Active and stable PtPd diesel oxidation catalysts under industry‐defined test protocols

Nanoparticle‐supported Pt and Pd catalysts are employed industrially to convert CO and hydrocarbon residue from incomplete diesel fuel combustion. However, these catalysts deactivate over time due to sintering, especially for Pt nanoparticles which readily generate volatile species under high operating temperatures. Here, we turned the detrimental vapor‐mediated sintering of Pt into an advantage by using a physical mixture of Pt and Pd catalysts prepared using a raspberry‐colloid‐templating (RCT) method. The RCT method produced Pt/Al2O3 and Pd/Al2O3 catalysts with partially embedded NPs to inhibit surface‐mediated sintering pathways. As validated using an industry‐defined emission control test protocol, aging a physical mixture of Pt/Al2O3 and Pd/Al2O3 at high temperature produced an alloyed PtPd/Al2O3 catalyst that outperformed the fresh catalyst mixture and both individual catalysts for hydrocarbon conversion, while exhibiting high catalytic stability and resistance to sintering and to SO2 poisoning. X‐ray photoelectron spectroscopy revealed that in the aged catalyst mixture, half of the Pd content existed in their more active metallic state, compared to the less active oxide forms in the fresh mixture and both individual catalysts, explaining the unusual activity enhancement. Our results represent a practical approach to producing active and stable PtPd/Al2O3 diesel oxidation catalysts for emission control applications.