Cost effective manufacturing of catalytic converters for diesel generators in Lebanon

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  • Collaborators
    AUB & Jubaili Bros
  • Subcategroy
    Manufacturing
  • Read time
    5 minutes
  • Videos
    1
  • Technical PDFs
    3
  • Coordinator
    Mohammad Hamid


Background:

Emission levels from distributed diesel generators in Lebanese urban areas are far beyond acceptable limits, impairing the wellbeing of residents and increasing the risk of disease. The only applied standards come from executive decrees which relate to ambient air‑quality limits and the National Standards for Environmental Quality (NSEQ)[1]. For example, MoE Decision 52/1 (1996, amended 2001) establishes national air quality standards, and Decision 8/1 (2001) defines general Emission Limit Values (ELVs) for large point sources (power plants, factories)[2]. These refer to ambient caps on molecules such as NOx, CO, SOx, and particulate matter but do not explicitly cover neighbourhood backup generators.

There is yet no codified and enforced Lebanese standard on stack emissions for distributed diesel generators, rendering the issues of air quality and disease inducing pollutants out of control. The ministry of environment requires an environmental impact assessment for new or expanding diesel generator projects and Libnor's NL-484:2016 details the required characteristics of diesel oil used in the local market[3]— however, these efforts have proven to be insignificant when controlling for diesel generator-based emissions, especially in densely populated urban areas. After the compounded crises that the country underwent starting 2019, one researcher estimates that the level of toxic emissions from generators may have quadrupled[4].

In the absence of numeric stack limits, Lebanon has relied on recent directives and local orders to control generator emissions. Most notably:

  • MoE Circular 4/1 (not publicly posted but reported in the press) imposes environmental requirements on all private generators. It mandates pollution-control devices (catalytic converters and particulate filters) and requires compliance with prescribed “limit values” for exhaust pollutants (e.g. CO, NOx, PM)[5]. The text refers to adhering to these “emission limit values”. In effect, operators must meet these concentration limits, though the law itself does not list them.
  • Local orders (Beirut): Governors have issued enforcement notices for generators. For example, in Nov. 2024 the Governor of Beirut ordered all commercial and residential generators to install the required filters and meet the MoE standards by 31 Dec 2024. Owners were warned that noncompliance (e.g. failing to fit a filter or meet height/limit requirements) could lead to the generator being shut down[6].

Importantly, these generator rules came via administrative circulars and local directives, not through a new environmental law. No cabinet decree or Libnor standard was published to enshrine specific numeric limits for genset emissions. Enforcement so far is through the existing environmental compliance system (permits and compliance certificates, which mainly target large plants) and through municipal/public safety orders. In practice, compliance has been irregular.

This problematic dynamic between economic, environmental and energy crises place the challenge of controlling diesel based emissions at the centre of academic, policy making and industrial manufacturing efforts.


Problem statement:

The application and enforcement of an environmental law to limit harmful emissions from diesel generators has several complexities. In addition to a challenging local context, electricity rationing by the local utility company reaching over 20 hours per day, and a problematic political economy (diesel generator “mafias”), the cost of energy in Lebanon is one of the highest within the region (utility tariffs reaching 0.27 USD per kWh and diesel generator tariffs starting at approximately 0.35 USD per kWh). Within a suffocating economy striving for reforms, and given the added costs associated with installing catalytic converters or filtration systems that could reach up to 50% of the cost of a diesel generator system[7], enforcing new environmental standards on diesel-based emissions might result in an uncontrolled increase in electricity tariffs that further burden the end consumer.

The challenge:

With the central aim of decreasing the costs of installing catalytic converters, is it possible under an academia-industry-sponsor collaboration to innovate, design, and manufacture catalytic converters locally in Lebanon?

A catalytic converter is an advanced emission control device installed in the exhaust system of diesel engines. It functions by facilitating chemical reactions that convert harmful pollutants—primarily carbon monoxide (CO) and unburned hydrocarbons (HC)—into less harmful compounds such as carbon dioxide (CO₂) and water vapour (H₂O), thereby significantly reducing toxic emissions and aiding compliance with environmental regulations. The core of the catalytic converter consists of a ceramic or metallic substrate, which provides a high surface area. This substrate is coated with a thin layer of precious metals—typically platinum, palladium, and rhodium—that serve as catalysts to accelerate oxidation reactions without being consumed in the process.

The challenge is multi-faceted and relates to enhanced material and chemical engineering, design innovation and increased manufacturing efficiency for various components which includes the casing, and material sourcing, reuse and alternative precious metal configurations that account for environmental concerns and available local capacities.

Workign Structure & Partners

AUB & Jubaili Bros

Hussein Magharbel 

Operations Manager - Jubaili

Mohammad Najib Ahmad

Professor of chemical engineering - AUB

Hashem Mehieddine 

Product & Solutions manager - Jubaili

Nessreen Ghaddar

Professor of mechanical engineering - AUB

Karim Jubaili

Director of operations - Jubaili

Mohamad Hamid

Project Coordinator - AUB
This initiative originated during the SERMED event of May 16, 2025, held at American University of Beirut (AUB) aimed at enhancing collaboration between academia and industry. At this event, Jubaili Bros proposed the local design and manufacturing of catalytic converters as a strategic response to the environmental and economic challenges associated with diesel generator emissions in Lebanon.
Following this initial proposal, a series of technical discussions and coordination meetings were initiated between Jubaili and AUB. These meetings will continue in a structured format, with the objective of defining a clear collaboration framework, identifying technical requirements, and assigning institutional responsibilities. The eventual partnership model—whether based on sponsored research, joint development agreements, or consultancy —will be determined based on mutual feasibility, available capacities, and alignment with strategic objectives.
AUB is expected to take the lead on the research and development component, particularly in areas such as materials science, catalytic chemistry, mechanical design, and emissions testing. The university may also serve as a platform for expanding the scope of collaboration to include external academic or industrial contributors, should additional expertise, technology, or resources be required. These external contributions may be sought internationally, particularly where there is a demonstrated benefit to the core objectives of cost reduction, design efficiency, or environmental performance.
Ultimately, the goal is to establish a locally viable, technically sound, and economically sustainable solution to address diesel generator emissions, while building local capacity in clean technology manufacturing and environmental compliance.