Activity of Catalytic Ceramic Papers to Remove Soot Particles—A Study of Different Types of Soot

Co,Ce nanoparticles supported on stacked wire mesh cartridges. Activity and stability in diesel soot combustion

In this work, Co3O4 nanoparticles were successfully synthesized by precipitating a precursor salt solution in the form of microdroplets generated by a nebulizer, as an efficient, fast and low-cost approach. After drying and calcination, synthesized particles were deposited on stacked wire mesh monoliths by immersing the structures in a suspension containing synthesized Co3O4 particles and commercial ceria nanoparticles as a binder. These structured catalysts were evaluated for the combustion of diesel soot which constitutes a crucial step in the regeneration of catalytic particulate filters (CDPFs). Thermal and mechanical stability of Co,Ce washcoated monoliths were investigated. For this, successive catalytic evaluations of the structured system, with intermediate treatments at 900 °C (accelerated aging), were carried out indicating a very good activity and stability of the catalysts developed. Adherence tests showed good adhesion of the catalytic layer to the metallic substrate. Fresh and aged catalysts were fully characterized by Scanning Electron Microscopy (SEM), Transmission Electron Microscopy (TEM), X-ray Diffraction (XRD), Laser Raman Spectroscopy (LRS) and Temperature-Programmed Reduction (TPR). It was found that the catalytic coating resulted composed of nanometric CeO2 and Co3O4 along with chromium, iron and manganese oxides coming from the migration of the metallic substrate, in the catalytic cartridge calcined at 600 °C. Despite after calcination at 900 °C spinels of Co, Fe, Cr and Mn were observed, these oxides did not significantly affected the catalytic activity. Although this aging treatment at 900 °C was severe and is not expected under real conditions, it highlights the potential application of the catalytic metallic cartridges here developed.

Mn and Co decorated biomorphic ceria fiber catalysts for soot and benzene total oxidation

Mn or Co supported CeO2 fiber catalysts were synthesized following a biotemplating route and evaluated in soot combustion and benzene total oxidation. The catalysts were characterized by SEM, EDX, N2 physisorption, FTIR-ATR, XRD, RAMAN and XPS. SEM results confirmed that the "twisted ribbon" morphology of the biotemplate was mostly maintained. XRD and Raman showed that Mn and Co cations partially insert into ceria lattice and also segregate at the surface of the fibers. XPS allowed to determine that both set of catalysts exhibit Ce3+ and Ce4+ species, in addition to adsorbed and lattice oxygen. Also, the average oxidation state (AOS) of surface Mn could be calculated. Compared to bare Fib Ce, the performances for both reactions were improved for the supported catalysts, except from the catalyst with lowest Mn content for soot combustion. The catalytic activity was discussed in terms of the physicochemical features of the supported catalysts.

Synthesis of Co,Ce Oxide Nanoparticles Using an Aerosol Method and Their Deposition on Different Structured Substrates for Catalytic Removal of Diesel Particulate Matter

The synthesis of Co and Ce oxide nanoparticles using precipitation of precursor salt solutions in the form of microdroplets generated with a nebulizer proved to be an efficient, fast and inexpensive method. Different morphologies of single oxides particles were obtained. Ceria nanoparticles were almost cube-shaped of 8 nm average size, forming 1.3–1.5 μm aggregates, whereas cobalt oxide appeared as rounded-edged particles of 37 nm average size, mainly forming nanorods 50–500 nm. Co3O4 and CeO2 nanoparticles were used to generate structured catalysts from both metallic (stainless steel wire mesh monoliths) and ceramic (cordierite honeycombs) substrates. Ceria Nyacol was used as a binder to favor the anchoring of catalytic particles thus enhancing the adhesion of the coating. The resulting structured catalysts were tested for the combustion of diesel soot with the aim of being used in the regeneration of particulate filters (DPFs). The performance of these structured catalysts was similar to or even better than that exhibited by the catalysts prepared using commercial nanoparticles. Among the catalysts tested, the structured systems using ceramic substrates were more efficient, showing lower values of the maximum combustion rate temperatures (TM = 410 °C).

Ceramic Papers as Structured Catalysts: Preparation and Application for Particulate Removal

Fibers represent a type of structure of great interest in catalysis since they combine high area to volume ratio and can be fabricated from many types of materials, such as ceramic oxides, polymers, and alloys. They can be used in isolated form or structured, as in the case of the ceramic papers synthesized in this work, following a modified papermaking technique. The addition of cationic and anionic polyelectrolytes improved the retention of ceramic fibers during the ceramic paper formation stage by adsorption processes, through the formation of floccules. In the complex aqueous system containing charged macromolecules, the amounts of polyelectrolytes to be added were determined by titrations. To enhance mechanical properties of ceramic papers, different classes of nanoparticle suspensions can be used as binders. As a novel alternative, we have used different borate-type compounds. Among them, we selected natural ulexite, which was purified and used as a binder of ceramic fibers. In order to improve mechanical resistance and flexibility, measured from tensile indexes and elastic module, the amounts of NaCaB5O6(OH)6.5H2O and the calcination temperature were varied. In this contribution, to take advantage of the unique characteristics of the ulexite-containing ceramic papers, they were impregnated with Co,Ce and Co,Ba,K and tested for diesel soot combustion.