Ceria-based nanoflake arrays integrated on 3D cordierite honeycombs for efficient low-temperature diesel oxidation catalyst

Abstract A new, surfactant-free hydrothermal method has been developed for the growth of CeO 2 -based nanoflake arrays onto three-dimensional-channeled cordierite honeycomb substrates. Herein, a leaching-crystallization mechanism was proposed where the hydrothermal reaction, only involving cerium nitrate and water, leached the cordierite surface slightly and induced the formation of CeO 2 nanoparticles subsequently. Further continued reaction reincorporated Al and Si atoms leached from cordierite into CeO 2 , finally recrystallizing Ce-Al-Si composite nanoflake structures. By using atomic layer deposition process, well-dispersed, size-controlled Pt nanoparticles were uniformly decorated on the CeO 2 -based nanoflakes to form the Pt/ CeO 2 nano-array-based monolithic catalyst. Despite 5-50 times reduction in the active material usage compared with the traditional wash-coated catalyst, the Pt/CeO 2 nano-array monolithic catalyst exhibited good catalytic oxidation activities over various individual gases, such as propylene, propane, CO, and NO oxidation, with 90% conversion efficiencies at temperatures below 200 °C. Under the simulated exhaust condition of low-temperature diesel combustion (LTC-D) developed by US DRIVE, the monolithic catalyst with low Pt loading (˜1 g/l) exhibits 90% conversion of catalytic oxidation over CO and hydrocarbonsat temperatures as low as ˜180 °C, much superior to the performance of traditional washcoated catalysts.