The state-of-the-art Ammonia Slip Catalyst (ASC) has a dual-layer washcoat architecture with a bottom layer of Pt/Al2O3 and a top layer of Cu/SSZ-13. A trade-off between the NH3 conversion and N2 selectivity presents a challenge in the ASC design. While a sufficiently thick and active zeolitic top layer increases the N2 selectivity, it also imposes a diffusion barrier to the reacting species in reaching the bottom Pt layer, lowering NH3 conversion. Here we describe a systematic study to identify the ASC architecture and composition that optimizes the trade-off. The in-house synthesized ASC samples span the single layer Pt/Al2O3, conventional dual-layer Pt/Al2O3 + Cu/SSZ-13, uniform single layer of mixed Pt/Al2O3 + Cu/SSZ-13, and a hybrid design comprising a bottom layer of mixed Pt/Al2O3 + Cu/SSZ-13 and a thin top layer of Cu/SSZ-13. The overall Pt and Cu loadings are fixed across the series of samples with the Cu distributed between the two layers. The best results are obtained with the combination of a base mixed layer that provides for effective coupling between Pt and Cu active sites and a top Cu/SSZ-13 layer of an intermediate thickness and nominally half of the total Cu loading. This design has sufficient oxidation activity to convert the NH3 and reduction activity to limit NOx slippage. A 1 + 1 dimensional model which follows from our recent work [3] is effective in predicting most of the data and assists in converging on the best composition and architecture. The hybrid design exhibits a linearly decreasing dependence of the NH3 conversion and logarithmically increasing dependence of the N2 selectivity on the top layer Cu loading. The intersection of the two functions is shown to provide a good balance between the two opposing performance variables. The model is used to identify the combination of Pt loading and Cu loading distribution giving the maximum N2 yield for a specified temperature and space velocity.
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