The Roles of Phosphorus and Soot on the Deactivation of Diesel Oxidation Catalysts

Abstract

The deactivation of diesel oxidation catalysts (DOCs) by soot contamination and lube-oil derived phosphorus poisoning is investigated. Pt/CeO2/-Al2O3 DOCs aged using three different protocols developed by the authors and six high mileage field-returned DOCs of similar formulation are evaluated for THC and CO oxidation performance using a bench-flow reactor. Collectively, these catalysts exhibit a variety of phosphorus and soot morphologies contributing to performance deactivation. To isolate and examine the contribution of each deactivation mechanism, performance evaluations are carried out for each DOC ''as received'' and after removal of surface carbon in a high-temperature oxidizing environment. In such a manner the deactivation contribution of soot contamination is de-convoluted from that of phosphorus poisoning. It will be shown that this is accomplished while preserving phosphorus (and to a lesser degree sulfur, calcium and zinc) chemistries and concentrations within the washcoat. Washcoat contaminant information and materials changes are characterized using electron-probe microanalysis (EPMA), X-ray diffraction (XRD), scanning electron microscopy and energy dispersive spectroscopy (SEM-EDS), BET surface area, oxygen storage capacity (OSC), X-ray fluorescence (XRF) and inductively coupled plasma (ICP) analysis, from which the relative severity of each mechanism can be quantified. Results show that soot contamination from diesel exhaust severely degrades THC andmore » CO oxidation performance by acting as a catalyst surface diffusion barrier. This results in a considerable increase of light-off temperatures. In contrast, phosphorus poisoning, which is considered a significant deactivation mechanism in three-way catalysts, is shown to have minimal effect on DOC oxidation performance for the conditions studied here. Material changes include the formation of both Ce(III-IV) and aluminum phosphates which do not significantly hinder the THC and CO oxidation in lean exhaust. In addition, thermal aging and sulfur poisoning are shown to produce minimal contributions to the overall deactivation. Consequently, performance of aged DOCs after soot removal is observed to be comparable to that of a fresh catalyst under our testing conditions.« less