Synthesis of macroporous three-way catalysts via template-assisted spray process for enhancing mass transfer in gas adsorption

Abstract

Catalyst particles with macroporous structures have been attracting much attention because of their high molecular diffusions and catalytic activities. In this study, macroporous-structured three-way catalyst (TWC) particles were synthesized via a template-assisted spray process followed by an additional heating process. Several process parameters, i.e., carrier-gas type, template size, and reaction temperature, were investigated to enable preparation of macroporous particles with controllable porous structures and interconnected pore networks. The mass transfer coefficients of the obtained macroporous TWC particles were assessed using the Linear Driving Force approximation to understand the effects of the macroporous structure on the mass transfer improvement. The results showed that the introduction of macropores into TWC particles enhances the mass transfer coefficient.