A new catalytic converter that could cut fuel consumption and manufacturing costs has been designed by a scientist from Imperial College London.

The new design is said to have the potential to reduce fuel consumption by 3% and also lower emissions. Crucially it also uses up to 80% less rare metal, a development that could significantly reduce costs for vehicle manufacturers. Platinum in cat components currently accounts for 60-70% of manufacturing costs and also causes problems with theft.

The inventor of the prototype device is Dr Benjamin Kingsbury, who is also a Research Associate in the Department of Chemical Engineering at Imperial College London. He commented, “Catalytic converters are the most important component in a vehicle for controlling exhaust emissions. Yet their design has not changed since they were first developed in the 1940s. The prototype I have developed could make cars cheaper to run because they use less fuel. It could potentially help manufacturers to reduce their costs. Drivers could also be a major beneficiary of this device, which could save on fuel costs and ultimately lead to reduced emissions.”

A conventional catalytic converter is a ceramic block, which is honeycombed with microscopic channels that are coated in a rare metal such as platinum. Emissions travel from the engine to the exhaust system and through the channels, where the precious metal causes a chemical reaction to occur that eliminates the harmful pollutants.

The new design of the device increases fuel efficiency because it prevents back pressure, which is a build up of gases that can make the engine work harder, affecting its performance.