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PROMETHEUS: A Copper-Based Polymetallic Catalyst for Automotive Applications. Part I: Synthesis and Characterization
1Monolithos Catalysts & Recycling Limited, 11476 Athens, Greece.
Materials (Basel, Switzerland)
|February 12, 2021
Summary
A novel copper-based catalyst, Prometheus, significantly reduces platinum group metals (PGMs) in automotive emission control. This cost-effective catalyst demonstrates comparable or superior performance to commercial options, aiding compliance with strict European emissions standards.
Area of Science:
- Materials Science and Engineering
- Environmental Chemistry
- Catalysis
Background:
- Strict European exhaust emissions standards necessitate reductions in toxic vehicle gas emissions.
- Current catalytic converters rely heavily on platinum group metals (PGMs), increasing demand and cost.
- There is a significant need for cost-effective catalytic converters with reduced PGM loading.
Purpose of the Study:
- To introduce the Prometheus catalyst, a novel polymetallic nanosized copper-based catalyst.
- To evaluate the synthesis and characterization of a large-scale, three-metal (copper, palladium, rhodium) nano-catalyst.
- To demonstrate reduced PGM loading while maintaining or improving catalytic performance for automotive emission control.
Main Methods:
- Synthesis of the Prometheus catalyst using a wet impregnation method on a cerium-zirconium oxide (CeZrO4) carrier.
- Characterization using inductively coupled plasma mass spectrometry (ICP-MS), X-ray fluorescence (XRF), energy-dispersive X-ray spectroscopy (EDS), scanning electron microscopy (SEM), X-ray diffraction (XRD), and N2 sorption.
- Testing of catalytic performance on a synthetic gas bench (SGB) for the abatement of CO, CH4, and NO.
Main Results:
- Successful large-scale synthesis of a three-metal (Cu/Pd/Rh) nano-catalyst.
- Achieved up to an 85% reduction in PGM loading by utilizing copper as an active catalytic phase.
- Demonstrated high catalytic activity for CO, CH4, and NO abatement, comparable or superior to commercial catalysts.
Conclusions:
- The Prometheus catalyst offers a cost-effective alternative for automotive emission control by significantly reducing PGM content.
- The novel copper-based catalyst maintains high catalytic performance, aiding compliance with stringent environmental regulations.
- This development represents a significant advancement in the field of PGM-reduced automotive catalysts.
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