In the present study,
we prepared a 12 nm thick Ir overlayer via
pulsed cathodic arc plasma deposition on a 50 μm thick Fe–Cr–Al
metal (SUS) foil. Using this thin-film catalyst made NH
3
–O
2
reactions more environmentally benign due to
a much lower selectivity for undesirable N
2
O (<5%) than
that of a Pt overlayer (∼70%) at 225 °C. Despite its small
surface area, Ir/SUS exhibited promising activity as an ammonia slip
catalyst according to a turnover frequency (TOF) >70-fold greater
than that observed with conventional Ir nanoparticle catalysts supported
on γ-Al
2
O
3
. We found that the high-TOF
NH
3
oxidation was associated with the stability of the
metallic Ir surface against oxidation by excess O
2
present
in simulated diesel exhaust. Additionally, we found that the Ir overlayer
structure was thermally unstable at reaction temperatures ≥400
°C and at which point the Ir surface coverage dropped significantly;
however, thermal deterioration was substantially mitigated by inserting
a 250 nm thick Zr buffer layer between the Ir overlayer and the SUS
foil substrate (Ir/Zr/SUS). Although N
2
O formation was
suppressed by NH
3
oxidation over Ir/Zr/SUS, other undesired
byproducts (i.e., NO and NO
2
) were readily converted to
N
2
by coupling with a V
2
O
5
–WO
3
/TiO
2
catalyst in a second reactor for selective
catalytic reduction by NH
3
. These results demonstrated
that this tandem reactor configuration converted NH
3
to
N
2
with nearly complete selectivity at a range of 200–600
°C in the presence of excess O
2
(8%) and H
2
O (10%).