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Fabrication of a Novel Catalyst Reactor with Improved Strength and Catalytic Performance Used for Automotive Exhaust Treatment

Cai, Huangyue, Guo, Fangwei, Zhang, Xing, Wang, Xin, Hu, Li, Zhao, Xiaofeng, Xiao, Ping
Industrial & engineering chemistry process design and development 2019 v.58 no.10 pp. 4024-4031
carbon monoxide, catalysts, catalytic activity, cement, cordierite, microstructure, modulus of rupture, nitric oxide, process design, zirconium oxide
Yttria-stabilized zirconia hollow fibers (YSZ-HFs) containing radial wall microchannels with one end opening on the inner surface were prepared, and robust reactor modules of YSZ-HFs for automotive emission were prepared by bundling fibers with cement glue. 100% open-cell ratio and the unique microstructure of the YSZ-HFs catalytic reactor facilitated deposition of LaMnO₃ three-way catalysts. Compared with the commonly used cordierite (2MgO-2Al₂O₃-5SiO₂) honeycombs (CHs), the YSZ-HFs improved the reducibility and sintering resistance of the attached catalyst film. Higher effective conversion of CO and NO was found in the YSZ-HFs samples in comparison to the CHs samples. Moreover, the YSZ-HFs samples achieving higher flexural strength (∼135 MPa) can better preserve the mechanical properties and the integrity of the catalyst film after 200 thermal shock cycles at 900 °C, due to the small thermal mismatch between the YSZ-HFs and the catalysts, as well as the intrinsic merit of zirconia.