From the powder to the honeycomb. A comparative study of the NSR efficiency and selectivity over Pt–CeZr based active phase

• Four catalyst scales from powder to full size coated DPF was evaluated in NSR process.
• NSR efficiency is very affected by the scale up from the powder to the impregnated DPF.
• N2O selectivity is enhanced with the scale up.
• NOx desorption and diffusion phenomenon are highlighted on monolith.
• Powder and supported catalysts exhibit same trends toward the reductant mixture.

The efficiency and the selectivity of a model platinum based catalyst supported on a modified ceria–zirconia oxide was evaluated in the NOx storage-reduction (NSR) process at four catalytic scales: powder, (0.5″ × 1.5″) flow-through monolith (FTM) system, small size (1″ × 2″) and full size (5.66″ × 10″) catalysed Diesel Particulate Filter (DPF).The washcoating of the active phase over FTM affects both the NOx storage properties and the NOx reduction step. The reduction step efficiency is especially decreased at low temperatures. It is associated with an incomplete regeneration of the storage sites and with a strong NOx desorption peak during the rich pulses of the NSR process for the FTM supported system. The NOx reduction selectivity is also strongly affected by the upscale, with an important N2O selectivity detected over FTM. The recorded NOx profiles during NSR cycles indicate a probable diffusion limitation. However, same trends were observed for both powder and FTM systems concerning the effect of the reductant mixture, for both NSR efficiency and N-compounds selectivity.After incorporation of the active phase in the porosity of the DPF, a sharp drop in NOx storage properties and subsequently in NSR efficiency are observed. Supplementary tests suggest that the diffusion from the platinum oxidizing sites to the storage sites is again very affected by the upscale. Finally, the engine bench tests confirm the low DeNOx activity of the DPF system.

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