded XL Catalytic Converter

New for 2007New for 2007

XL Catalytic XL Catalytic ConvertersConverters

• 30 % - 50 % more brick density

• Proprietary wash coat technology

• Advanced loading techniques

• Reasonable price

Emissions Emissions BasicsBasics

Clean AirClean Air• Clean Air Act of 1970

calls for 90% reduction in auto emissions

• Tier 1 standards: 0.25 g/mi HC; 3.4 g/mi CO; 0.4 g/mi NOx

• Aftermarket OBDII regulations: 70 % HC; 70 % CO; 30 % NOx

0102030405060708090

HC NOX COPollutant

Auto Emissions

19502000

• *Umicore Automotive Catalyst, Converter 101, 2003

Air/Fuel Air/Fuel RatioRatio

Reduction Reduction Takes AwayTakes Away Oxygen Oxygen MoleculesMolecules

2NO 2NO → N→ N22 + O + O22 (Reduction)(Reduction)

Oxidation Oxidation AddsAdds Oxygen Molecules Oxygen Molecules2CO + O2CO + O22 → 2CO→ 2CO22 (Oxidation)(Oxidation)

2C2CxxHHyy + (2x + y/2)O + (2x + y/2)O22 → → 2xCO2xCO22 + yH + yH2200 (Oxidation)(Oxidation)

Reduction and Reduction and OxidationOxidation

2-Way Converter2-Way Converter – CO and HC Conversion – CO and HC Conversion –Oxidation only (Palladium and/or Platinum Only)

3-Way Converter3-Way Converter – CO, HC and NOx Conversion– CO, HC and NOx Conversion–Oxidation and Reduction (Rhodium and Palladium and/or Oxidation and Reduction (Rhodium and Palladium and/or Platinum)Platinum)

3-Way Converter3-Way Converter + Air–+ Air– CO, HC and NOx CO, HC and NOx ConversionConversion

–Oxidation and Reduction (Rhodium and Palladium and/or Oxidation and Reduction (Rhodium and Palladium and/or Platinum)Platinum)

Types of Catalytic Types of Catalytic ConvertersConverters

Light Off Temperature:Light Off Temperature: 300°C (550°F)300°C (550°F)

Normal Operating Temperature:Normal Operating Temperature: 500°C - 700°C (900°F- 1200°F)500°C - 700°C (900°F- 1200°F)

Catalytic Reaction IncreasesCatalytic Reaction Increases Rear Brick Temperature by:Rear Brick Temperature by: 75°C - 150°C (150°F - 300°F)75°C - 150°C (150°F - 300°F)

Mat CuresMat Cures 300°C - 350°C (550°F - 650°F)300°C - 350°C (550°F - 650°F)

Brick Melts @Brick Melts @ 1410°C (2500°F)1410°C (2500°F)

Matting Melts @Matting Melts @ 1600°C - 1800°C (2900°F - 3900°F)1600°C - 1800°C (2900°F - 3900°F)

Critical Critical TemperaturesTemperatures

Cold Start Cold Start EmissionsEmissions

Catalytic Converter Catalytic Converter Components:Components:

Precious MetalsPrecious Metals

Catalyst – Catalyst – alter the rate of a reaction and remains alter the rate of a reaction and remains chemically unchanged at the end of the chemically unchanged at the end of the reaction reaction

Rhodium (Rh) – Rhodium (Rh) – used in reductionused in reductionPalladium (Pd) – Palladium (Pd) – used in oxidationused in oxidationPlatinum (Pt) - Platinum (Pt) - used in oxidationused in oxidation

Precious Metal Precious Metal PerformancePerformance

Precious Precious Metal CostsMetal Costs

Wash CoatsWash Coats

Wash CoatWash Coat

Wash Coat Functions:Wash Coat Functions:I.I. Vehicle by which precious metals are bound to Vehicle by which precious metals are bound to

Ceramic BrickCeramic BrickII.II. Proper binding will NOT allow metals to migrateProper binding will NOT allow metals to migrateIII.III. Optimum spacing for superior conversion Optimum spacing for superior conversion

efficienciesefficienciesIV.IV. Increases Surface AreaIncreases Surface Area

AluminaAlumina

Wash coatWash coat

Cerium Cerium – functions as an O– functions as an O22 Sponge Sponge»Absorbing OAbsorbing O22 when in excess when in excess»Releasing OReleasing O22 when in absence or low when in absence or low conditionsconditions

Cerium works best when the engine is cycling from Cerium works best when the engine is cycling from slightly rich to slightly leanslightly rich to slightly lean

Proper engine cycling is maintain by OProper engine cycling is maintain by O22 Sensors Sensors

CeriumCerium

SubstrateSubstrate

I.I. Ceramic Honey Comb Ceramic Honey Comb BrickBrick

I.I. Wash Coat Wash Coat • Precious Metal – CatalystPrecious Metal – Catalyst• Cerium – OCerium – O22 Sponge Sponge• Alumina – Increases Surface AreaAlumina – Increases Surface Area

Catalytic Catalytic Converter BrickConverter Brick

Synthetic Cordierite

Wall Thickness:

0.006 inches

Ceramic Ceramic Honeycomb Honeycomb SubstrateSubstrate

Cell Density: 400Cells per

Square Inch

Support MatsSupport Mats

Basic Components:Basic Components:•Ceramic Fiber - provides high temp. resiliencyCeramic Fiber - provides high temp. resiliency•Vermiculite - expands w/ heat Vermiculite - expands w/ heat •Organic Binder - holds material togetherOrganic Binder - holds material together

Matting –Matting – selected specifically for each converter to selected specifically for each converter to maximize holding, protecting, sealing and thermal insulation maximize holding, protecting, sealing and thermal insulation characteristics for the life of the convertercharacteristics for the life of the converter

MattingMatting

Mat Mat InstallationInstallation

*3M Catalytic Converter Mat Products. (2003). Designers Guide, (4th ed.)

Multiple Cycle Multiple Cycle ExpansionExpansion

*3M Catalytic Converter Mat Products. (2003). Designers Guide, (4th ed.)

Mat CuringMat Curing

ShellShell

• 409 Stainless Steel – low expansion coefficient• Extruded Ribbed Body

I. provides recess cavity to protect matting material II. increases air flow, matting no longer obstruction air flow

• Lap Joint Necks – minimizes turbulence from protruding necks

• Ribbed Body – minimizes distortion and expansion• Specific Shell Dies – each neck size has specific die

Catalytic Catalytic Converter ShellConverter Shell

409 Stainless Steel

ClamClam ShellShell

Aluminized steel

Heat Heat ShieldShield

Room TemperatureRoom Temperature

1200°F1200°F 1300°F1300°F 1500°F1500°F

750750°F°F 950950°F°F

Shell Color Shell Color Versus Versus

TemperatureTemperature

OpportunitiesOpportunities

The Good The Good News!!!!News!!!!

A Catalytic A Catalytic Converter is Converter is

Designed to Work Designed to Work on a Properly on a Properly Tuned EngineTuned Engine

This Means More This Means More

Business for YOU!!!Business for YOU!!!

Vehicle Vehicle Emissions Emissions InformationInformation

• *Umicore Automotive Catalyst, Converter 101, 2003

Catalytic Converter Catalytic Converter Performance Versus Performance Versus

Air/Fuel RatioAir/Fuel Ratio

More Fuel Less Oxygen(Poor Oxidation)(Poor Oxidation)

2CO + O2 → 2CO22CO + O2 → 2CO2

Less Fuel More Oxygen(Good Oxidation)(Good Oxidation)2CO + O2 → 2CO22CO + O2 → 2CO2

Emissions Emissions Related IssuesRelated Issues

Subaru Head Gaskets

Honda EGR Valves

Reasons for Reasons for Catalytic Catalytic

Converter FailureConverter Failure• Excessive Operating TemperaturesExcessive Operating Temperatures• Use of Leaded FuelUse of Leaded Fuel• Oil ContaminationOil Contamination• MisfiresMisfires• Defective Engine Coolant Temperature Sensor (ECT)Defective Engine Coolant Temperature Sensor (ECT)• Excessive Fuel PressureExcessive Fuel Pressure• Damaged Exhaust SystemDamaged Exhaust System• Defective O2 sensor or wiringDefective O2 sensor or wiring• Defective Fuel InjectorDefective Fuel Injector

Wash coat Wash coat SurfaceSurface

SinteringSintering

PoisoningPoisoning

WARNINWARNING!!!!G!!!!

You are Now You are Now Entering…..Entering…..

The Wonderful The Wonderful World ofWorld of

Electronic Electronic Engine Engine

ControlsControlsRated PG-13Rated PG-13

THE MAGIC THE MAGIC BOXBOX

Master Switch in the fuel control feedback loopMaster Switch in the fuel control feedback loop

Function:Function:–Monitors amount of unburned oxygen in exhaustMonitors amount of unburned oxygen in exhaust

•Produces a voltage signal from approximately 0.1 volts Produces a voltage signal from approximately 0.1 volts (lean) to 0.9 volts (rich)(lean) to 0.9 volts (rich)•Signal is used to constantly fine-tune the fuel mixture so Signal is used to constantly fine-tune the fuel mixture so the catalytic converter do its jobthe catalytic converter do its job

–OBD II Vehicles – second sensor monitors OBD II Vehicles – second sensor monitors converter efficiency converter efficiency

O2 SensorsO2 Sensors

O2 Sensor O2 Sensor FunctionFunction

Monitoring Catalytic Monitoring Catalytic ConverterConverter

PO420PO420

General MotorsFord

PO420PO420

General MotorsFord

ReflashReflash

PO420PO420General Motors

Catalytic Catalytic ConverterConverterExtendedExtendedCoverageCoverage

Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before star ting work.

03-073November 25, 2003Applies To: 1998-99 Accord V6 - ALL1999-01 Odyssey - ALL MIL Is On With DTC

Special Policy Adjustment - # 05551 - (Sep 14, 2005) Models:2001-02 CHEVROLET IMPALA, MONTE CARLO2001-02 PONTIAC GRAND PRIX2001-02 BUICK REGAL EQUIPPED WITH 3.4L (RPO LA1 - VIN E) OR 3.8L (RPO L36 - VIN K) V6 ENGINEConditionSome customers of 2001-02 Chevrolet Impala, Monte Carlo; Pontiac Grand Prix; and Buick Regal model vehicles, equipped with a 3.4L (RPO LA1 - VIN E) or 3.8L (RPO L36 - VIN K) V6 engine, may experience a condition where the vehicle exhaust is replaced due to complaints of lack of power or illumination of the Malfunction Indicator Lamp (MIL). This may be due to the front endcone insulation from the catalyt ic converter breaking away and blocking the front of the first catalyst brick and preventing the free flow of exhaust gas through the converter.Special Policy AdjustmentThis special policy covers the condition described above for a period of 10 years or 120,000 miles (190,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. The repairs will be made at no charge to the customer.

Catalytic Converter

catalytic converter

Fuel Fuel IssuesIssues

TOP TIER TOP TIER GasolineGasoline

What are the benefits of TOP TIER Detergent Gasoline?TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline

containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and . Also, use of

TOP TIER Detergent Gasoline will help reduce deposit related concerns.reduced emissions

A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail

stations of some fuel marketers. This gasoline meets detergency standards

developed by four automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline

containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit

from the use of TOP TIER Detergent Gasoline.

Bulletin No.: 04-06-04-047GDate: November 28, 2006

Fit IssuesFit Issues

CALL TRAVIS @(800) 231-

Over Over 550550 Direct Fit Converters Means Direct Fit Converters Means

Over Over 60006000 Possible Applications Possible Applications

IMCO’s Product IMCO’s Product LineLine

OEMOEM

Toyota

17140 - 0A090• 0A080• 20360• 0A170• 20290• 20160• 0A260• 7 PART #’S

17140- 0A030• 0A030• 0A060• 0A080• 0A080• 0A170• 0A240• 5 PART #’S

OEMOEM

CausesCauses

I.I. Wrong Application in CatalogueWrong Application in CatalogueII.II. Wrong Application in FieldWrong Application in FieldIII.III. Improper ManufactureImproper ManufactureIV.IV. Improper DesignImproper DesignV.V. Freight DamageFreight DamageVI.VI. Vehicle DamageVehicle Damage

Technical Technical Service Service

BulletinsBulletins

Master Part Master Part CheckCheck

Vehicle Fit Vehicle Fit TestsTests

AssemblyAssembly

Converter Converter AssemblyAssembly

Questions?Questions?

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