Characterization of the Evolution of Noble Metal Particles in a Commercial Three-Way Catalyst: Correlation between Real and Simulated Ageing

Ageing of automotive catalysts is associated to a loss of their functionality and ultimately to a waste of precious resources. For this reason, understanding catalyst ageing phenomena is necessary for the design of long lasting efficient catalysts. The present work has the purpose of studying in depth all the phenomena that occur during ageing, in terms of morphological modification and deactivation of the active materials: precious metal particles and oxidic support. The topic was deeply investigated using specific methodologies (FT-IR, CO chemisorption, FE-SEM) in order to understand the behavior of metals and support, in terms of their surface properties, morphology and dispersion in the washcoat material. A series of commercial catalysts, aged in different conditions, have been analyzed, in order to find correlations between real and simulated ageing conditions. The characterization highlights a series of phenomena linked to the deactivation of the catalysts. Pd nanoparticles undergo a rapid agglomeration, exhibiting a quick loss of dispersion and of active sites with an increase of particles size. The evolution of the support allows highlighting also the contribution of chemical ageing effects. These results were also correlated with performance tests executed on synthetic gas bench, underlining a good correspondence between vehicle and laboratory aged samples and the contribution of chemical poisoning to vehicle aged ones. The collected data are crucial for the development of accelerated laboratory ageing protocols, which are instrumental for the development and testing of long lasting abatement systems.

Automated summary

Understanding catalyst ageing phenomena is crucial for designing long lasting efficient catalysts. The study investigates morphological modification and deactivation of active materials during ageing, using specific methodologies to analyze the behavior of metals and support in washcoat material. Results show correlations between real and simulated ageing conditions, shedding light on rapid agglomeration of Pd nanoparticles and chemical ageing effects on the support. Performance tests indicate a good correspondence between vehicle and laboratory aged samples, emphasizing the importance of chemical poisoning in vehicle aged catalysts.