Question

What does a catalytic converter actually do?

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Answer

It converts the most harmful exhaust gases into less harmful ones using a chemical reaction on a precious-metal surface — and it does essentially nothing until it is hot, which is why the first few minutes of a journey produce a disproportionate share of a car's pollution.

The three reactions in a modern petrol car's three-way converter:

Nitrogen oxides are reduced to nitrogen and oxygen. NOx causes respiratory harm and forms smog.

Carbon monoxide is oxidised to carbon dioxide. CO is acutely toxic.

Unburnt hydrocarbons are oxidised to carbon dioxide and water.

How it works physically. A ceramic honeycomb — chosen to pack an enormous surface area into a small volume — is coated with platinum, palladium and rhodium. These act as catalysts, lowering the energy needed for the reactions so they proceed in the fraction of a second the gas is in contact. The metals are not consumed, which is why a converter lasts for years, and why a stolen one has real scrap value.

Why it needs to be hot. Below roughly 200–300°C the catalyst barely functions. Reaching that light-off temperature takes a few minutes, which is why converters are mounted close to the engine, why short journeys are disproportionately polluting, and why cold-start emissions are so heavily regulated.

Why the three-way converter needs precise fuelling. The oxidation and reduction reactions require opposite conditions, and both proceed well only within a very narrow band around the ideal air-fuel ratio. This is what the oxygen sensors are for — they let the engine management hold that ratio continuously. A failed sensor therefore damages the converter as well as raising emissions.

What destroys them: leaded fuel, which poisons the catalyst permanently; oil or coolant burning in the engine, which coats it; repeated misfires, which dump unburnt fuel in and overheat it; and physical impact.

Diesels differ. They run an oxidation catalyst, a particulate filter, and frequently selective catalytic reduction using AdBlue for NOx, because a three-way converter cannot work in the oxygen-rich diesel exhaust.

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