Yuxi Gaoa,
Xiaodong Wu*a,
Shuang Liub,
Duan Weng*a and
Rui rana
aKey Laboratory of Advanced Materials of Ministry of Education, School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China. E-mail: wuxiaodong@tsinghua.edu.cn; duanweng@tsinghua.edu.cn
bInstitute of Materials Science and Engineering, Ocean University of China, Qingdao 266100, China
First published on 7th June 2016
MnOx–CeO2 mixed oxide supported on γ-Al2O3 was sulfated in dry and wet atmospheres to explore the effect of water during sulfur poisoning. The fresh and poisoned catalysts were characterized by Brunauer–Emmett–Teller (BET), thermo-gravimetric analysis (TGA), NH3 temperature-programmed desorption (NH3-TPD), infrared spectroscopy (IR), H2 temperature-programmed reduction (H2-TPR), NO temperature-programmed oxidation (NO-TPO) and soot temperature-programmed oxidation (soot-TPO). The results show that water hinders sulfate deposition on the catalyst. The wet sulfated catalyst with abundant surface hydroxyl groups has higher surface acidity than the dry sulfated one. Although the presence of water does not prevent the deprivation of redox properties, the generated surface acid sites may promote the NO2 utilization efficiency and deep oxidation of soot by O2, resulting in less deactivation of the wet sulfated catalyst.
As water vapor is one of the major components of exhaust gas (≈10%) from diesel engines,13 the catalyst tolerance to sulfur poisoning under wet atmosphere have been widely evaluated. A few of studies has focused on SO2 and H2O in reactant gas. Oi-Uchisawa et al. studied the effect of NO, H2O and SO2 during the soot oxidation catalyzed by Pt/SiO2 and draw the conclusion that SO3 (or H2SO4) produced from SO2 has a role as a catalyst that accelerates the carbon oxidation by NO2 in the presence of H2O, and H2O is indispensable for this promoted oxidation process, possibly as a reactant for the hydrolysis of partially oxidized species.14 Hernández-Giménez et al. provided a descriptive discussion of CO2, H2O and SO2 effect on CeZr and CeZrNd catalysts during reaction and paid special attention to the soot combustion mechanism. They concluded that the inhibiting effect follows the order of SO2 > H2O > CO2.15 However, the corresponding structural variations of the catalysts were not taken into account. On the other hand, some literatures studied the effects of water and sulfur dioxide treatment on catalyst separately but the synergistic effect was not considered. For example, Peralta et al. studied water and sulfur dioxide on Ba,K/CeO2 respectively, but did not involve the effect of water vapor and SO2 pumped in together.16 Tikhomirov et al. studied wet sulfated MnOx–CeO2 mixed oxides but the water effect on sulfur poisoning was not analyzed.17
In our previous studies, severe sulfur poisoning under dry condition was observed for MnOx–CeO2/Al2O3 catalyst, although the activity could be partially recovered after regeneration in oxidative or reducing atmosphere.18–20 In this study, the mixed oxides catalyst was sulfated in dry and wet atmospheres, respectively. The amounts and types of the deposited sulfates were analyzed and the soot oxidation activities of the catalysts were measured. Water effect on sulfur poisoning were explored based on the catalyst redox property and surface acidity.
:
Ce molar ratio of 15
:
85 and a mass ratio of (Mn3O4 + CeO2)
:
Al2O3 = 1
:
2. As proved in our previous work,10 the manganese species existed mainly in the form of Mn3O4 in the mixed oxides. The as-received powders were grinded for 10 min and were labeled as MCA-F.
Sulfur poisoning processes were treated with SO2 as sulfur species in automobile exhaust gas is almost exclusively SO2.21 Dry sulfated catalyst (MCA-DS) was obtained by flushing 100 ppm SO2/10% O2/N2 through 1 g MCA-F catalyst (50–100 mesh) at 350 °C. The sulfation poisoning lasted for 3.5 h until a significant deactivation was observed. During the process, the SO2 concentration was monitored by an emission analyzer (ecom EN-2F, RBR, Germany). Wet sulfated catalyst (MCA-WS) was obtained by a similar process except 10% H2O was added in the inlet gas. For reference, a sulfate-impregnated sample (MCA-IS) was prepared by impregnating H2SO4 solution on MCA-F with a theoretical content of SO3 at 6 wt%, followed by drying at 110 °C overnight and calcination at 500 °C for 2 h.
Specific surface areas (SBET) of the samples were measured by means of the N2 adsorption at −196 °C (F-Sorb 3400, Gold APP Instrument). The samples were degassed at 220 °C for 2 h before the measurements to remove adsorbed water and other atmospheric contaminants.
Infrared spectra (IR) on the samples were recorded on a FTIR spectrometer (Thermo Nicolet iS50) equipped with a MCT detector. The spectra was taken under RT. Diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) with ammonia desorption were also taken in the same apparatus from 50 to 350 °C.
NH3 temperature-programmed desorption (NH3-TPD) tests were performed. The sample powders were firstly treated in N2 at 500 °C for 30 min. Then the samples were exposed in 1000 ppm of NH3/N2 at RT. After N2 flushing for 30 min, the reactor were ramped from RT to 600 °C at a heating rate of 10 °C min−1 under N2 stream and the outlet NH3 concentration was analyzed by an infrared spectrometer (MKS 2030).
H2 temperature-programmed reduction (TPR) was carried out in a fixed bed reactor. 50 mg sample was pretreated under He flow at 400 °C for 30 min. The reduction test was performed in 10% H2/Ar (50 mL min−1) from room temperature (RT) to 900 °C at a heating rate of 10 °C min−1 and H2 consumption was recorded using a thermal conductivity detector (TCD).
NO temperature-programmed oxidation (NO-TPO) tests were carried out in the same apparatus in soot-TPO tests. 100 mg catalyst powders were mixed with 300 mg silica and the inlet gas mixture was 1000 ppm NO/10% O2/N2.
The mass loss of the catalysts within the temperature range from 500 to 1000 °C was calculated, and the results are listed in Table 1. The sulfation degree was defined as molar ratio of (cerium which formed sulfate)/(total cerium), in which cerium in sulfates was estimated by the mass loss (SO3) based on the assumption of the conversion from Ce(SO4)2 to Ce2O3. The sulfation degree of MCA-DS and MCA-WS was calculated as 24% and 18%, respectively. It suggests that the presence of water vapor in the sulfation atmosphere prevents the catalyst absorbing SO3 and sulfates deposition. The deposition of sulfates blocks the pore structure and reduces the BET surface area of the catalyst. As listed in the Table 1, MCA-DS with more deposited sulfates has a smaller specific surface area than MCA-WS. The outlet SO2 concentration was recorded during the sulfation process, and the SO2 conversion curves as a function of time are shown in Fig. 2. It is seen that the SO2 oxidation is always close to 100% within the first 100 min. After then, the SO2 conversion decreases more rapidly under the dry condition, which may be due to the severe loss in redox property of the catalyst with the formation of more sulfates. It is noted, nevertheless, that the gap between the SO2 conversions under different conditions is not so large to induce the different amounts of sulfates deposited on the catalysts. Thus, the less sulfates on MCA-WS may be more probably caused by the hindering effect of the water adsorbed on the Ce and Mn sites on the SO3 adsorption and sulfate deposition.
Ammonia was employed as probe molecule to determine the type of acid sites in catalysts and the results are shown in Fig. 4. Bands coordinated to adsorbed species are listed in Table 2. As the temperature went up, the peaks attributed to Brønsted and Lewis acid sites in MCA-F decrease in intensity gradually and almost disappear at 250 °C. The peaks attributed to Brønsted acid sites on the two sulfated catalysts disappear at 300 °C and Lewis acid sites even remain a certain intensity at 350 °C. These results indicate that stronger acid sites are formed on the sulfated catalysts compared with the fresh one. It has been reported that Lewis acid sites on sulfate may transfer to Brønsted acid sites in the presence of water.38,39 However, no obvious differences can be found on the spectra of the two poisoned catalysts in this case.
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| Fig. 4 DRIFT spectra of the adsorbed NH3 species on (a) MCA-F, (b) MCA-DS and (c) MCA-WS catalysts from 50 to 350 °C. | ||
| Wavenumbera (cm−1) | Species | Reference |
|---|---|---|
| a The data inside and outside the bracket are for MCA-DS/MCA-WS and MCA-F, respectively. | ||
| 1590 (1620) | N–H bond in the NH3 linked to Lewis acid sites | 29 |
| 1417 (1447), 1683 (1690) | NH4+ chemisorbed onto Brønsted acid sites | 30 |
| 3402 (3275), 3362 (3182) | νs(NH3) coordinated to Lewis acid sites | 31 |
| 3464 (3378) | νas(NH3) coordinated to Lewis acid sites | 31 |
| 1533 | Coordinated to amide species (–NH2) | 25 |
| 1247 | NH3 adsorbed on Lewis acid | 32 |
The sulfated catalysts exhibit similar DRIFT spectra of the adsorbed NH3 species, implying the same origin of surface acid sites, probably arising from the formation of sulfates. Nevertheless, ammonia is not a reliable probe for the quantitative evaluation of acid solids via FTIR spectroscopy. In order to estimate the surface acidity more quantitatively, NH3-TPD was performed and the obtained profiles are shown in Fig. 5. The profiles can be deconvoluted into three Gaussian functions associated with weak acidity attributed to acid sites of ceria40,41 characterized by the peak at around 100 °C, weak acidity attributed to aluminum-bonded hydroxyl42 characterized by the peak at around 165 °C, and medium acidity mainly attributed to surface sulfate28,43,44 characterized by the peak at around 250 °C. With the assumption of one NH3 molecule absorbing on one acid site,45 the amounts of acid sites on the catalysts were calculated. The results in Table 3 reveals that the surface acidity of the catalysts is in the order of MCA-WS > MCA-F > MCA-DS. The formation of cerium sulfates and dehydration of alumina reduce the surface acidity of MCA-DS severely. It is suggested that the formation of sulfates compensates the losses in both Brønsted and Lewis acid sites to some extent. During wet sulfation, the water promotes the hydrolysis of sulfates and the synergistic effect between sulfates and water enhances the surface acidity of MCA-WS greatly. It contributes not only to the medium acidity but also weak acidity.
| Catalyst | NH3 desorption (mmol g−1) | |||
|---|---|---|---|---|
| Total | 90–105 °C | 160–170 °C | 245–255 °C | |
| MCA-F | 0.35 | 0.09 | 0.19 | 0.06 |
| MCA-DS | 0.27 | 0.05 | 0.12 | 0.10 |
| MCA-WS | 0.52 | 0.15 | 0.16 | 0.22 |
H2-TPR profiles of the catalysts are shown in Fig. 6 to characterize the redox property of the catalysts. MCA-F exhibits three overlapped peaks at 155, 285 and 385 °C which may be ascribed to the reduction of highly dispersed MnOx clusters, larger MnO2/Mn2O3 crystallites and CeO2 promoted by the adjacent MnOx species, respectively.9,20 Another individual peak centered at 770 °C is ascribed to the reduction of CeO2 unpromoted by MnOx. This is confirmed by the distinct peak at 725 °C in the profile of pure CeO2. For both of the poisoned catalyst, the low-temperature reduction peaks disappear almost completely. Instead, an intensive peak is found at 542 °C for MCA-DS, which is ascribed partially to the reduction of sulfates as indicated by the reduction behavior of the reference sample MCA-IS. It is difficult to distinguish the specific sulfates because both cerium sulfates and manganese sulfates decompose at 480–600 °C.28,46 The profile of pure Ce(SO4)2 is also acquired with an intensive peak at 563 °C. This peak shifts to lower temperatures for the sulfated catalysts, indicating the promoted reducibility of sulfates by the residual active metal oxides in the sulfated catalysts. This peak shifts to 521 °C for MCA-WS compared with MCA-DS. It has been reported that bulk sulfate species are less reducible than surface sulfates.28 Thus, the shift should be associated with the formation of more surface sulfates on MCA-WS than on MCA-DS, which is in agreement with the TGA and IR results. A shoulder peak is observed at around 450 and 485 °C on MCA-WS and MCA-IS, respectively. It is ascribed to the reduction of the unsulfated ceria16 and manganese oxide, indicating the preservation of oxidation ability of the wet and impregnated sulfated catalyst.
Soot-TPO tests were conducted in the presence of NO + O2 to measure the activities of the catalysts for soot oxidation. The profiles of COx and NO2 during the soot-TPO are shown in Fig. 8. The temperature corresponding to 50% conversation of soot was denoted as the light-off temperature (T50), and the CO2/(CO + CO2) ratio was defined as the selectivity to CO2.51 The results are listed in Table 4. The fresh catalyst has a satisfactory catalytic performance compared to the commercial platinum catalyst (T50 ≈ 440 °C).52 However, the mixed oxide catalyst shows a poor resistance to sulfur dioxide. Both of the poisoned catalysts have low selectivity to CO2. The T50 of MCA-WS shifts to higher temperatures by 54 °C, while the increase in the light-off temperature of MCA-DS is almost doubled (96 °C). The water reduces the deactivation of the catalyst to a great degree. However, they show similar NO oxidation activities in Fig. 7. Thus, the different NOx-assisted soot oxidation activities between the two poisoned catalysts cannot be well explained by their NO oxidation abilities. In our previous studies, we reported the preferential NO2 absorption on soot rather than on catalyst driven by surface acidity over the sulfated Pt/Al2O3 (ref. 53) and Pt/H-ZSM5 catalysts.54,55 This mechanism may also exist over the sulfated mixed oxide catalysts. According to Table 3, the amount of total surface acidity follows the order of MCA-WS > MCA-F > MCA-DS. The stronger surface acidity may promote the NO2 transfer from catalyst to soot and hereby the NO2 utilization efficiency on MCA-WS compared with MCA-DS, although the further experimental evidences remain to be proceeded.
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| Fig. 8 The outlet COx and NO2 concentration profiles during the soot-TPO over the catalysts. Reactant gas: 1000 ppm of NO/10% O2/N2. Loose catalyst-soot contact. | ||
| Catalyst | Reaction in NO + O2 | Reaction in O2 | ||
|---|---|---|---|---|
| T50 (°C) | SCO2 | T50 (°C) | SCO2 | |
| MCA-F | 426 | 97 | 573 | 99 |
| MCA-DS | 518 | 75 | 575 | 83 |
| MCA-WS | 480 | 71 | 562 | 64 |
| Uncatalyzed | 610 | 45 | 612 | 47 |
Soot oxidation mechanism with the assistance of NOx involves roughly the soot ignition by NO2 at low temperatures and soot oxidation by O2 at high temperatures.17 It is noted in Fig. 8 that the produced NO2 is almost completely consumed by reacting with soot over the poisoned catalysts, while excess NO2 remain for the fresh catalyst. Therefore, the influence of O2-assisted soot oxidation ability cannot be excluded when considering the NOx-assisted soot oxidation activities of the poisoned catalysts. The soot-TPO tests in O2 were performed and the results are shown in Fig. 9 and Table 4. It is generally known that the soot oxidation activity in O2 is generally determined by active oxygen on ceria-based oxide catalysts.56,57 MCA-DS exhibits a similar T50 to MCA-F but a poor selectivity. More interestingly, MCA-WS shows even higher activity in O2 than MCA-F. The repeated experiments show that the error range is around ±2 °C for the T50. The difference of T50 between MCA-F and MCA-WS is 11 °C, which cannot be merely contributed by the experimental scatter. Thus, the higher soot oxidation activity of this catalyst cannot be ascribed to the deprivation of redox property.
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| Fig. 9 COx profiles of soot-TPO over the catalysts. Reactant gas: 10% O2/N2. Loose catalyst-soot contact. | ||
The soot oxidation occurs generally at the temperatures above 300 °C. According to Table 3, the amount of medium acidity follows the order of MCA-WS > MCA-DS > MCA-F. It has been reported that the oxidation of surface oxygenated complexes (SOCs) such as carboxyl esters and acid anhydrides may be more difficult than the formation of SOCs. The hydrolysis and decarboxylation of these intermediates can be catalyzed by acid sites especially a strong acid like H2SO4.14,17,58,59 However, the product of this acid-assisted SOC decomposition appears to be CO, resulting in low selectivity to CO2 for soot oxidation. These are in good consistent with the low T50 and low SCO2 for the O2-assisted soot oxidation over MCA-WS with more stable acid sites.55
Although the wet sulfated catalyst maintains the activity to some degree, the robustness of the MCA oxide catalyst towards sulfur poisoning still need to be improved. Our previous work found that tungsten modification on Pt/Al2O3 catalyst can decrease the deposition of sulfate during sulfur poisoning.60 Flouty et al. also found that molybdenum impregnation on ceria can show a better resistance to sulfur poisoning for soot oxidation catalysis.61 Thus, the acid additive may be a promising way to improve the sulfur tolerance of the mixed oxide catalyst.
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