En route to more efficient catalytic converters

Scientists have developed a new catalytic converter design.

Smaller, cheaper and more fuel-efficient catalytic converters are now a possibility thanks to a new manufacturing process created by Imperial College, London.

Wth space at a premium in modern cars, the ability of engineers' to halve the size of the hollow ceramic block below the catalyst - known as the substrate - is very significant.

The scientists have developed a process - known as ‘phase inversion and sintering' - which allows a thinner layer of catalyst to be produced which covers a greater internal surface area, thereby reducing the amount of catalyst needed by 80% and increasing the volume of exhaust gas that can be detoxified at one time.

The new catalyst also reduces the pressure within the converter (by potentially 40-70%) and so cuts the amount of energy it drains from the engine. The resultant fuel saving could be between two and three percent.