The thermal deactivation of Pd/CeO2–ZrO2 (Pd/CZ) three-way catalysts was studied
via nanoscale structural
characterization and catalytic kinetic analysis to obtain a fundamental
modeling concept for predicting the real catalyst lifetime. The catalysts
were engine-aged at 600–1100 °C and used for chassis dynamometer
driving test cycles. Observations using an electron microscope and
chemisorption experiments showed that the Pd particle size significantly
changed in the range of 10–550 nm as a function of aging temperatures.
The deactivated catalyst structure was modeled using different-sized
hemispherical Pd particles that were in intimate contact with the
support surface. Therefore, Pd/CZ contained two types of surface Pd
sites residing on the surface of a hemisphere (Pds) and
circular periphery of the Pd/CZ interface (Pdb), whereas
a reference catalyst, Pd/Al2O3, contained only
Pds. In all Pd particle sizes investigated herein, Pd/CZ
exhibited higher reaction rates than Pd/Al2O3, which nonlinearly increased with increasing slope as the weight-based
number of surface-exposed Pd atoms ([Pds] + [Pdb]) increased. This finding contrasted with that of Pd/Al2O3, where the reaction rate linearly increased with [Pds]. When the Pds sites in both catalysts were equivalent
in terms of their specific activities, the activity difference between
Pd/CZ and Pd/Al2O3 corresponded to the contribution
from Pdb, where oxygen storage/release to/from CZ played
a key role. This contribution linearly increased with [Pdb] and therefore decreased with Pd sintering. Although both Pds and Pdb sites showed nearly constant turnover
frequencies despite the difference in the Pd particle size, the values
for Pdb were more than 2 orders of magnitude greater than
those for Pds when assuming a single-atom width one-dimensional
Pdb row model. These results suggest that the thermal deterioration
of the three-phase boundary site, where Pd, CZ, and the gas phase
meet, determines the activity under surface-controlled conditions.