PROMETHEUS: A Copper-Based Polymetallic Catalyst for Automotive Applications. Part II: Catalytic Efficiency an Endurance as Compared with Original Catalysts

PROMETHEUS catalyst, a copper-based polymetallic nano-catalyst has been proven to be suitable for automotive emission control applications. This novel catalyst consists of copper, palladium and rhodium nanoparticles as active phases, impregnated on an inorganic oxide substrate, CeO₂/ZrO₂ (75%, 25%). The aim of PROMETHEUS catalyst’s development is the substitution of a significant amount (85%) of Platinum Group Metals (PGMs) with copper nanoparticles while, at the same time, presenting high catalytic efficiency with respect to the commercial catalysts. In this work, an extensive investigation of the catalytic activity of full scale PROMETHEUS fresh and aged catalyst deposited on ceramic cordierites is presented and discussed. The catalytic activity was tested on an Synthetic Gas Bench (SGB) towards the oxidation of CO and CH₄ and the reduction of NO. The loading of the washcoat was 2 wt% (metal content) on Cu, Pd, Rh with the corresponding metal ratio at 21:7:1. The concentration of the full-scale monolithic catalysts to be 0.032% total PGM loading for meeting Euro III standard and 0.089% for meeting Euro IV to Euro VIb standards. The catalytic activity of all catalysts was tested both in rich-burn (λ = 0.99) and lean-burn conditions (λ = 1.03).