JOHN J. MOONEY
                New Jersey Institute of Technology                                                               

To the question who are you? My response is: I am a Chemical Engineer. I am really proud of being a Chemical Engineer. I am known as the co-inventor, along with Carl D. Keith, of the 3-way catalytic converter used on almost every passenger car and light-duty truck made in the world.

I started my Masters degree in Chemical Engineering taking evening classes at Newark College of Engineering (NCE), now the New Jersey Institute of Technology (NJIT). Prior studies of chemistry at Seton Hall University led me to Chemical Engineering. Chemistry opened the world for me and explained so much. I found myself interested in how to make the chemistry happen. Looking back, the step toward a M.S. in Chemical Engineering was the most important step for my ensuing career.

The next key component was choosing an employer aligned with my interests. I found Engelhard through the Electrochemical Engineering course and applied for an opening in the Engelhard Gas Equipment Division, where I saw a perfect fit. The first two assignments were hydrogen purification, and catalytic dissociation of ammonia to hydrogen (75%) and nitrogen gas. These projects were successful and led to an increasing level of assignments.

I quickly excelled and was transferred to the growing Chemical Division, a great step forward. My first project was to develop a production process for 1/8 diameter spherical alumina catalyst support beads in a boehmite alumina slurry oil-dropped forming scheme, which we called the "sphere column". Many unique problems required innovation to design a continuous process with sufficient production volume through-put.

A small duty was to provide support for the new PTX catalytic converter (an oxidation catalyst) starting application trials for propane fueled fork lift trucks. The key mounting technique used to secure the fragile ceramic catalyst unit within a steel shell utilized corrugated knitted wire mesh. This material had been invented by Otto H. York, for whom the Otto H. York Department of Chemical Engineering at NJIT was named. Carl Keith and I designed a diesel oxidation catalyst (DOC), a new PTX version and opened the market for diesel emissions control. Ford Science Laboratory became interested in the PTX and I provided all follow through and joint cooperative efforts, thus other duties increased and PTX tasks proliferated. This led to an assignment as Section Head of the new auto exhaust catalyst development project.

The Clean Air Act Amendments of 1970 set hydrocarbon, carbon monoxide and oxides of nitrogen exhaust standards and thereby created the emission control market. I visited Detroit, Europe and Japan and met with all car-makers. This experience was surreal: one Chemical Engineer with an interpreter and teams of other engineers and scientists all thirsty for knowledge, understanding, limits, and pitfalls we would face. Thereafter, there ensued an enormous series of back and forth mini-tasks and technical meetings with almost every foreign car-maker. I became known at the Catalytic Converter teacher. These efforts and the reputation of Engelhard combined in securing 26 automobile companies as PTX customers.

Competition soared in the U.S. Ford had settled on our PTX catalytic converter. General Motors had 40 potential catalyst suppliers (they initially insisted on base-metal catalysts before accepting precious metal types). GM designed pelleted catalytic converters rather than the PTX monolithic type; so we also developed pellet catalyst technology. GM decided to reduce potential suppliers to ten and then to four- and we were No. 4. We were then asked to prepare and submit a full production qualification batch of pelleted catalyst for GM scrutiny prior to approval. We became the first approved catalyst supplier. I was assigned as Technical Director of the Auto Exhaust Catalyst project a few weeks later at the end of January 1974. The assignment still included customer sampling, application engineering, sales and marketing, as well as R&D. Once again, it was the reputation of a working Chemical Engineer that achieved this assignment.

The PTX was an oxidation catalyst. NOx control with exhaust gas recirculation (EGR) was inadequate. Catalytic reduction of NOx (oxides of nitrogen N2O, NO and NO2) to N2 required a reductant such as HC, CO or H2 - this was possible in rich air/fuel calibrations. Thus, car companies and catalyst companies were working on a dual bed catalytic converter system utilizing a fuel rich NOx reduction catalyst, an air pump for air injection, followed by an oxidation catalyst.

Before this occurred, a unique solution was discovered. The Engelhard invention of the three-way catalyst by Mooney, Keith and others, permitted destruction of the three exhaust pollutants in a single catalyst bed. From laboratory experiments, Carl Keith and I recognized that the TWC catalyst would operate efficiently at the stoichiometric air/fuel ratio mixtures. However, we subsequently discovered that, in fact, the actual engine system with fuel injection and closed loop oxygen sensor control did not maintain the stoichiometric mixture. Rather the air/fuel mixture fluctuated widely rich and lean of this desire point. This meant that when A/F was lean the excess oxygen would exit the tailpipe and would not be available for required oxidation reactions on the rich swing. Our solution was to incorporate rare earth oxides and base metal oxide components within the catalyst layer along with Pt and Rh. These oxides were reducible oxide forms to donate and accept oxygen, for instance: Ce+4 and Ce+3 oxides. Thus, within the catalyst layer, the A/F tended toward the stoichiometric value where simultaneous oxidation and reduction reactions would proceed. Carl Keith and I went over these actual engine performance results in detail. Also important were durability performance results. We concluded: 1) Simultaneous oxidation of the HC and CO and reduction of NOx were apparent. The catalysts were hydro-thermally stable and durable; and 2) certain PGM + base-metal catalyst test series showed very high simultaneous oxidation and reduction rates that were greatly improved in the presence of multi-valance base-metal oxides even though the air/fuel mixture in the bulk gas varied widely rich and lean of the perfect stoichiometric mixture.

For the last 30 years, 3-way catalysts have been installed on over 800 million gasoline fueled automobiles and light-duty vehicles all over the world. The SAE places it as one of the ten top automobile inventions. It introduced on-board catalytic chemical processing to everyday life. It has destroyed estimated emissions of over 6 billion tons of hydrocarbons, 6 billion tons of oxides of nitrogen and 60 billions tons of carbon monoxide. It is directly associated with the elimination of leaded gasoline which caused widespread air borne lead pollution. Lead was a pervasive atmospheric pollutant and proven to negatively affect childrens mental development- a loss of up to 6 to 10 IQ points! The new 3-way catalyst with closed-loop oxygen sensor A/F control system facilitated improvements in fuel economy, engine power. It provides full range fuel flexibility to incorporate biofuels. Without the durable and efficient TWC catalytic converter, ambient pollution would be at very dangerous levels. These inventions have had positive political, environmental and societal impacts. The U.S. Clean Air Act amendments of 1970 called for 90% reduction of the three automobile emissions. The TWC catalytic converter technology was the principal technology necessary to achieve the Clean Air Act target and has continued so throughout the world. It is a great success story in the fight to improve ambient air quality that has contributed to healthier lives for billions of people.

The Engelhard auto exhaust catalyst business reached over $100 million profit per annum for many years and supported R&D budgets of the same level. The overall world market is in the ten billion $ area.

Education and degrees

St. Georges Grammar School, Paterson, NJ, June 1943

St. Josephs High School, Paterson, NJ, June 1947

Seton Hall University, Urban Div., Newark, NJ, BS Chemistry (completed Aug 1954), 1955

Newark College of Engineering, Newark, NJ, MS in Chemical Engineering, 1960

Fairleigh Dickinson University, Teaneck, NJ, MBA Marketing, 1992

New Jersey Institute of Technology, Newark, NJ, DSc, Chemical Engineering (honoris causis), 2007

Motivation to pursue Chemical Engineering

Chemistry studies led me to Chemical Engineering. I believed it would provide a broader base for my developing interests. A brief interview with NCE Professor Charles L. Mantell, Head of Chemical Engineering, provided the final motivation. I knew this was just the right decision as I worked toward becoming a working Chemical Engineer.

Mentors

A young Chemical Engineer is blessed to have someone of character interested in providing guidance and counseling. If this happens, my first advice is to listen and remember that you have to make your own way in life and career. I have been blessed with several mentors.

Dr. Carl D. Keith selected me as Chemical Division Process Engineer. He had an excellent sense for business and a special intuition for people. When I became Technical Director, he let me choose 3-way catalyst development as the top project without question. As this project quickly unfolded, Carl saw how important this project was to Engelhard. He and I went over catalyst test results from the engine laboratory and together made the observations that defined the invention of the 3-way catalytic converter.

My wife Claire has been my mentor for 53 years. Claire, who has a BS in Chemistry, can write clearly, logically, and succinctly. She has become my editor. My writing skills improved because of Claire's mentoring. An important lesson to a young Chemical Engineer is that communication skills are very important to your career.

Significant Career Projects

A final career project developed small engine catalytic converters for lawn and garden equipment, chainsaws, and 2-wheeled vehicles a large market with formidable barriers. Small engines produce terrible unhealthy micro-environments for users, workers and neighbors. I had concepts and organized a small 4-man team with a budget. Our major improvement in catalyst thermal resistance was carried over to close coupled automobile catalysts. Two entirely automated catalyst processes were developed and an entirely new automated ceramic catalyst assembly technology. We developed a unique catalytic plate technology that did not add any weight to hand-held 2-stroke engine equipment and a new mounting system that would last for the life of a professional grade chainsaw. Engelhard would serve the entire small engine industry.

Significant Activities

I served on the Board of Directors of the Manufacturers of Emission Control Association (MECA) for 22 years and as President for 3 years (in late 1990s). MECA was formed to provide reliable technical information regarding emission control technologies to government officials and regulators (federal, state and local) and built a reputation as a credible information source. I provided key support for strict California ARB standards. Light-duty California vehicles almost reach zero emissions of HC, CO and NOx now called partial zero emission vehicles. The Chemical Engineers role in supporting legislative and regulatory activities or industry standards involving public welfare is quite a responsibility.

Additional Accomplishments

The catalytic converter has led toward the elimination of leaded gasoline in the world. The catalytic converter is poisoned by lead giving authorities another reason beside its damage to human health to eliminate lead in gasoline. Tetraethyl lead should never have been permitted to be added to gasoline fuel in the first place as its corrosive nature resulted in short engine life. More detrimental is that lead had long been known as a severe human poison and solid nanoparticle air borne lead from leaded gasoline combustion was estimated to be the major source of over 80% of the human lead burden. The 1979-80 Boston study by Needleman of lead in childrens teeth found leaded gasoline responsible for permanent retardation of childrens mental health development permanent loss of up to 6 IQ points as well as detriments to learning and classroom behavior. The study was confirmed in England and the Netherlands and more recently in Africa up to10 IQ point loss was found. I had a role in convincing China, India and Africa to simply switch to unleaded gasoline which immediately stopped this destructive atmospheric pollutant Then new cars (and second-hand cars from the US, Europe and Japan) equipped with advanced emission controls and 3-way catalysts can bring cleaner air to citizens. The leaded vs. unleaded gasoline battle was a long tough fight and is still not over as several nations still use leaded gasoline. See www.unep.org/pcfv for pamphlet on myth of valve seat recession.

A second great benefit of the catalytic converter was its incorporation into the total engine system as an engine tool. When General Motors introduced the 1975 catalytic converter it gained 28% improvement in fuel economy and substantial improvement in engine performance due to engine MBT spark timing recalibration over 1974 MY vehicles and other manufacturers followed. The TWC closed-loop oxygen sensor feed-back control system gained an additional 8 to 12% in fuel economy and provides fuel flexibility for the existing vehicle parc without any loss of emissions control or relative fuel economy; ie. switching to ethanol, saturates and biofuels.

Career Phases (most enjoyable and challenging)

Working with scientists, engineers and technicians of auto company technical teams, of associated industry, and with the Engelhard team, was a true pleasure. My Chemical Engineering background, necessary for exhaust catalyst technology, also related well to fuels and engine systems and served me well in these working relationships. It was a big challenge for mechanically minded automotive engineers to accept the notion of a catalytic converter and to switch from carburetion to fuel injection.

I have a new challenge and am focused on getting diesel engine particle emissions into full US national discussion - particularly solid nanometer soot particles that penetrate the lung alveoli and move into the blood stream: this fraction is regarded as one of the largest health concerns by health authorities and is found to be carcinogenic and a cause of heart attacks. This discussion is underway in California (CA ARB) and in New Jersey. But our current regulatory test procedure cannot differentiate this fraction. I am quite active with a Swiss team (called VERT), who found the solution to diesel engine soot contamination in tunnel construction air and compiled in-depth scientific and engineering based qualification procedures for particle filter technology that eliminates 99.9% of diesel nanoparticle soot particles. The VERT system is a proven success with very low failure rate.

I am still trying to bring leaded gasoline to a final end in the world through my not-for-profit company (EETPI) working with the UNEP Partnership for Clean Fuels and Vehicles (PCFV). Fifty-one African countries still used leaded gasoline in 2002. The major barrier was valve seat recession (VSR) in older engines. VSR did not occur in actual use, but the lead industry used this argument effectively to delay decisions to accept unleaded gasoline. As Valve Seat Recession Chairman I studied published papers and found that proper VSR mechanisms were defined and confirmed (but somehow overlooked) in published papers and valve seat recession myth simply carried on in published literature. My report of findings to the VSR Committee resulted in a UNEP pamphlet that was delivered to appropriate officials in 51 African countries www.unep.org/pcfv. Within two years, by December 31, 2006, all but one African country has banned leaded gasoline as the direct result of this effort. .Even in retirement, in a give-back mode a Chemical Engineer can influence decisions that benefit many children and adults that unknowingly were suffering terribly. Once a Chemical Engineer, a Chemical Engineer for life.

Professional Recognition (partial list)

• Fellow, Society of Automotive Engineers (SAE); 1990, first SAE recognition of exhaust emission control

• American Institute of Chemical Engineers Award for Innovation, Arthur Dehon Little Award of 1999

• Laureate, Walter Ahlstrom Prize 2001, Awarded by Finnish Academies of Technology

Received (along with Carl D. Keith) for invention and commercialization of the three-way catalytic converter. The Ahlstrom Prize is awarded in recognition of significant technological achievements which enable, or will enable, widely applicable industrial advances in the use of energy, in the utilization of raw materials, or in minimizing detrimental environmental impacts. The development may represent new breakthroughs in equipment design or improved processes. Primary consideration will be given to engineering achievements that have led to important benefits in industry to the well-being of society.

• Laureate, National Medal of Technology 2002 (team award with Carl D. Keith). Presented by President George W. Bush at White House ceremony on November 6, 2003. For invention, commercialization of the three-way catalytic converter and world wide use on all automobiles.

• American Institute of Chemical Engineering, Life Time Achievement in International Chemical Engineering, Kazutoshi Fujimura Award, 2005.

How would I like to be remembered? Maybe they could remember he never gave up!

What is your single major predication about the future of chemical engineering?

Our 21st century society needs Chemical Engineers more than ever for many urgent societal technical needs for our populated world. Obvious are: energy conversion; improved processing efficiency; alternate fuel processes; safe nuclear energy; safe radioactive waste processing, storage and upgrading; clean coal processes; pharmaceuticals and health care; return of vital US industry to our shores. My prediction is that the internet will serve more and more as a means to commit Chemical Engineers to stay in touch with their University to undergo formal and routine review, maintenance and upgrading of basic Chemical Engineering fundamentals and skills. I can imagine a formal process by which some numerical or alpha marker can be added to the ChE degree indicating sustained level of skills being maintained.

What is your greatest a) hope and b) concern about the future of the profession?

I hope Chemical Engineering will be well represented on influential national working groups such as the National Academy of Engineering and Sciences. I am concerned that science and engineering representation in the political area is woefully lacking (similarly economists) and far over populated by the legal profession. I would like to see engineers and scientists, at a point in their career, become more deeply involved in federal, state or local government so that their individual valuable viewpoint can be heard, thus providing a more balanced overall view, and to actually have a vote to influence a final outcome.

What is you advice for new graduates entering the profession?

You are entering the profession and need working experience. Your initial performance is very important. Medical Doctors say learn one, do one, teach one when they talk about medical procedures. Therefore, read, learn, listen and do as much as possible in your first assignment. First, always think safety! Consider embarking on an advanced degree at night. Stay up-to-date in your profession. Dedicate time to read journals. As you become proficient in an area, think to publish.

What is your advice for high schoolers considering chemical engineering?

Try to be in an advanced high school program with advanced math, physics and chemistry. I advise summer school classes for review just before entering chemical engineering. However, my daughter Kathleen Mooney, University of Pittsburgh ChE graduate, recommends a full summer vacation because, she says, that is the last break you will have until graduation. All undergraduate engineering courses are very tough and dropout rate is high in the first year. The effort needed is actually very great and so is the reward as, if you persevere, you will become a professional within 4 or 5 years. The world then really opens up for you. The world and our nation really need you. Get going and good luck!

Is there anything about you that few people know that you would like to share?

My major US Army assignment was one year duty (55-56) at the Enewetak (aka Eniwetok) Atoll, Marshall Islands atomic proving ground. In 1956 I witnessed 17 atom bomb and two hydrogen bomb tests. Most tests were at night - all of us in formation and each verbally accounted for and positioned on the beach with our backs to the bomb explosion site and eyes forward before countdown to the explosion. Most atomic bomb detonations were 12 to 20 miles north of our site but closest for me was 7.5 miles away. The two thermal nuclear hydrogen bomb tests were conducted on/near the Bikini Atoll which was ~ 175 miles away. The atomic explosions produced intense light for about 30 seconds and were of relatively short duration. The hydrogen bomb explosion light intensity lasted about 5 minutes and the rolling pressure waves come much later (~175 miles to travel) but were quite strong and broke glassware in our hospital. The physical experience of an atomic bomb explosion is really something. At count down end, light instantly filled the whole night sky to the level of noon sunlit tropical intensity without noise of any kind. I could see my elongated defined shadow extending a hundred yards. Next peripheral vision detects a rapid visual event zooming through the lagoon water speed in water is faster than air. Next came a pressure wave felt on your back without the intense thunder noise one would expect. After 30 seconds the light intensity diminished rapidly and when we cautiously turned around the typical mushroom cloud was still developing with a certain beauty to the mushrooming cloud with ultraviolet and bluish light flashing around. This too diminished in several minutes and the cloud has drifted off to the west out-of-sight over the Pacific. I never want to see or hear of another atmospheric atomic explosion and hope none more occur even in test. I do hope that in the US we can return to safe use of nuclear power generation and rational means for caring for radioactive waste. Chemical Engineers can play a leading role in many associated activities.

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