Design and Performance Analysis of a Honeycomb-Shaped Brass Alloy Catalytic Converter for Sustainable Emission Control in 4-Stroke Engines

The automotive sector is a cornerstone of economic growth and technological innovation, yet it remains a significant contributor to global greenhouse gas (GHG) emissions, responsible for 24% of the worldwide total. It is actively exploring sustainable solutions to reduce its carbon footprint, including the development of advanced and economical catalytic converter technologies. Catalytic converters reduce harmful emissions by promoting efficient combustion, but their reliance on expensive and scarce metals like palladium and rhodium drives the search for alternative materials. Identifying suitable materials that balance ecological significance with productive outcomes, while ensuring sustainability and cost-effectiveness, remains a persistent challenge. To address this issue, this research has been conducted to explore the feasibility of using Honey comb shaped Brass alloy catalytic converter as cost-effective and sustainable substitute. Experimental data demonstrated that Brass-based catalytic converter reduces HC emissions by up-to 23.48%, CO level lowered by 20.96% and CO2 concentration increased by 39.96% compared to conventional catalyst converter. Brass's affordability and sustainability enable wider adoption and frequent replacement of wornout converters, ensuring consistent emission control. These findings position Brass as a viable alternative to traditional precious-metal-based catalysts, advancing the automotive sector’s transition to net-zero emissions. This research aligns with regulatory goals and global efforts to reduce GHG emissions, paving the way for greener transportation solutions.