Industrial Catalytic Converter

Common Failure Modes of Industrial Catalytic Converters

Industrial engines are tough on catalytic converters. Long hours, high exhaust temps, vibration, and dirty fuel—everything adds stress. Knowing how converters fail helps keep engines running and avoids surprises.

Substrate Damage

The substrate is the heart of an industrial catalytic converter. Most failures start here.

Cracks and collapses: Ceramic substrates can crack from sudden temperature changes. Metal substrates handle it better but still bend or warp if overstressed.

Foil deformation: In metal honeycomb substrates, thin foils can warp under vibration or uneven heating. That can block flow or touch the shell.

Material, foil thickness, and shape matter. Pick the right ones for the job.

Washcoat Problems

The washcoat sits on the substrate and holds the catalyst.

Peeling or flaking: Poor prep or thermal cycling can make it come off.

Poisoning: Sulfur, phosphorus, or oil residues can deactivate the catalyst.

Fuel quality and maintenance are key to keeping it working.

Catalyst Issues

Even with a perfect substrate and washcoat, the catalyst can lose power.

Sintering: High heat makes particles clump, surface area drops.

Chemical poisoning: Some exhaust compounds stick to active sites, cutting efficiency.

Engines running low load or dirty fuel see this more.

Housing and Mounting

The shell keeps the substrate safe and in place.

Cracked welds or bent shells: Thermal expansion and vibration cause this.

Loose mats: Let the substrate move, leading to wear or uneven gas flow.

Good housing and mats prevent early failures.

Flow Distribution

Even a perfect substrate needs proper flow.

Hot spots: Uneven flow overheats parts of the substrate or washcoat.

Backpressure: Too much slows the engine, reduces conversion.

Check inlet/outlet cones, install carefully.

Contamination

Industrial exhaust isn’t clean.

Clogging: Dust, soot, oil block channels.

Corrosion: Moisture and chemicals eat at the metal and housing.

Filters and regular checks help a lot.

Bottom Line

Failures aren’t usually one thing. They pile up—thermal stress, vibration, wrong material, dirty fuel. Know these issues, pick the right substrate, design flow well, keep maintenance tight. The industrial catalytic converter will last longer, and the engine stays compliant.