Characterization of secondary pores in washcoat layers and their effect on effective gas transport properties

Abstract

It is well known that the performance of monolithic catalysts is limited by gas transport resistance in the washcoat layer. Gases are transported via two types of pores within the washcoat layer: primary pores, which exist inside the particle of catalyst support material (e.g., Al2O3), and secondary pores, which are voids among particles of the catalyst support material. Primary pores play an important role in the effectiveness of catalytically active components such as Pt, Rh, and Pd, while secondary pores facilitate gas transport in the washcoat layer. This paper reports the characterization of secondary pores and their effect on gas transport. In order to evaluate the gas transport properties of a washcoat layer, effective gas permeability was measured. Four samples with different pore morphologies were prepared, and their secondary pore properties were characterized with scanning electron microscopy, mercury porosimetry and synchrotron X-ray computed tomography. The obtained pore properties were correlated with the effective gas permeability, and based on the obtained correlation, we formulated a model for the gas permeability of the pores. This new model was compared to the conventional Kozeny-Carman equation.