CHAPTER – 9
ENGINE EMISSION
CONTROL
Prepared by:
Mohammed Samir
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Engine emission control refers to the systematic process of reducing, controlling, or
eliminating harmful gases and particles that are produced during the combustion of fuel
in an internal combustion engine.
These harmful emissions—such as carbon monoxide (CO), hydrocarbons (HC),
nitrogen oxides (NOx), particulate matter (PM), and carbon dioxide (CO₂)—are
released through the engine’s exhaust. If left uncontrolled, they contribute to air
pollution, global warming, acid rain, and serious health hazards for humans.
Purpose of emission control:
1. To reduce air pollution
– Harmful gases like CO, HC, and NOx from engines pollute the air. Emission control
reduces these pollutants and keeps the environment clean.
2. To protect human health
– Emissions can cause serious health problems such as asthma, lung diseases, cancer,
and heart issues. Controlling emissions helps safeguard public health.
3. To meet government regulations
– Countries have strict emission standards (e.g., Bharat Stage, Euro norms). Emission
control systems are necessary to comply with these legal limits.
4. To reduce global warming
– CO₂ is a greenhouse gas. By improving fuel combustion and reducing emissions,
engines contribute less to climate change.
5. To prevent acid rain
– NOx and SO₂ (from diesel) form acids in the atmosphere, causing acid rain.
Controlling these emissions helps prevent it.
6. To improve engine efficiency
– Emission control systems (like ECU, sensors) also help optimize combustion,
leading to better fuel economy and smoother performance.
7. To increase engine life
– Cleaner combustion reduces carbon deposits and engine wear, extending the life of
engine components.
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8. To improve vehicle resale value
– Vehicles with well-maintained emission systems are more likely to pass pollution
tests and maintain value.
9. To support sustainable development
– Reducing emissions aligns with global goals for sustainable and responsible
industrial practices.
10. To maintain visibility and cleanliness in urban areas
– Emission control reduces smog and soot, making cities cleaner and safer to live in.
Constituents of exhaust gases:
When fuel is burned inside an internal combustion engine, various gases are released
through the exhaust. These gases are a mixture of harmless and harmful components,
depending on how complete the combustion was.
1. Carbon Dioxide (CO₂)
➢ Formed when fuel is completely burnt with sufficient oxygen.
➢ It is non-toxic but a major greenhouse gas.
➢ Contributes to global warming.
2. Carbon Monoxide (CO)
➢ Formed due to incomplete combustion of fuel (lack of oxygen).
➢ It is a colorless, odorless, and highly toxic gas.
➢ Prevents oxygen from binding to blood (hemoglobin).
3. Hydrocarbons (HC)
➢ These are unburnt or partially burnt fuel particles.
➢ Result from poor combustion, misfiring, or fuel leakage.
➢ Contribute to smog formation and are carcinogenic (cancer-causing).
4. Nitrogen Oxides (NOx)
➢ Formed when nitrogen and oxygen in air react at high combustion temperatures.
➢ Includes NO (Nitric oxide) and NO₂ (Nitrogen dioxide).
➢ Cause acid rain, smog, and respiratory problems.
5. Oxygen (O₂)
➢ Some oxygen remains unburnt in the exhaust if fuel is lean (more air, less fuel).
➢ High O₂ indicates incomplete fuel usage.
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6. Water Vapor (H₂O)
➢ Formed during complete combustion of hydrogen in fuel.
➢ Harmless and usually released as vapor in the exhaust.
7. Particulate Matter (PM)
➢ Microscopic soot or carbon particles, especially from diesel engines.
➢ Can include metals and toxic substances.
➢ Causes lung damage, breathing problems, and pollution.
8. Sulfur Dioxide (SO₂)
➢ Produced when fuel contains sulfur impurities (more common in diesel).
➢ Causes acid rain and eye/lung irritation.
9. Aldehydes
➢ Formed due to incomplete combustion of hydrocarbons.
➢ Strong-smelling and toxic, irritate eyes and nose.
Engine emission and legal requirements:
Legal requirements for engine emissions refer to the official rules and pollution limits
set by the government to control the amount of harmful gases released by vehicles into
the environment.
In Nepal, these legal limits are enforced by:
➢ Department of Transport Management (DoTM)
➢ Ministry of Forests and Environment
The main aim is to:
➢ Reduce air pollution (especially in cities like Kathmandu),
➢ Protect public health, and
➢ Maintain environmental balance.
Nepal generally follows Indian (Bharat Stage) and European (Euro) norms as a
reference, since it imports most vehicles from India and other countries.
Bharat Stage (BS):
Bharat Stage norms are emission standards set by the Government of India, introduced
by the Central Pollution Control Board (CPCB) to regulate air pollutants from internal
combustion engines.
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Nepal adopts many Indian vehicles, so BS norms indirectly affect Nepal’s vehicle
market.
BS Norms Timeline:
Standard Year Introduced Key Change
in India
BS-I 2000 CO, HC limits
BS-II 2005 Stricter fuel quality (low
sulfur)
BS-III 2010 Introduced fuel injection,
better combustion
BS-IV 2017 Mandatory across India, used
widely in Nepal
BS-VI 2020 (Skipped Comparable to Euro VI, ultra-
BS-V) low emissions
Key Features of BS-VI:
➢ 70% lower NOx in diesel engines
➢ 50% lower PM in diesel
➢ Compulsory Diesel Particulate Filter (DPF) and Selective Catalytic
Reduction (SCR)
➢ OBD (On-board diagnostics) introduced
Euro Norms:
Euro emission standards are European Union regulations that define acceptable
emission levels for vehicles sold in Europe.
These are also followed globally (and referenced in Nepal) for imported vehicles from
Europe or Japan.
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Euro Norms Timeline:
Euro Year Remark
Standard Introduced
Euro I 1992 Start of regulations
Euro II 1996 Reduced CO & HC
Euro III 2000 Diesel NOx limits
Euro IV 2005 Stricter PM control
Euro V 2009 Lower NOx
Euro VI 2014 Advanced control systems like
DPF, SCR
Other Legal Requirements (Nepal):
1. Pollution Under Control (PUC) Test:
➢ Mandatory emission check for all running vehicles.
➢ Must be renewed every 6 months (for petrol) and every 3 months (for
diesel).
➢ Issued by authorized pollution testing centers.
2. Import Restrictions:
➢ Nepal bans used vehicles older than a certain age.
➢ Some cities (like Kathmandu) restrict older diesel vehicles.
➢ Vehicles must meet minimum emission standards (BS-III or above).
3. Fuel Quality Regulation:
➢ Nepal Oil Corporation imports fuel (often BS-IV grade).
➢ Sulfur content in fuel is regulated to match vehicle technology.
Importance of Legal Requirements:
➢ Helps reduce smog and pollution-related diseases.
➢ Encourages use of cleaner engine technologies.
➢ Supports sustainable urban development.
➢ Aligns Nepal with international environmental standards.
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Types of emission control system
Emission control systems are a set of mechanical, chemical, and electronic devices
integrated into an internal combustion engine and its exhaust system, designed to
reduce, control, or eliminate harmful pollutants emitted during the combustion process.
These systems work by modifying the combustion process, treating exhaust gases, or
preventing the escape of unburnt fuel vapors to ensure that the engine complies with
environmental regulations and minimizes its impact on air quality.
The complexity of these systems ranges from simple mechanical valves to sophisticated
electronic modules and catalytic converters, all aimed at optimizing fuel combustion
and converting toxic gases into less harmful substances before they reach the
atmosphere.
Types:
Exhaust gas recirculation (EGR) system:
The Exhaust Gas Recirculation (EGR) system is an emission control technology used
in internal combustion engines to reduce the formation of nitrogen oxides (NOx), which
are harmful pollutants produced at high combustion temperatures.
The EGR system works by recirculating a controlled portion of the exhaust gases back
into the engine’s intake manifold, mixing it with the fresh air-fuel mixture. This process
lowers the combustion temperature, because the inert exhaust gases absorb heat without
participating in combustion, thereby reducing NOx formation. NOx (Nitrogen Oxides)
are mainly formed when nitrogen (N₂) and oxygen (O₂) in the air react at high
temperatures inside the combustion chamber. The reaction that forms NOx is highly
temperature-dependent, and it significantly increases above about 1300°C (2372°F).
When the combustion temperature drops, less energy is available, so fewer nitrogen
molecules dissociate, and the chemical reactions that form NOx occur at a much slower
rate. Therefore, lowering the combustion temperature reduces the rate of NOx
formation, resulting in less emission of these harmful gases.
The EGR system is widely used in both petrol (spark ignition) and diesel (compression
ignition) engines and is considered one of the most effective and economical methods
to control NOx emissions.
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Working:
The EGR system works by recirculating a controlled amount of exhaust gas back into
the intake manifold to reduce combustion temperature and NOx formation. After
combustion, some exhaust gases exit the cylinder through the exhaust valve. At certain
engine conditions—typically during medium load and steady RPM (usually between
1500–2500 rpm)—the EGR valve opens to allow a portion of these exhaust gases to re-
enter the intake manifold.
These inert exhaust gases mix with the fresh air-fuel charge, reducing the overall
oxygen content of the mixture. As a result, when the mixture is compressed and ignited,
the combustion occurs at a lower temperature than normal. This lower peak temperature
significantly reduces the formation of nitrogen oxides (NOx).
Importantly, the EGR valve is not always open. It remains closed during engine idling,
full acceleration, and cold start, to avoid affecting engine performance. The valve’s
opening is precisely controlled by either a vacuum actuator or the Engine Control Unit
(ECU), depending on the type of EGR system (mechanical or electronic).
Thus, the EGR system ensures efficient NOx reduction without sacrificing engine
performance under varying driving conditions.
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Evaporative emission control system:
The Evaporative Emission Control System (EVAP) is an emission control system
designed to prevent the release of fuel vapors from the fuel tank and fuel system into
the atmosphere. Instead of letting these hydrocarbon vapors escape, the system
captures, stores, and later reuses them by sending them back into the engine for
combustion.
Since gasoline is volatile, it evaporates easily, especially in warm conditions. The EVAP
system operates by capturing the fuel vapors that naturally form inside the fuel tank,
especially when the engine is off or when the vehicle is parked under the sun. These
vapors contain hydrocarbons (HC), which are harmful to the environment and
contribute to smog and air pollution. Instead of letting these hydrocarbon vapors escape
into the atmosphere, the system traps them in a charcoal canister. The EVAP system
plays a vital role in meeting emission standards by reducing evaporative hydrocarbon
emissions to nearly zero.
Key Components:
1. Fuel Tank
o Stores fuel and generates vapors due to heat and pressure changes.
2. Charcoal Canister
o Absorbs and temporarily stores fuel vapors from the fuel tank.
3. Purge Valve
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o Controls the flow of stored vapors from the charcoal canister into the
engine intake manifold.
4. Purge Flow Sensor
o Monitors the rate of vapor flow during purging to ensure proper engine
performance.
5. Pressure Control Valve
o Regulates pressure within the fuel system to prevent excessive buildup
or vacuum.
6. Rollover Valve (Rull over Valve, likely a typo)
o Prevents fuel spillage in case of a vehicle rollover by sealing the fuel
tank.
7. Fuel Pressure Sensor
o Measures fuel tank pressure to detect leaks or abnormalities in the EVAP
system.
8. Throttle Body
o Where purged vapors are mixed with fresh air and burned in the engine.
9. Branch Line
o Connects various components, allowing vapor flow between the fuel
tank, canister, and engine.
When fuel in the tank evaporates due to heat or agitation, the vapors are directed
through a branch line to the charcoal canister, where they are temporarily stored. The
canister contains activated charcoal that absorbs and holds the fuel vapors until they
can be safely purged.
Once the engine reaches the right operating conditions—typically when it is warm and
running at cruising speed—the engine control unit (ECU) activates the purge valve.
This allows the stored vapors to be drawn into the intake manifold through the throttle
body, where they mix with incoming air and are burned in the combustion process. The
purge flow sensor monitors the vapor flow rate to ensure smooth engine operation.
To maintain proper pressure within the system, the fuel pressure sensor and pressure
control valve work together. The sensor detects pressure changes, while the valve
adjusts to prevent excessive vacuum or pressure buildup, which could lead to fuel tank
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damage or leaks. The rollover valve acts as a safety feature, sealing the system in case
of a vehicle rollover to prevent fuel spillage.
In summary, the EVAP system captures, stores, and recycles fuel vapors, contributing
to lower emissions and better fuel efficiency while complying with environmental
regulations.
Positive crankcase ventilation
The Positive Crankcase Ventilation (PCV) system is an emission control system used
in internal combustion engines to prevent the release of blow-by gases (unburnt fuel-
air mixture that escapes past the piston rings) into the atmosphere. It does this by
recirculating these gases back into the intake manifold, where they are burned during
normal combustion.
It was one of the first emission control systems introduced and is still used in modern
vehicles, especially petrol engines.
As the engine operates, a small amount of combustion gases (blow-by) leaks past the
piston rings and enters the crankcase. These gases contain unburned hydrocarbons, oil
vapors, and other contaminants that can degrade engine oil and create sludge if left
unchecked. The PCV system uses engine vacuum to draw these gases out of the
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crankcase through the PCV valve, which regulates the flow based on engine load and
speed.
The PCV valve acts as a one-way check valve, allowing gases to flow from the
crankcase into the intake manifold while preventing backfires from reaching the
crankcase. At idle, when vacuum is high, the valve restricts flow to maintain proper idle
quality. Under acceleration, when vacuum drops, the valve opens wider to allow
increased flow. The gases are then mixed with the incoming air-fuel mixture and burned
in the combustion chamber.
Fresh air enters the crankcase through a breather tube connected to the air intake system,
ensuring proper ventilation and preventing pressure buildup. This closed-loop design
maintains crankcase pressure slightly below atmospheric pressure, improving piston
ring sealing and reducing oil leaks.
In summary, the PCV system is a simple yet effective method of controlling crankcase
emissions while improving engine efficiency and longevity by recycling blow-by gases
back into the combustion process.
Catalytic converter
A catalytic converter is an essential emission control device fitted in the exhaust system
of petrol and diesel vehicles. Its main function is to convert harmful exhaust gases like
carbon monoxide (CO), unburnt hydrocarbons (HC), and oxides of nitrogen (NOx) into
less harmful substances such as carbon dioxide (CO₂), water vapor (H₂O), and nitrogen
gas (N₂) before they are released into the atmosphere.
It uses a chemical reaction with catalysts—typically platinum (Pt), palladium (Pd), and
rhodium (Rh)—to speed up the conversion process without being consumed
themselves.
Types of Reactions:
➢ Reduction Catalyst (Rhodium)
Converts nitrogen oxides (NOx) → Nitrogen (N₂) + Oxygen (O₂)
➢ Oxidation Catalyst (Platinum/Palladium)
Burns remaining hydrocarbons (HC) → Water (H₂O) + Carbon Dioxide (CO₂)
Converts carbon monoxide (CO) → Carbon Dioxide (CO₂)
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When the engine burns fuel, it produces three main pollutants: nitrogen oxides (NOx),
carbon monoxide (CO), and unburned hydrocarbons (HC). The catalytic converter uses
chemical reactions to transform these into less harmful substances. Inside its stainless
steel housing, there's a ceramic or metallic honeycomb structure coated with precious
metal catalysts - typically platinum, palladium, and rhodium.
As hot exhaust gases flow through the converter, they come into contact with these
catalysts. The first section contains rhodium which breaks down nitrogen oxides into
harmless nitrogen and oxygen through a reduction reaction. Further along, platinum
and palladium facilitate oxidation reactions that convert carbon monoxide into carbon
dioxide and burn remaining hydrocarbons into water vapor.
For optimal operation, the converter requires high temperatures (400-600°F minimum)
which is why it's mounted close to the engine. Modern systems use oxygen sensors
before and after the converter to monitor its efficiency. The upstream sensor helps adjust
the air-fuel mixture, while the downstream sensor checks if the converter is working
properly.
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