Full-scale monolithic three-way catalysts (TWCs) comprising
Rh,
oxygen-scavenging ZrO2–CeO2 (ZC), and
γ-Al2O3 as a binder component were studied
after real engine aging. The fatal irreversible deactivation that
occurred under stoichiometric-lean-rich perturbation at 1000 °C
for 40 h (SLR aging) was attributed to the complete encapsulation
of Rh nanoparticles by ZC, leading to the physical blockage of gas
adsorption. Preaging the catalyst under a rich condition at 1000 °C
for 40 h (R aging) drastically mitigated this deactivation, i.e.,
the catalyst with R–SLR combined aging sustained its catalytic
performance much better than the catalyst with SLR aging at the same
temperature (1000 °C) and total time (80 h). X-ray mapping and
high-temperature environmental electron microscopic analyses suggested
that R aging promoted the migration of Rh nanoparticles across the
ZC surface toward the boundary with the Al2O3 binder. Owing to the strong bonding with the Al2O3 surface, Rh nanoparticles were trapped at or near the boundary.
Consequently, these Rh nanoparticles were unlikely to be fully covered
by ZC even under the SLR aging condition because the encapsulation
was induced through repetitive oxygen release/storage cycles at the
Rh/ZC interface. Thus, we propose that Rh nanoparticles in contact
with ZC and Al2O3 played crucial roles to hinder
the encapsulation caused by SLR aging at 1000 °C. Rh nanoparticles
supported on the dual-oxide support of ZC and Al2O3 were subjected to engine aging and chassis dynamometer tests.
The deterioration extents of the TWC and oxygen storage capacity performances
were successfully mitigated using this dual-oxide support formulation.