Abstract— Motor vehicles are the
primary transportation that is currently in
use began to be out of control. Increased
motor vehicles user provides a variety of
negative impacts, one of which is the
emissions gas from motor vehicles that
are harmful to the environment. Motor
vehicles exhaust emissions contribute
60% of air pollution, while industrial
sector 25%, households 10% and waste
5%. The content of harmful compounds
in vehicle exhaust emissions such as
sulfur oxide (SOx), nitrogen oxide
(NOx), carbon oxides (COx),
hydrocarbons (HC), heavy metals (Pb)
and particulates have harmful effects on
human health, breathing, internal organ
disorders such as the lungs and liver,
neurological disorders, reproductive
disorders, decrease intelligence in
children and even causes death. Carbon
monoxide is one of the most widely
produced emissions and has a direct
impact on human health. Developed
countries have made various alternatives
to reduce the number of motor vehicle
exhaust emissions, one of which is by
catalytic converter method using pure
metals such as Platinum (Pt), Palladium
(Pd) and Rhodium (Rh) as catalyst. This
method is quite good in reducing exhaust
emissions of motor vehicles but this
method is less efficient because the raw
materials used can not absorb heavy
metals perfectly and the cost is relatively
expensive. In this study, we will develop
an innovation in suppressing motor
vehicle exhaust using “ECOLY
Exhaust” which is based on smart
technology. The working principle of
this tool is to adsorb emission gas by
using adsorbents made from zeolites that
modified by Nickel (Ni) metal as
catalytic converter, which can convert
CO gas into CO2 gas in the form of pore
ceramic so it can be cleaned after occur
CO gas absorption for several time.
ECOLY Exhaust also uses a sensor-
based automatic alarm which can
provide a sound signal if the pore
ceramic has absorbed the exhaust gases
in large quantities so that the rider can
clean the pore ceramics by installing a
toluene spray tube in the exhaust hole
that has been provided for the
regeneration process. The expected
result of this research is the production of
ECOLY Exhaust can reduce the exhaust
emissions of motor vehicles with
relatively cheap production cost.
Keywords : Exhaust, Gas Emission,
Catalytic Converter, Smart Technology
1. INTRODUCTION
1.1 Background
The increasing public demand for motor
vehicles makes motor vehicles as the
primary means of public transportation
for Indonesians whose usage begins
uncontrollably. The latest data from
2012-2015 from the central statistical
agency shows the development of the
number of motor vehicles by type (Table
1). The increasing use of motor vehicles
provides various negative impacts for
both the Indonesian people and the
environment caused by exhaust
emissions generated by motor vehicles.
Motor vehicle exhaust emissions
contribute 60% of air pollution, while the
industrial sector 25%, 10% households
and waste 5% (Saepudin and Admono,
2005). Motor vehicle exhaust
contributions that exceed 50% of air
pollution make it a complicated problem
 to solve. The results of previous studies have shown the content of derived from natural materials such as rice husk ash (Sembodo,
motor vehicle exhaust compounds including sulfur oxide (SOx), 2006), zeolites (Handayani and sulistiyono, 2009), guava stems
nitrogen oxide (NOx), carbon oxides (COx), hydrocarbons (HC), (Lestari, 2010), Palm Kernel Shell (Gultom, 2014) and some other
heavy metals (Pb) and particulates has a harmful impact on human natural ingredients. Handayani and sulistiyono 2009 have done
health such as respiratory disorders, internal organ disorders such research in lowering content of chromium iv (Cr (iv)) using zeolite
as lung and liver, neurological disorders, reproductive disorders, adsorbent gives good result, this is because of zeolite surface area
decreased intelligence in children and causes of death. maximum and large pores so that absorption occurs in maximum
addition besides zeolit also adsorbents are environmentally
Table 1.Data on the development of motor vehicles from 2012-2015 friendly and inexpensive.
Type of Motor Year
Vehicles 2012 2013 2014 2015 1.2 Problem Formulation and Project Scope
Passenger car 10.432.259 11.484.514 12.599.038 13.480.973 Based on the previous analysis, the purpose of this research
Bus 2.273.821 2.286.309 2.398.846 2.420.917 is to develop an innovation process in suppressing motor vehicle
Freight cars 5.286.061 5.615.494 6.235.136 6.611.028 exhaust by using adsorbent derived from Ni modified zeolite which
Motorcycle 76.381.183 84.732.652 92.976.240 98.881.267 is packaged in the form of "ECOLY Exhaust" pore ceramic based
Total 94.373.324 104.118.969 114.209.260 121.394.185 on smart technology. The working principle of this tool is the
adsorption of emissions of motor vehicle emissions by using
Several studies have been conducted to reduce motor adsorbents derived from Nickel modified metal zeolite (Ni) as
vehicle exhaust emissions one of them by making Catalityc catalytic converter which can convert CO gas to CO2 gas in the
Converter. The working principle of this method is to reduce the form of pore ceramic so it can be cleaned after absorption of
metal from exhaust emissions by using a metal catalyst such as exhaust gas. ECOLY Exhaust also uses a sensor-based automatic
platinum (Pt). This method is quite effective in reducing exhaust alarm which can provide a sound signal if the pore ceramic has
emissions but because the raw materials used have a relatively high absorbed the exhaust gases in large quantities so that the rider can
cost and not all metals can be reduced with this catalyst like lead. clean the pore ceramics by installing a toluene spray tube in the
The lead metal can only be derived using the principle of exhaust hole that has been provided for the regeneration
adsorption. The metal adsorption process can use adsorbents process.The expected result of this research is the production of
 "ECOLY Exhaust" based on smart
technology that can reduce motor vehicle
exhaust emissions and can convert CO
gas into CO2 gas with relatively cheap
production cost.
Project Scope
Product Reducing Emissions Disposal of
Motor Vehicles with Porous
Ceramics as a catalytic converter
Timing Available MEI 2018
Market Motorcycle Accessories Shop
Constraints The location of raw materials is
difficult to reach
Stackholders Motor Vehicle Manufacturer, End
Users
2. LITERATURE RIVIEW
2.1 Danger of Exhaust Emission
Exhaust emissions are pollutant
gases produced by motor vehicles, as
well as some emissions of exhaust gases
produced by motor vehicles as follows:
carbon monoxide (CO), various
hydrocarbon compounds, Sulfur (SOx),
and dust particles including lead (Pb).
2.1.1 Carbon monoxide
WHO states that patients with
heart or lung disease should not be
exposed to CO gas with a level that can
form COHb levels above 2.5% because
the patients is a group that is sensitive to
CO exposure. Exposure of CO of 35
mg/m3 for 1 hour and 20 mg/m3 for 8
hours was equivalent in COHb formation
above 2.5%. So that WHO sets CO
exposure standards should not exceed 25
ppm (29 mg / m3) for 1 hour and 10 ppm
(11.5 mg / m3) for 8 hours (Aprilia,
Devita Nur et al., 2017).
2.1.2 Sulfur Oxide and Particulate
The inhaled SO2 will hydrate to
produce sulfuric acid in the respiratory
tract, which then dissociates into its
derivatives, bisulfites and sulfites.
Bisulfite and sulfite can be absorbed into
the blood or other body fluids, which will
cause tissue damage through free radical
mechanisms. Increased SO2
concentration, causing rainwater pH to
be lower than the baseline scenario,
reaching 5.12 in 2060, when SO2
concentration in Indonesia reaches the
highest value. Besides impacting
rainwater pH reduction, SO2 emission
increase also affects global temperature
reduction (Dewi and Susandi, 2000).
2.1.3 Lead (Pb)
Pb metal contained in gasoline
will emit 0.09 grams of lead per 1 km.
The lead gas is mainly derived from the
combustion of gasoline additive
materials from motor vehicles consisting
of tetraethyl Pb and tetramethyl Pb. The
Pb particles in the air come from other
sources such as the alkyl Pb and Pb-
oxide factories, charcoal burning and so
on. The largest Pb pollution comes from
the combustion of gasoline, which is
produced by various Pb components,
especially PbBrCl and PbBrCl.2PbO
(Fardiaz, 1992). Pb emissions into the air
can be a gas or particle as a less than
perfect result in a motor vehicle. If the
combustion process in a motor vehicle is
less than perfect, so that more the amount
of Pb to be emitted into the air.
Compounds contained in motor vehicles
are PbBrCl, PbBrCl.2PbO, PbCl2, Pb
(OH) Cl, PbBr2, and PbCO3.2PbO,
among these compounds PbCO3.PbO is
a compound that is harmful to health.
Effect of Pb on health, especially on the
synthesis of hemoglobin and the system
of the central nervous and peripheral
nerves. Influence on blood Hb forming
system that can cause anemia. Humans
absorb lead through the air, dust, water
and food. Tetraethyl lead (TEL), which
is a lead metal material (lead) is added to
low-quality fuel to decrease octane
values. Organic Pb is absorbed primarily
through the gastrointestinal and
respiratory tract and this is the primary
source of Pb in the body. Besides of that
manganese in MMT and karsiogenik on
MTBE (additive material on gasoline
other than TEL that produces harmful
substances for the body) (Anonymous,
2010).
2.2 Zeolite Application as Metal
Adsorbent
Handayani and Sulistiyono, 2009
have conducted research by absorbing
chromium metal using zeolite. The
zeolite is activated by heating 150 0C so
that the pore size reaches 50 mesh, it
aims to get a tight zeolite pore making it
difficult to enter by other ions. This is
due to the presence of water molecules
that close the pores of the zeolite so that
it can cover the surface of the pores. By
heating it is expected that water
molecules can come out to create
intermolecular cavities. From the results
of experiments that have been done,
good absorption of chromed metal by
zeolite is proved by the langmuir
method.
Emelda et al., 2013 has also
studied the absorption of Cr3+ metals by
using zeolite with activation of H2SO4
0,15 N and NaOH 0,5 N solutions with a
ratio of 1 g zeolite: 10 ml of H2SO4
solution and 1 g zeolite: 10 ml NaOH
solution for 3 hours while stirring. After
that, do filtering and washing with
aquades which then in the heat at a
temperature of 150 0C for 3 hours to
reduce the water content in the zeolite
that can cover the pore surface. The
results obtained in this study is the
decrease of Cr3+ metal.
2.2 Catalytic Converter Application
The catalytic reaction
mechanism of the catalytic converter
proceeds according to the Langmuir-
Hinshelwood type between the adsorbed
oxygen and CO adsorbed with the
catalyst, and it is unclear whether the two
react individually or are a combination of
both (Cole et al., 2010).
Irawan, 2012 has conducted
research in the design of catalytic
converters using copper to reduce carbon
monoxide exhaust emissions resulting in
Catalytic Converter various models of
catalyst materials that are ready to be
used to reduce Carbon Monoxide
exhaust emissions from gasoline-
powered motors. In addition, Manunggal
(2013) has also conducted research on
copper catalytic converter applications
with the addition of Secondary Air
Supply System (SASS) produces good
results in reducing pollution of air
pollution due to exhaust gas and noise
pollution by motor vehicles.
3. PRODUCT DESIGN
3.1 Product Spesification
The product specifications of
Ecolly Exhaust can be shown in Figure 1.
And product for regeneration can be
shown in Figure 2.
Figure 1. Design of Ecoly Exhaust
Figure 2. Design of tube sprayers for
regeneration
3.1 Concept Creation
The product created is a catalytic
converter made from metal NiCl2 mixed
with zeolite adsorbents and supported by
clay then mixed with PVA as agent
Foam. The product is hollowed as much
as 19 holes with a diameter of 2 mm
holes and the distance between holes 3
mm. In this product is installed sensors
that identify when the catalyst has
expired life (lifetime) which is then
connected with an automatic alarm so
that the vehicle users know that the
catalyst is out of service. Then we
provide a cleanser with toluene material
as regeneration of the catalyst in order to
re-use the catalyst.
4. PRODUCT MANUFACTURING
4.1 Market Analysis
Marketing This product will be
started in one of the sales of motorcycle
accessories located in Yogyakarta and
seen the interest of consumers for one
month, after which will be the
development of distribution to several
manufacturers of motorcycle accessories
located in Yogyakarta with minimum
production capacity of 30 pcs / month.
4.2 Materials
The main materials used in this
product include Zeolite, NH4NO3 2 M,
Ni(NO3)2.6H2O as well as additives are
Aquades, Clay, Poly Vinyl Acid (PVA),
HCl and Toluene.
4.2.1 Natural Zeolite
Natural zeolite is a material that
has many uses. Zeolites have been
widely applied as adsorbents, ion
exchangers, and as catalysts. Zeolite is a
crystalline alumina silica tetrahydric
porous crystalline having a three-
dimensional skeletal structure. Natural
zeolite is formed because of complex
chemical and physics process of rocks
which undergoing various changes in
nature (Lestari, 2010).
4.2.2 Catalyst from Nickel (Ni)
Nickel metal catalysts have good
activity and selectivity in a reaction, but
the active phase of the nickel catalyst
itself does not have a large surface, so the
reaction becomes ineffective and
inefficient because not all of the active
centers can make contact with the
reactants. Therefore nickel metal needs
to be distributed on a surface of a buffer
solid having a large surface area (Bakri 4.3.4 Compressive Strength Instrument
et al., 2008). The compressive strength
instrument is used to find out the
4.3 Instrumentation maximum compressive strength in the
Instrumentation used in the pore ceramics.
manufacture of this product is X-Ray
Diffraction (XRD), Gas Sorption 4.3.5 Burn Test Instrument
Analyzer (GSA), Scanning Electron Burn Test Instrument is used to
Microscope-Electron Diffraction X-ray determine the maximum temperature of
(SEM-EDX), and compressive strength the pore ceramics to be burned.
and burn test.
4.4 Manufacturing Process
4.3.1 X-Ray Diffraction (XRD)
XRD is an instrumentation used to
characterize the crystalline structure
and crystal size of the Ni-modified
Zeolite ceramic pore, the higher the
crystallinity of a material the better the
material is used as the adsorbent.

4.3.2 Gas Sorption Analyzer (GSA)

GSA is an instrument used to
determine the pore surface area, pore
volume and pore distribution of the
pore ceramics used as the adsorbent.
The larger surface area of the pore
ceramic, the better the likelihood of
the interaction between the adsorbent
and the exhaust gas, and the larger the
pore volume the more exhaust gas that
can be adsorbed and the better the pore
distribution the better the material is
used as the adsorbent.
Figure 3. Manufacturing Process
4.3.3 Scanning Electron Microscope- Block Diagram
Electron Diffraction X-ray (SEM-EDX) 4.4.1 Zeolite Dealumination
SEM-EDX is an instrument used Zeolite Dealumination is
to see the morphological differences of conducted by mixing 400 grams of
pore ceramics and compounds found in zeolite plus 50 mL of HCl 6 N and
pore ceramics after modification with Ni boiled for 3 hours. After that it is
metal. neutralized with aquades. This process
aims to obtain SiO2 in zeolites.
4.4.2 Synthesis of Zeolite Catalysts
modified by Ni metal
The synthesis process of Ni metal
modified zeolite catalyst refers to a
study that has been done by
Septiansyah, 2011. The Nickel-Zeolite
catalyst is obtained from impregnation
between nickel chloride (NiCl2) and
zeolite in liquid medium. Zeolite
samples weighed as much as 120
grams were fed into a round bottom
flask containing 100 mL of 0.4 M
NiCl2 solution then refluxed at 80-90
°C for 24 hours. After the reflux
process is complete, the sample is then
washed with aquades until it reaches
the wash pH (pH = 5). Dryed at oven
at 110 oC for 4 hours, after dry sample
then calcined in kiln at 500 - 600 oC
for 2 - 3 hours. Calcination time is
calculated after reaching a constant
temperature. The calcined samples
were then analyzed by GSA (Gas
Sorption Analyzer) to determine the
surface area of Ni metal modified
zeolite catalyst.
4.4.3 Manufacture of Pore Ceramics
As Catalytic Converter
Manufacture of pore ceramics as
Catalytic Converter is conducted by
mixing clay material with Ni-Zeolite
catalyst and Foaming Agent in the
form of PVA with respectively
composition ratio of 60%, 30%, and
10%. In stirring with rotation 64 rpm
for 2 hours then ceramic body in press
with pressure 25 MPa and pore made
with 19 holes with size 3 mm. While
the size of material that is made is 70
mm long and 50 mm diameter. After
that the ceramic body heated in the
furnace at a temperature of 500 oC
with a heating rate of 50 oC/minute
and holding time of 2 hours.
4.4.4 Pore Ceramic Regeneration
Process with Toluene through Sensor
CO
The regeneration process is carried
out by using the CO MQ7 sensor to
detect the remaining CO gas that has
not been converted by the catalyst on
the pore ceramics. Sensor CO MQ7
will send data to Arduino as data
processor. Data from Arduino is sent
to Piezo Speaker as indicator and
produced a sound signal indicating
that the pore ceramic has reached life
time and must be regenerated so that
the adsorption and catalytic converter
process goes maximum. After the
alarm sounds, the toluene spray tube is
mounted on the pipe provided on the
exhaust body, and the waste of this
regeneration process will be
accommodated at the pre-installed
container at exhaust mouth, this
process is conducted manually.
5. FEASIBILITY STUDY
5.1 Raw Materials
5.1.1 Availability of Natural Zeolite
Zeolite is a group of minerals
which in the sense / naming of minerals
is one type of non-metallic minerals or
mineral industry. Geologically, zeolite is
first found in tuff rocks formed from
sedimentation, volcanic dust that has
undergone alteration process. Indonesia
is in the area of a series of volcanoes
ranging from Sumatra, Java,
Nusatenggara, to Sulawesi. Various
types of volcanic rocks are produced,
including a fine-grained pyroclastic tuff
rocks that are acidic and arranged dasit-
riolit or volcanic glass volcano. This fine
tuff is widespread following the path of
the volcano which has partly or entirely
undergone a process of alteration or
diagenesis into zeolite. Therefore,
geologically Indonesia has great
potential to produce zeolites such as
those found in Sumatra (Lampung, North
Sumatra), Java (West Java, Central Java,
East Java), East Nusa Tenggara, and
Sulawesi (Kusdarto, 2008).
5.1.2 Availability of Nickel Metals as
Catalyst
The nickel metal used as a
catalyst is not a pure metal, it is intended
to suppress the production price of the
pore ceramics, so that the nickel metal
used may be NiCl2, [Ni(NH3)]2+,
Ni(NO3)2 (Septiansyah, 2011; Suyati
2012; Bakri, 2008).
5.1 Manufacturing Process and
Economic Aspects
The process of making Ecoly
exhaust has a low complexity this is
because the availability of materials that
are abundant in nature and the price of
cheap materials make it not a difficult
problem other than that the tools used are
simple tools that can be obtained in the
laboratories engineering as a first step
making Ecolly exhaust. The availability
of abundant materials and the use of
simple tools make Ecolly exhaust is the
right solution in resolving environmental
issues with a low cost.
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