Metal Oxide Nano-Array Catalysts for Low Temperature Diesel Oxidation. Final Report

In this project, a series of metal oxide nanostructure arrays (nano-arrays) with or without metal decoration, have been successful integrated onto monolithic honeycombs with well-defined size, shape, and chemical compositions, forming a new type of monolithic catalysts. These catalysts have displayed good durability and catalytic performance toward various gas phase catalytic reactions, while showing good potential of reducing the material usage. Specifically in situ grown onto monolithic honeycomb substrates, the metal oxide nanostructure arrays (nano-arrays) (e.g., CeO2, Co3O4, (Cu, Mn)O2, (La, Sr)MnO3, TiO2, etc.), with or without Pt-group metal (PGM) decoration, have displayed good durability and catalytic performance toward catalytic oxidation of hydrocarbons and CO, while showing good potential of reducing the material (noble metal and metal oxides) usage. As unique supports, the nano-array ‘forest-like’ structure configuration proves to improve the dispersion and immobilization of metal nanocatalysts under various aging and reactive conditions, besides the lower pressure drop and improved adherence to the monolith substrates over wash-coated catalysts. On the other hand, electronic interactions between metals and nano-array support are found to be adjustable toward favoring catalytic oxidation while improving the catalyst robustness. Furthermore, chemical leaching treatment in these metal oxide based catalysts could help tune their chemical and structural characteristics, boosting low temperature oxidation reactivity while maintaining robustness. Both CeO2 and TiO2 nano-array supported PGM catalysts have shown promising low temperature reactivity with 90% conversion at temperatures approaching 150oC toward CO, HC, and NOx oxidation under both probe and simulated exhaust conditions.