Cordierite, catalytic converter

Recently, it is reported that Xi02 particles with metal deposition on the surface is more active than pure Ti02 for photocatalytic reactions in aqueous solution because the deposited metal provides reduction sites which in turn increase the efficiency of the transport of photogenerated electrons (e ) in the conduction band to the external sjistem, and decrease the recombination with positive hole (h ) in the balance band of Xi02, i.e., less defects acting as the recombination center[l,2,3]. Xhe catalytic converter contains precious metals, mainly platinum less than 1 wt%, partially, Pd, Re, Rh, etc. on cordierite supporter. Xhus, in this study, solutions leached out from wasted catalytic converter of automobile were used for precious metallization source of the catalyst. Xhe XiOa were prepared with two different methods i.e., hydrothermal method and a sol-gel method. Xhe prepared titanium oxide and commercial P-25 catalyst (Deagussa) were metallized with leached solution from wasted catalytic converter or pure H2PtCl6 solution for modification of photocatalysts. Xhey were characterized by UV-DRS, BEX surface area analyzer, and XRD[4]. 

The cordierite extruded monoliths, having 400 square cellsAn, were similar to those used in automobile catalytic converters. However, instead of using an alumina washcoat as in the catalytic converter, these catalyst supports were loaded directly with 12 to 14 wt.% Pt in the same manner as the foam monoliths. Because these extruded monoliths consist of several straight, parallel channels, the flow in these monoliths is laminar (with entrance effects) at the flow rates studied. 

The use of catalytic converters to reduce the amount of unbumed hydrocarbons in exhaust gases is an additional example of the use of metals. Reactions of these unbumed hydrocarbons in the atmosphere are described later, in the section on photochemical smog. The catalyst currently used is a cordierite or alumina support treated with an AI2O3 wash coat containing rare earth oxides and 0.10% to 0.15% Pt, Pd, and/or Rh, which catalyzes the combustion of hydrocarbons in the exhaust gases to carbon dioxide and water. Platinum,... 

Two types of catalytic converters are currently being used for meeting the passenger car emission standards in the U.S. three-way converters and dualbed converters. Both converters contain three-way catalysts, but with the dual-bed converter the three-way catalyst is followed by an air injection/ oxidation catalyst system. As for the earlier oxidation catalysts two forms of catalyst support are used pellets (thermally stable transitional alumina) and monoliths (cordierite honeycombs coated with a thin alumina washcoat). Figure 7 shows four catalytic converters currently being used by General Motors. 

The new mesoporous materials have extremely high surface-to-volume ratios. An example of these materials is MCM41, which was invented by DuPont. A simple structure that can be manufactured in the laboratory is illustrated in Eigure 15.14. The structure initially contained a periodic array of polymer spheres. When close packed, these spheres leave 26% of the volume empty. We can then infiltrate a liquid into these pores, burn out the spheres, and convert the liquid to a polycrystalline ceramic. Another synthesized porous ceramic is the cordierite honeycomb structure used to support the Pt catalyst in automobile catalytic converters. In this case the cylindrical pores are introduced mechanically in the extrusion process. 

FIGURE 37.10 Looking through two ceramic extruded cordierite honeycomb substrates for catalytic converters. 

Washcoat technology was initially developed for the automobile catalytic converter, consisting of a ceramic monolith of many small parallel channels, in the mid-1970s. Monoliths have since then developed into a variety of different materials and configurations, essentially cordierite based [3]. 

Catalytic Converter. A device to remove noxious components from the hot exhaust gases of diesel and petrol engines, by passing them over a suitable catalyst to promote their breakdown. Cordierite ceramic honeycombs are the usual catalyst carriers. 

Pellets and ceramic monolithic substrate structures were initially involved in three-way catalytic converters for washcoat deposition, while metal foil monolithic substrates were also introduced since the late 1970s. TWCs manufactures were soon concentrated on cordierite (2Mg0-2Al203-5Si02) ceramic monoliths or on Fe-based alloys foil monoliths (iron-chromiimi—alimiimmi ferritic steels). Both options are used nowadays, although ceramic monoliths are preferably used, despite the several advantages of the latter [2]. 

Fig. 1.3 Catalytic converter made of cordierite (a) and a diagram of its operating principle (b)...

Parent, M.,Vanhoe, H., Moens, L., and Dams, R. (1997). Investigation of HfO+ interference in the determination of platinum in a catalytic converter (cordierite) by inductively coupled plasma mass spectrometry. Talanta 44(2), 221. 

In general, both cordierite and metallic monoliths are unsuitable as catalytic supports. To process a monolith into an active monolithic catalyst, a layer of porous catalytic support must be deposited on the walls between channels. y-Alumina appeared to be the most effective support for automotive catalysts. The alumina layer is deposited by sol-gel technique (so called washcoating). Adherence of 7-alumina to cordierite is relatively strong. However, to form the stable 7-alumina layer on a metallic surface, we need to use an appropriate alloy that is appropriately processed before the layer is deposited. Stainless steel containing chromium, aluminum, and yttrium subjected to thermal treatment under oxidizing conditions meets requirements of automotive converters. Aluminum in the steel is oxidized to form 7-alumina needles (whiskers) protruding above the metal... 

Samples under study are commercial cordierite honeycomb catalysts. The catalytic washcoat is conventionally composed of ceria-promoted transition alumina-supported 5Pt/lRli (weight %). Samples are cut from original converters in the form of cylinders of 1 inch (diameter) X 3 inches (length) to meet the geometrical requirements of the experimental set-up (see below). 

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