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196 203 JMTR Jul16
196 203 JMTR Jul16
JOHNSON MATTHEY
TECHNOLOGY REVIEW www.technology.matthey.com
CeO2-ZrO2 mixed oxides have a surface area below Another strategy for improving the stability of
2 m2 g–1 and the particles undergo significant CeO2-ZrO2 materials is the use of Al2O3 particles as
coalescence and growth. One study found a crystallite diffusion barriers, introduced to form Al2O3-CeO2-ZrO2
size of 19.6 nm after thermal treatment at 1000C for hybrid oxides as shown in Figure 2. Compared to
5 hours under static air (14). Although total oxygen CeO2-ZrO2 mixed oxides, the Al2O3-CeO2-ZrO2 hybrid
storage capacity (OSC-cI) and the amount of O2 oxides still have a high surface area and OSC after
adsorption/desorption per mol of CeO2 (OSC-cII) durability ageing under the same conditions (14).
showed no obvious changes, the oxygen release rate There is however difficulty in controlling the metal-
(OSC-r) suffered a sharp decrease as shown in Table I. support interfaces which may have a negative effect on
For the further improvement of stability of the particular reactions occurring in the catalytic converter
CeO2-ZrO2 composite, ternary CeO2-based composite (17). The most negative influence for automotive
materials were introduced. As Lee’s group reported, exhaust catalysts is the formation of rhodium aluminate
La3+ and Sm3+ can effectively stabilise the cubic compounds at the Rh-Al2O3 interface (18).
Ce0.40Zr0.60O2 phase that plays a critical role in oxygen As mentioned above, strategies that simultaneously
mobility and OSC, while other rare earth elements have take into account catalyst stability and control of the
the opposite effect (15). The ternary component content metal-support interface should be developed, to
also affects the OSC stability according to Chen et al. ensure high activity and sufficient durability, which
(16): a high neodymium content will gradually convert are then able to meet upcoming emission standards.
the CeO2-ZrO2 cubic phase into a Nd0.50Zr0.50O1.75 This is a promising research field but with some great
cubic phase which leads to a decline in the OSC. technological challenges.
Diffusion barriers
High temperature
High temperature
Mechanical mixtures
Fig. 2. Schematic illustration of Al2O3 particles as diffusion barriers in CeO2-ZrO2 mixed oxides to improve washcoat
thermal stability
contrast, the OR sintering mechanism occurs when PtO2 723 362 217
material evaporates from the surface of a smaller
PtCl2 854 427 256
particle with higher surface energy, and transfers onto
the surface of a larger particle. PtCl4 643 322 193
Sintering of active precious metal nanoparticles is
Pd 1828 914 548
closely related to reaction temperature and the size
and composition of the nanoparticles (17). When PdO 1023 512 307
quasi-liquid layers form on the crystal surface, migration Rh 2258 1129 677
of surface atoms and crystallites will occur at the Hüttig
Rh2O3 1373 687 412
or Tamman temperatures of the bulk phase that are often
used to semi-empirically describe the temperatures at
which atomic migration and crystallite migration can atmosphere (23), shape and composition of metal
occur. The ratio of the melting point (Tmelting) of unique nanoparticles (24), metal dispersion (25), the loading
particles with radius, r, and heat of fusion, L, to that of of the metal on supports (26) and the interactions
the bulk phase (T0) can be given by Equation (ii) (21): between the supports and metals (27).
Higher durability requires a lower sintering rate to
2/3
Tmelting 2 s maintain enough metal surface for long-term use and
=1– s – l (ii)
T0 sLr l this is often accomplished through stabilising the active
metal nanoparticles. Figure 4 shows the three typical
where and represent the surface free energy and strategies for precious metal sintering suppression
density of the solid and liquid, respectively. Table II (28–30): (a) support anchoring for metal nanoparticles,
exhibits T0, TTamman and THüttig of platinum, palladium, (b) alloying of active metals and (c) inhibition of atomic
Rh and their compounds. Metallic Pt, Pd and Rh have and crystallite migration via support encapsulation
higher Hüttig and Tamman temperatures than the technology, for instance the construction of core-shell
corresponding compounds, demonstrating that higher nanostructures and atomic layer deposition. In TWC,
valency metals may have poorer thermal stability.
Equation (ii) highlights that the melting point of unique Strategy 1: Anchoring effect
particles depends on their composition, size and also
surface free energy.
Oxidising
The experimental observations show that temperature
Supports Supports
is a dominant factor for sintering (22). The sintering
behaviours of active precious metals can also be Strategy 2: Alloying effect
affected by any other conditions that lead to changes
in the surface energy of the particles, such as reaction Alloying
PM1 PM2
Fig. 3. Two conceptual models for sintering of active Fig. 4. Three typical strategies for precious metal sintering
precious metal particles suppression in TWC
Oxidation
Supports Supports
Reduced precious metal Oxidised precious metal
supported catalyst supported catalyst
O
O
1/2N2 + CO2
NC
O
C
NCO
N Disintegration
Supports Supports
Formation of adatom Non-oxidative redispersion
complexes
Fig. 5. A schematic representation of redispersion for active precious metals
(40). However, it should be noted that oxy-chlorination ions into the skeleton of Al2O3 and CeO2-ZrO2 mixed
may cause a narrow temperature window for oxidation oxides is an effective method for improving structure
of metallic species and the loss of precious metals due stability, but atomic scale insertion still presents a
to the formation of volatile MOxCly compounds. In the challenge in manufacture. In our opinion, the use of
case of Pt, Pt(OH)xCly and α-PtO2 will transform into alloying effects to stabilise precious metal nanoparticles
PtOxCly above 500C, resulting in Pt loss, as reported is very helpful for the improvement of thermal durability.
by Lieske et al. (41). Christou and coworkers reported Nevertheless, further optimising the composition and
a new ‘oxalic acid’ regeneration methodology for aged content of the alloys and reducing undesirable metal-
commercial TWC without any negative effects, which support interactions still pose great challenges in TWC
may be a promising method for further investigation application and manufacture.
to improve durability (42). In our experience, however,
artificial regeneration of TWC is difficult to achieve Acknowledgements
for industrial applications. Thus, these regeneration
methods are considered undesirable for improvement The authors are grateful for support by the National
of durability of TWC and more attention should be given Natural Science Foundation of China (21463015) and
to other strategies. the Provincial Natural Science Foundation of Yunnan,
The composition of gasoline engine tail-pipe China (2014FA045).
emissions fluctuates quickly and dramatically between
oxidation and reduction environments during operation. References
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The Authors
Jun-Jun He graduated from Tianjin University, China, in 2011, with a PhD in Chemical Engineering
and Technology and subsequently worked as a Research and Design Engineer at Kunming
Institute of Precious Metals (IPM), China. His main research field is new washcoat recipe design
and applications. He is also Head of the gasoline aftertreatment team at IPM.
Ting-Ting Zheng has a Bachelor’s degree in Chemical Engineering from Northwestern University,
China, and a Master’s degree in Catalysis Science from IPM. She works at State-Local Joint
Engineering Laboratory of Precious Metal Catalytic Technology and Application and is devoted to
the research and development of TWC in emissions control.
Dr Yun-Kun Zhao received his PhD from Lanzhou University, China, and had a postdoctoral
career at Peking University, China. As a Senior Professor at IPM, he has specialised in platinum
group metals assaying methods and catalytic materials development. Since 2002, he is Technical
Director at Kunming Sino-Platinum Metals Catalysts Co Ltd. His main responsibility is to develop
catalysts for exhaust emissions control.