575j Catalytic NOx Reduction Using Paper-Structured Catalyst for the Purification of Automobile Exhaust Gas

Hirotake Ishihara1, Hirotaka Koga1, Takuya Kitaoka1, Hiroyuki Wariishi1, Akihiko Tomoda2, and Ryo Suzuki2. (1) Department of Forest and Forest Products Sciences, Graduate School of Bioresource and Bioenvironmental Sciences, Kyushu University, 6-10-1 Hakozaki, Higashi-ku, Fukuoka, 812-8581, Japan, (2) F.C.C. Co. Ltd., 7000-46 Nakagawa, Hosoe-cho, Kita-ku, Hamamatsu, 431-1304, Japan

Air pollution caused by exhaust gases from combustion engines and systems has recently become one of the serious environmental issues on a global scale. To purify exhaust gas, monolithic ceramic honeycombs are widely used as a support of catalyst components in practical applications; however it has several disadvantages, e.g. small sideways gas diffusion and low thermal conductivity. Thus, there has been increasing interest in the new catalytic materials with micro-meter scale porous structures, which enable the effective gas diffusion during the catalytic reaction. In our previous works, we have successfully prepared the Cu/ZnO catalyst powder/inorganic fiber composites, called paper-structured catalyst, by a papermaking technique. The paper-structured catalyst possessed a unique fiber-network microstructure and demonstrated a high catalytic efficiency and durability as compared with the original catalyst powder in the methanol reforming process for hydrogen production. In this study, a novel paper-structured catalyst containing Pt/Al2O3 powders was prepared aiming at the effective catalytic reduction of nitrogen oxides (NOX) in the automobile exhaust gas. Fine powders of Pt/Al2O3 catalyst were successfully supported on the ceramic fiber network by a papermaking technique with a dual polyelectrolyte system; the total retention of inorganic components reached up to ca. 95%. The paper composite was flexible, lightweight and easy-to-handle. The ceramic fiber network tailored in the paper-structured catalyst formed a characteristic porous microstructure (average pore size: ca. 20 µm, porosity: ca. 70%). Conversion efficiency from NOX to N2 by using paper-structured catalyst was superior to those by original catalyst powders, commercial honeycomb catalyst or pellet-shaped catalyst. Besides, the paper-structured catalyst demonstrated a quick response in the catalytic NOX reduction at a rapid increasing reaction temperature. Loading of catalyst powders or pellets brought about both poor heat transfer and heterogeneous gas flow. On the other hand, paper-structured catalyst possessed a unique micro-porous structure that can promote the effective heat and gas transfer to the active surfaces, surpassing that of a commercial honeycomb catalyst. Therefore, the paper-structured Pt/Al2O3 catalyst is expected to be a promising catalytic material in the practical applications for the purification of automobile exhaust gas.