Catalyst for purifying exhaust gas and method for production thereof

~ 13~4962 CATALYST FOR PURIF~ING EXHAUST GAS AND METHOD FOR PRODUCTION THEREOF BACKGROUND OF THE INVENTION Field of the Invention:

This invention relates to a catalyst for purifying exhaust gas and a method for production thereof.

More particularly, it relates to a catalyst for purifying exhaust gas by simultaneous removal of such harmful components as hydrocarbons (HC), carbon 10 monoxide (CO), and nitrogen oxides (NOx) contained in the exhaust gas from the internal combustion engine of an automobile, for example, especially a catalyst for purifying exhaust gas which retains outstanding durability even when it is used under such harsh 15 conditions as experienced in an oxidizing atmosphere at elevated temperatures and which exhibits a high scrubbing performance at low temperatures to the harmful components.

Description of the Prior Art:

Heretofore, there have been proposed numerous catalyts for purifying exhaust gas emanating from the internal combustion engine of an automobile, for example.

At present, three-way catalysts for simultaneous removal of CO, HC, and NOX constitute the 25 mainstream of the trend of the catalyst for purifying exhaust gas.

The three-way catalysts mentioned above are generally produced by depositing such active components as platinum (Pt), palladium (Pd), and rhodium (Rh) 30 either singly or jointly as dispersed on such a refractory inorganic oxide as alumina or zirconia in a powdered form thereby preparing a catalyst composition and coating a monolithic carrier of cordierite, for example, with the catalyst composition. Of these 35 three-way catalysts, that which has platinum-family metals including rhodium dispersed densely on activated ~ 133~962 alumina and also has cerium oxide (ceria) incorporated ln the catalyst composition is claimed to possess an outstanding purifying ability.

Further, the practice of adding to the 5 catalyst active composition a promoter component selected from among the comounds of rare earth elements, the compounds of the elements of Group VIII, the alkali metal compounds, and the alkaline earth metal compounds for the purpose of promoting and stabilizing the 10 catalytic activity of noble metals as the active component of catalyst is now in vogue. Particularly, cerium oxide (CeO2), a rare earth compound, manifests a conspicuous effect as a promoter catalyst and has found widespread utility.

Generally, rhodium is a noble metal component which contributes in a large measure to the catalyst's ability to purify the waste gas of NOX and permit combustion at low temperatures. It has been known, however, that under such harsh conditions as experienced 20 in an oxidizing atmosphere at elevated temperatures, rhodium is diffused in an alumina and consequently deprived of activity [refer to J. Catal., 50, 407 (1977)] and rhodium and ceria undergo undesirable interaction. In Japanese Patent Laid-open SHO 25 61(1986)-11,147, for example, it is disclosed that the interaction of rhodium and alumina is diminished by regulating the particle diameter of rhodium. This method, however, necessitates intricate steps as for wet reduction. We have confirmed that this method is not 30 sufficient for the purpose of curbing the interaction of rhodium and ceria. As ways of incorporating ceria in the catalyst composition, a method which comprises depositing ceria on the catalyst composition by impregnating activated alumina with a solution of ceria 35 and a method effects the incorporation by pouring the bulk of an oxide, hydroxide, or carbonate of cerium into the other components of the catalyst composition have I33~962 been known. When the ceria is deposited as on activated alumina, however, a disadvantage ensues that the ceria particles are liable to grow and the ceria is deficient in thermal stability. When the bulk of cerium compound 5 is poured into the catalyst composition, there is a disadvantage that the consumption of ceria is so large as to render the produced catalyst very expensive and the frequency of contact between ceria and rhodium is increased to an extent of inducing an undesirable 10 interaction and consequent loss of activity. Japanese Patent Laid-Open SHO 60(1985)-171,223 and Japanese Patent Laid-Open SHO 62(1987)-168,544 have a disclosure to the effect that all the rare earth elements are as effective in stabilizing zirconium as yttrium, calcium, 15 and magnesia. The effect which such rare earth elements used in a catalyst are to manifest in aiding in the catalysis remains yet to be clarified.

In the field of catalysts, zirconia is used mostly for the purpose of stabilizing the specific 20 surface area and other similar physical properties of the catalyst composition. ~s concerns the use of zirconia as a carrier for a platinum-family metal, various methods are proposed as in Japanese Patent Publication SHO 57tl982)-29,215 and Japanese Patent 25 Laid-Open SHO 57(1982)-153,737, for example.

zirconia possesses highly desirable properties as a carrier for a platinum-family metal. It nevertheless is highly susceptible of thermal deterioration and liable to undergo heavy loss of 30 activity during a protracted use at elevated temperatures. An invention which consists in using zirconia as a thermally stable sintered article is disclosed, for example, in Japanese Patent Publication SHO 57(1982)-2,382. The thermally stable sintered 35 article of zirconia is deficient in binding force with such catalyst components as platinum-family metal and ceria and liable to induce growth of particles of the ~ 133~962 active component and growth of crystals and, as a result, the produced catalyst suffers from low thermal stability and poor durability.

An object of an aspect of this invention, therefore, is to provide a novel catalyst for purifying exhaust gas and a method for the production thereof.

Another object of an aspect of this invention is to provide a catalyst for purifying exhaust gas which retains outstanding durability when it is used under such harsh conditions as encountered in an oxidizing atmosphere at elevated temperatures and exhibits a high scrubbing ability at low temperatures to the harmful components contained in the exhaust gas.

SUMMARY OF THE INVENTION The objects of various aspects of the invention described above are accomplished by a catalyst for purifying exhaust gas produced by coating honeycomb carriers of monolithic structure with a catalyst composition comprising cerium oxide particles stabilized with (a) zirconia or (b) zirconia and at least one member selected from the group consisting of yttria and calcia, refractory inorganic oxide particles, 0.02 to 2% by weight, based on the amount of catalyst composition, of rhodium, and 0 to 10% by weight, based on the amount of catalyst composition, of at least one platinum-family metal selected from the group consisting of platinum and palladium.

In the present invention, it has been found that the durability characteristic of rhodium is prominently improved by allowing rhodium to be incorporated in the catalyst composition as deposited in a high concentration on particles of such a refractory inorganic oxide as alumina, and adjusted in the form of aggregate particles of a relatively large average diameter.

It has been further found that an amorphous ceria compound excellent in thermal stability and ` ~ 13~962 promoting effect is obtained by depositing ceria as dispersed on zirconia or zirconium hydroxide of a high surface area and this amorphous ceria hardly undergoes an interaction with rhodium. It has been also found that the catalyst composition which contains the inorganic oxide carrying rhodium in a high concentration obtained as described above and the ceria stabilized with zirconia inhibits the undesirable interaction with rhodium and retains outstanding durability and low-temperature activity even when it is used under such harsh conditions as encountered in an oxidizing atmosphere at elevated temperatures. This invention has been completed as the result.

According to an aspect of the invention, a catalyst for purifying exhaust gas produced by coating honeycomb carriers of monolithic structure with a catalyst composition comprising (1) cerium oxide particles dispersed on (a) zirconia or (b) zirconia and at least one member selected from the group consisting of yttria and calcia, said dispersed particles being obtained by impregnating zirconium oxide or hydroxide having a specific surface area of from 60-200 m2/g with a solution of (i) a cerium salt or (ii) a cerium salt and at least one salt selected from the group consisting of yttrium salts and calcium salts, drying and then calcining the resultant impregnated particles, wherein said cerium oxide is contained in a range of 10% to 50% by weight based on said zirconia and the chart of the Xray diffraction spectrum thereof does not show a peak for the crystalline form of cerium oxide, (2) refractory inorganic oxide particles, (3) 0.02 to 2% by weight of rhodium, and (4) 0 to 10% by weight of at least one platinum-family metal selected from the group consisting of platinum and palladium, based on said catalyst composition.

` ~ I33~962 The objects described above are also accomplished by a method for the production of a catalyst for purifying exhaust gas, which comprises preparing a catalyst composition composed of a refractory inorganic oxide having rhodium carried therein in an amount in the range of 0.02 to 2 % by weight based cn the amount of the catalyst composition, cerium oxide particles stabilized with (a) zirconia or (b) zirconia and at least one member selected from the group consisting of yttria and calcia, and refractory inorganic oxide particles having carried thereon 0 to 10% by weight, based on the amount of the catalyst composition, of at least one platinum-family metal selected from the group consisting of platinum and palladium, converting the catalyst composition into an aqueous slurry, coating honeycomb carriers of monolithic structure with the aqueous slurry, and subsequently drying the resultant coated carrier.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is an X-ray diffraction diagram of a typical catalyst according to this invention, Figs. 2 to 4 are X-ray diffraction diagrams of catalysts for comparison, and 5a 13~4962 Fig. 5 is a chart showing the results of determination of the bond energy of Ce 3d S/2 as measured of the ceria used in the catalyst of this invention and in the catalysts for comparison with an 5 X-ray photoelectric spectroscope.

EXPLANATION OF THE PREFERRED EMBODIMENT The catalyst composition to be used in the present invention comprises cerium oxie stabilized with (a) zirconia or (b) zirconia and at least one member 10 selected from the group consisting of yttria and calcia, refractory inorganic oxide particles, rhodium and optionally at least one platinum-family metal selected from the group consisting of platinum and palladium. In this catalyst composition, the rhodium is deposited 15 either alone or in combination with the platinum-family metal on the stabilized cerium oxide particles and/or the refractory inorganic oxide particles.

The amount of rhodium to be carried is in the range of 0.02 to 2% by weight, preferably 0.1 to 1 % by 20 weight, based on the amount of the catalyst composition.

Preferable method for supporting rhodium resides in supporting in an amount of 1 - 20 % by weight of high supporting concentration to the refractory inorganic oxide particles. If this amount is less than 1% by 25 weight, the deposited rhodium assumes a state approximating to that of ordinary high dispersion, undergoes a heavy interaction with the refractory inorganic oxide such as alumina, and fails to retain desired durability. If this amount exceeds 20% by 30 weight, the initial performance is low and the rhodium particles are liable to grow during the course of use.

When the composition of the refractory inorganic oxide supported rhodium is prepared in the form of aggregate particles having a relatively large average diameter of 35 0.5 to 20~m, preferably 1 to 10 ~m and then dispersed in the catalyst composition, it serves to mitigate the interaction or reaction of rhodium with the refractory -- 6 - - ~ 1334~62 inorganic oxide or promoter substance without impairing the efficiency of the reaction for exhaust gas scrubbing.

The refractory inorganic oxides which are 5 usable herein include alumina, silica, titania, and zirconia, for example. It is particularly desirable to use alumina, especially activated alumina in the crystalline form of ~ , ~ , or ~ .

The method for the deposition of the 10 platinum-family metal including rhodium is not specifically defined. The conventional method of impregnation may be used for the deposition, for example. The composition can be obtained by thoroughly mixing the aqueous solution of a rhodium salt such as 15 rhodium nitrate, rhodium chloride, or rhodium sulfate with the refractory inorganic oxide in the form of particles and then drying and calcining the resultant mixture. The calcinatlon temperature is in the range of 300 to 700C, preferably 400 to 600C.

The cerium oxide composition stabilized with zirconia which constitutes the second characteristic of the present invention is obtained by impregnating zirconia or an amorphous zirconium hydrate such as zirconium hydroxide in the form of minute particles of a 25 large surface area in the range of 60 to 200 m2/g, preferably 80 to 200 m2/g, with the aqueous solution of a cerium salt and then drying the impregnated particles and calcing them at a temperature in the range of 400 to 700C, preferably 500 to 600C. The cerium salts 30 which are usable herein include cerium nitrate, cerium sulfate, cerium chloride, and cerium oxalate, for example.

The content of ceria in the cerium oxide composition stabilized with zirconia is desired to be in 35 the range of 10 to 50% by weight, preferably 20 to 30% -- 7 - ~ 13349~2 by weight. When the ceria content is in the preferred range of 20 to 30% by weight, the produced composition has ceria uniformly formed solid solutions.

The powdered zirconia-stabilized cerium oxide 5 composition may otherwise be produced by causing coprecipitation of the cerium salt with a zirconium salt.

The powdered zirconia-stabilized cerium oxide composition produced as described above, on analysis by 10 X-ray diffraction, shows a crystalline structure solely of zirconia. When this powder is calcined in the air at 900C for 10 hours, it shows in the X-ray diffraction diagram a curve for the teragonal crystal of zirconia, indicating that the zirconia is stabilized in the 15 tetragonal crystal by the ceria, as compared with the zirconia powder containing no ceria and showing a peak for the monoclinic crystal.

The calcination is preferable to be carried preferably out at a temperature in the range of 400 to 700C.

Further, the specific surface area to be measured after 10 hours' calcination in the air at 900C is not more than 10 m2/g in the case of the zirconia powder containing no ceria and not less than 30 m2/g in the case of the powdered zircoina-stabilized cerium 25 oxide composition containing ceria in the range of 10 to 50 ~ by weight. This comparison clearly indicates that the incorporation of ceria serves to stabilize thermally the composition.

When a sintered article of zirconia which has 30 acquired a specific surface area of less than 60 m2/g as the result of heat treatment, for example, is used as a zirconia source, no solid solution is obtained as evinced by the fact that the X-ray diffraction shows crystalline structures for both ceria and zirconia.

If the ceria content in the powdered zirconia-stabilized cerium oxide composition is less than 10% by weight based on the amount of zirconia, a ~ 133~9~2 peak for the monoclinic crystal of zirconia partly appears after 10 hours' calcination at 950C.

If the ceria content exceeds 50% by weight, a peak for ceria appears.

The powdered zirconia-stabilized cerium oxide composition is enabled to bring about a still better effect when the zirconia-stabilized cerium oxide is further stabilized with yttria and/or calcia.

The content of yttria and/or calcia in the cerium oxide 10 composition which has been stabilized with zirconia and yttria and/or calcia is in the range of 0.5 to 15% by weight, preferably 1 to 5 % by weight. The stabilized cerium oxide composition is identified by the fact that the X-ray diffraction diagram of the composition shows 15 no peak for the crystal of ceria. Stabilization with yttria and/or calcia may be carried out by impregnating a yttrium and/or calcium salt to zirconia or zirconium hydrate during or after impregnating a cerium salt to zirconia or zirconium hydrate, drying and calcining.

20 The calcination temprature is 400 to 700C, preferably 50~C to ~00C.

The stabilized cerium oxide of this invention is such that even after it has been exposed to an oxidizing atmosphere at an elevated temperature of not 25 less than 800C, the X-ray diffraction diagram thereof does not show a peak for the crystal of ceria or yttria but shows mainly a peak for the tetragonal crystal of zirconia. The absence of the peak for the crystal of ceria or yttria from the X-ray diffraction diagram may 30 be logically explained by a supposition that cerium and yttrium both form a solid solution with zirconia or they are deposited as idealy dispersed in the interstices between the zirconia particles.

It has been confirmed by us that the yttrium 35 and calcium incorporated in the composition are effective in stabilizing the zirconia and, at the same time, in altering the condition of oxidation of ceria.

- ~ 1334962 The result of the test by the method of X-ray photoelectric spectroscopy shows that the incorporation of yttrium or calcium brings about an addition to the oxidation number of Ce. This fact suggests that active 5 oxygen seeds have been formed on the surface of ceria.

The stabilized cerium oxide thus obtained is contained in a concentration in the range of 10 to 80% by weight, preferably 20 to 40~ by weight, based on the total amount of the catalyst composition.

The 10 incorporation of the stabilized cerium oxide in combination with the platinum-family metal permits production of a highly satisfactory exhaust gas scrubbing catalyst for use in the internal combustion engine.

The rhodium is carried on the particles of the cerium oxide composition stabilized with zirconia alone or with zirconia in combination with yttria or calcia and/or the particles of refractory inorganic oxide as described above. Optionally, particles of a refractory 20 inorganic oxide carrying no rhodium may be additionally incorporated in the catalyst composition. When a refractory inorganic oxide such as activated alumina or silica prepared with a large surface area is incorporated in the catalyst composition, it enables the 25 catalyst composition to acquire a physical effect such as, for example, diffusion of gas. When the refractory inorganic oxide has a rare earth element, a base metal element such as iron, chromium, manganese, or nickel, or a platinum-family metal other than rhodium carried 30 thereon, the produced catalyst composition enjoys a further improvement in the purifying ability.

The platinum-family metal other than rhodium, when necessary, may be deposited on the refractory inorganic oxide carrying rhodium, the cerium oxide 35 stabilized solely by zirconia or jointly by zirconia and yttria and/or calcia, or the refractory inorganic oxide not carrying rhodium. The amount of the platinum-family -- 10 - ~ 133~962 metal thus deposited is in the range of 0 to 10% by weight, more desirably 0.001 to 5% by weight, and most desirably 0.5 to 2% by weight. This deposition is effected in the same manner as that of rhodium mentioned 5 above.

From the compositions obtained as described above, a finished catalyst is produced by converting these compositions into an aqueous slurry by the use of a ball mill, wash coating honeycomb carriers of 10 monolithic structu~e, for example, with the aqueous slurry, then drying the coated honeycomb carriers, and optionally calcining the dry coated honeycomb carriers.

The calcination temperature is in the range of 100 to 700C, preferably 150 to 500C.

The honeycomb carriers of monolithic structure which are usable in this invention include carriers of such ceramic substances as cordierite, mullite, and -alumina and metallic monolithic carriers made of stainless steel and Fe-Cr-Al alloy, for example. The 20 amount of the catalyst composition to be carried per liter of these carriers is in the range of 50 to 300 g, preferably 100 to 250 g.

Now, the present invention will be described more specifically below with reference to working 25 examples. It should be noted, however, that this invention is not limited to these examples.

Example 1 With 100 ml of an aqueous solution of 50 g of cerium nitrate [Ce(N03)3. 6H2O], 50 g of minute 30 particles of zirconia having a specific surface area of 92 m2/g (produced by Daiichi Kigenso K.K.~ were impregnated and mixed. Then the impregnated minute particles were thoroughly dried and calcined at 500C for one hour. (The product was labeled as "sample No.

35 1.") Control 1 ~ ~33~962 Sample a was obtained by following the procedure of Example 1, except that alumina Y-alumina) having a specific surface area of 155 m2/g was used in place of zirconia.

5 Control 2 Sample b was obtained by following the procedure of Example 1, except that zirconia having a specific surface area of 45 m2/g was used instead.

Example 2 Sample No. 2 was obtained by following the procedure of Example 1, except that the amount of cerium nitrate was changed to 100 g.

Control 3 Sample c was obtained by following the 15 procedure of Example 1, except that the amount of cerium nitrate was changed to 200 g.

Example 3 With an aqueous rhodium chloride solution containing 0.5 g of rhodium, 5 g of alumina ( Y-Al2o3) 20 having a specific surface area of gO m /g was impregnated. Then, the impregnated alumina was thoroughly dried and subsequently calcined at 500C for one hour.

Then, 200g of alumina ( y -al2O3) having a 25 specific surface area of 155 m2/g was impregnated with an aqueous platinum chloride solution containing 2.5 g of platinum, to obtain platinum-containing alumina.

In a ball mill, the two powders obtained as described above and 100 g of cerium compound obtained in the same manner 30 as in Example 1 were wet pulverized for 20 hours, to obtain an aqueous slurry. Monolithic carriers of cordierite (33 mm in inside diameter and 76 mm in length) possessing about 400 cells per square inch of cross section were immersed in the aqueous slurry, 35 removed from the slurry, blown with compressed air to remove excess slurry from the cells, and then dried, to obtain a catalyst 3. The coating layer of the catalyst ~ 13319~2 was photographed in 3,000 magnifications at 300 randomly selected points and analyzed for distribution of platinum and rhodium by electron probe micro analysis (EPMA), to find that rhodium-containing alumina was 5 dispersed in the form of particles having an average diamter of 3 ~m and absolutely no platinum was aggregated in the form of particle. By the fluorescent X-ray test, the catalyst 3 was found to contain 0.081 g of platinum, 0.016 g of rhodium, and 0.90 g of CeO2 per 10 catalyst.

Example 4 Alumina containing rhodium and platinum was obtained by impregnating 10 g of alumina ( r -A1203 ) having a specific surface area of 155 m2/g with a mixed 15 solution of rhodium chloride and platinic chloride containing 0.5 g of rhodium and 2;.5 g of platinum, drying the impregnated alumina, and then calcining the dried alumina at 500C for one hour. In a ball mill, the powder thus obtained, 80 g of cerium compound 20 obtained in the same manner as in Example 2, and 210 g of y -alumina were wet pulverized to obtain an aqueous slurry. Thereafter, Catalyst 4 was obtained by following the procedure of Example 3. By the EPMA analysis, the coating layer of this catalyst was found 25 to contain the platinum and rhodium-containing alumina as dispersed in the form of particles having an average diameter of 5~m.

The amount of the catalyst carried was as shown in Table 1.

Control 4 An aqueous solution of rhodium chloride and platinic chloride containng 0.5 g of rhodium and 2.5 g of platinum was diluted with purified water.

Then, 220 g of y -alumina having a specific surface area of 155 m2/g was impregnated with the diluted aqueous solution, 35 dried, and then calcined at 500C for one hour. In a ball mill, the powder thus obtained and 80 g of commercially available cerium oxide were wet pulverized, - 13 ~ ~ 133~962 and treated by following the procedure of Example 3, to obtain catalyst d. When the coating layer of this catalyst was tested by EPMA, neither platinum nor rhodium was detected in the form of particles exceeding 5 0.5~m in diameter. The amount of the catalyst carried was as shown in Table 1.

Control 5 Platinum-containing alumina was obtained by impregnating 100 g of y -alumina with an aqueous 10 solution of platinic chloride containing 2.5 g of platinum, and then drying and calcining the impregnated y -alumina. In a ball mill, the powder thus obtained and 80 g of commercially available cerium oxide were wet pulverized, to obtain an aqueous slurry. Then, 120 g of 15 r- alumina was impregnated with an aqueous solution of rhodium chloride containing 0.5 g of rhodium and the resultant impregnated ~ - alumina was pulverized in a ball mill, to obtain an aqueous slurry. The rhodium in the aqueous slurry was fixed by passing hydrogen sulfide 20 gas through the rhodium-containing aqueous slurry.

Monolithic carriers were wash coated with the mixture of the two slurries obtained as described above.

The coated carriers were dried and calcined at 400C for one hour to obtain a finished catalyst e. When the 25 coating layer of this catalyst was tested by EPMA, neither platinum nor rhodium was found to be contained in the form of particles exceeding 0.5 ~m in diameter.

The amount of catalyst carried was as shown in Table 1.

Example 5 With an aqueous solution of rhodium nitrate containing 0.3 g of rhodium, 5 g of ~ -alumina having a specific surface area of 90 m2/g was impregnated.

The impregnated ~ -alumina was thoroughly dried and then calcined at 500C for one hour, to obtain 35 rhodium-containing alumina. Then, 100 g of cerium compound obtained in Example 2 was impregnated with an - 14 _ 133~962 aqueous solution of palladium nitrate containing 3.0 g of palladium and then dried and calcined at 500C for one hour.

An aqueous slurry was prepared by wet 5 pulverizing the two powders obtained as described above and 200 g of ~-alumina and then processed by following the procedure of Example 3, to obtain catalyst 5. When the coating layer of this catalyst was tested by EPMA, the rhodium-containing alumina was found to be dispersed 10 in the form of particles having an average diameter of 6 ~m. The amount of catalyst carried was as shown in Table 1.

Control 6 In a ball mill, 300 g of ceria-containing 15 alumina obtained in the as same manner as in Control 1 was wet pulverized to prepare an aqueous slurry and then processed by following the procedure of Example 3 to obtain wash coated monolithic carriers. Then, the carriers were calcined at 500C for one hour, 20 impregnated with an aqueous solution of palladium chloride and rhodium chloride, dried, and then calcined at 500C to obtain catalyst f. When the coating layer of the catalyst as tested by EPMA, neither palladium nor rhodium was detected in the form of particles exceeding 25 0.5 ~m in diameter. The amount of catalyst carried was as shown in Table 1.

Table 1 133~962 Example No. Catalyst No. Pt Pd Rh CeO2 Example 3 3 0.081 - 0.016 0.90 Example 4 4 0.080 - 0.016 1.15 Control 4 d 0.082 - 0.016 2.60 Control 5 e 0.081 - 0.016 2.55 Example 5 5 - 0.096 0.010 1.43 Control 6 f - 0.102 0.010 2.73 (g/pc) 10 Example 6 The samples obtained in Examples 1 and 2 Controls 1 to 3 and the same samples further calcined at 1,000C for 10 hours were subjected to X-ray diffraction. The peaks consequently obtained are shown 15 in Table 2.

Separately, the samples of Example 1 and Control 1 and commercially available ceria (having a specific surface area of 70 m2/g) calcined at 1,000C for 10 hours for comparison were tested for capacity for 20 oxygen storage. The results were as shown in Table 3.

This test was carried out with a conventional flow type apparatus by reducing a sample in hydrogen at 500C and then feeding oxygen pulses to the sample under continued flow of helium thereby determining the amount of oxygen 25 consumed by the sample. From the results of Table 2 and Table 3, it is noted that the ceria compound obtained in accordacne with this invention does not induce growth of ceria crystals but retains a highly desirable capacity for oxygen storage even after exposure to an oxidizing 30 atmosphere at the elevated temperature of 1,000C.

- 16 Table 2 1334962 Sample CeO2 content One hour' calcination Ten hour'calcination No. (% by weight) at 500C at 1,000C 1 29 ZrO2 (monoclinic) ZrO2 (tetragonal) 5 2 44 Zr2 (monoclinic) ZrO2 (tetragonal) a 29 A12O3 (Y ) Ce2 A12O3(~r~t ~)~ Ce2 b 29 ZrO2(monoclinic),CeO2 ZrO2 (monoclinic),CeO2 c 61 ZrO2(monoclinic),CeO2 ZrO2 (tetragonal),CeO2 Table 3 Sample No. Oxygen consumption (mol) per mol of Ce 1 9.8 x 10 a 0.1 x 10 2 Commercially available ceria 0.2 x 10 2 Example 7 The catalysts, Nos. 3 to 5, and the catalysts, Nos. d to f, for comparison were aged in an electric oven and then tested for catalytic performance. The 20 aging in the electric oven was carried out under very harsh conditions of oxidizing atmosphere at an elevated temperature, i.e. in the air at 900C, for 20 hours.

The evaluation of the catalytic performance was effected by the use of an electronically controlled 25 engine 4 cylinders 1,800 cc), with the catalyst inlet gas temperature varied continuously with a heat exchanger from 200 to 450C, to find ratios of removal of CO, HC, NOX. In this case, the engine was operated with the space velocity (S.V.) fixed at 90,000 hr 1, the 30 average air/fuel ratio (A/F) fixed at 14.6, and the 133~962 vibration at + 0.5 A/F l Hz.

The catalyst inlet gas temperature at which the ratios of removal of CO, HC, and NOX reached 50% (T50) and the ratio of purification (%) at 450C were as shown in Table 4.

The catalysts which had undergone the durability test in the engine were similarly tested for catalytic performance.

In the durability test, an electronically controlled engine (8 cylinders 4,400 cc) was operated in the mode of 60 seconds of steady driving lO and 6 seconds of decelerated driving (during which period the fuel was cu~ and the catalyst was exposed to an oxidizing atmosphere at elevated temperature)~ Thus, the catalyst was aged ~or 50 hours under conditions such that the catalyst temperature would reach 800C in the 15 steady driving.

The evaluation of the sample for catalytic peformance after the durable test with the engine was carried out in the same manner as described above. The results were as shown in Table 5. It is clearly noted 20 from the results o Tables 4 and 5 that the catalyst disclosed by the present invention experiences sparing deterioration and retains highly desirable durability not merely under the normal engine driving conditions but also under such harsh conditions as encountered in 25 an oxidizing atmosphere at an elevated temperature.

- 18 Table 4 133 49 S~ Catalyst No.

Temperature for 50% Ratio of purification(~) conversion (C) at 450C CO HC NO CO HC NO 3 372 375 369 85 83 87 4 365 371 360 88 87 88 d 426 431 422 69 65 71 e 403 410 401 72 70 72 355 358 356 97 98 96 f 394 397 399 83 85 82 Table 5 Catalyst No.

Temperature for 50~ Ratio of purification(~) conversion (C) at 450C CO HC NO CO HC NO 3 341 345 337 . 92 87 91 4 337 340 335 95 92 93 d 389 393 382 80 77 81 e 372 379 370 83 78 83 368 370 368 90 92 88 f 401 405 407 - 77 81 72 Example 8 A zirconia-stabilized cerium oxide (hereinafter referred to as "Ce-ZrO2") powder containing 26% by weight of ceria was prepared by mixing an aqueous 25 solution of cerium nitrate and zirconia having a specific surface area of 82 m2/g, drying the resultant mixture, and then calcining the dry mixture in the air at 500C for two hours.

-- 19 - .

133~962 Then, a mixed powder comprising 20 g of the Ce-ZrO2 powder and 80 g of activated alumina having a specific surface area of 100 m2/g was impregnated with an aqueous rhodium nitrate solution containing 0.1 g of 5 rhodium. The impregnated powder was dried and then calcined in the air at 500C for two hours, to prepare a catalyst composition.

This catalyst composition was converted into a slurry. Cylindrical monolithic carriers of cordierite 10 33 mm in outside diameter and 76 mm in length possessing about 400 gas-passing cells per square inch of cross section were coated with the catalyst composition slurry and then dried at 130C for three hours, to obtain a finished catalyst carrying 6.5 g of the catalyst 15 composition.

Part of the aforementioned Ce-ZrO2 powder containing 26% by weight of ceria was calcined in the air at 900C for ten hours and subjected to X-ray diffraction. The X-ray diffraction diagram showed only 20 a peak for the tetragonal crystal of zirconia as illustrated in Fig. 1. The calcined Ce-Z~O2 powder was found to possess a specific surface area of 42 m2/g.

Example 9 A finished catalyst was obtained by following 25 the procedure of Example 8, except that a Ce-ZrO2 powder containing 13% by weight of ceria was used and rhodium was carried on a mixed powder comprising 50 g of the Ce-ZrO2 powder and 50 g of activated alumina.

Control 7 A catalyst composition was prepared by impregnating 80 g of activated alumina having a specific surface area of lOO m2/g with a mixed aqueous solution containing 5.2 g of cerium nitrate as ceria, 14.8 g of zirconium nitrate as zirconia, and 0.1 g of rhodium 35 nitrate as rhodium, drying the impregnated activated alumina, and calcing the dry alumina in the air at 500C - 20 ~ 13349~ This catalyst composition was converted into a slurry. In the same manner as in Example 8, monolithic carriers were coated with the slurry to obtain a finished catalyst carrying 6.5 g of the catalyst 5 composition.

Control 8 A mixed powder comprising of 10 g of ceria powder having a specific surface area of 62 m2/g, 60 g of activated alumina powder having a specific surface 10 area of 100 m2/g, and 30 g of zirconia powder having a specific surface area of 82 m2/g was impregnated with an aqueous solution containing 0.1 g of rhodium nitrate as rhodium. The impregnated powder was dried and then calcined at 500C, to prepare a catalyst composition.

15 From this catalyst composition, a finished catalyst carrying 6.5 g of the catalyst composition was obtained by following the procedure of Example 8.

Control 9 A finished catalyst was obtained by following 20 the procedure of Example 8, except that a zirconia powder having a specific surface area of 38 m2/g was used instead.

Part of the Ce-ZrO2 powder obtained herein was calcined in the air at 900C for ten hours and subjected 25 to X-ray diffraction. The X-ray diffraction diagram showed a peak for the monoclinic crystal of zirconia and a peak for ceria as illustrated in Fig. 2. The calcined powder was found to have a specific surface area of 9.8 m2/g ~ 30 Control 10 A finished catalyst was obtained by following the procedure of Example 8, except that a Ce-ZrO2 powder containing 7~ by weight of ceria was used and rhodium was carried on a mixed powder comprising 80 g of the 35 Ce-ZrO2 powder and 20 g of activated alumina.

- 21 - 133~962 Part of the Ce-ZrO2 powder containing 7% by weight of ceria was calcined in the air at 900C for ten hours and subjected to X-ray diffraction. The X-ray diffraction diagram showed a main peak for the 5 monoclinic crystal of zirconia and a peak for the tetragonal crystal of zirconia as illustrated in Fig. 3.

The calcined powder was found to possess a specific surface area of 28 m2/g.

Control 11 A finished catalyst was obtained by following the procedure of Example 8, except that a Ce-ZrO2 powder containing 85% by weight of ceria was used instead and rhodium was carried on a mixed powder comprising 15 g of the Ce-ZrO2 powder and 85 g of activated alumina.

Part of the Ce-ZrO2 powder containing 85% by weight of ceria was calcined in the air at 900C for ten hours and then subjected to X-ray diffraction. The X-ray diffraction diagram showed a peak for ceria and partly a peak for the tetragonal crystal of zirconia as 20 illustrated in Fig. 4. The calcined powder was found to possess a specific surface area of 3.1 m2/g.

Example 10 A Ce-ZrO2 powder containing 28~ by weight of ceria based on zirconia was prepared by mixing an 25 aqueous solution of cerium nitrate and zirconium hydroxide having a specific surface area of 98 m2/g, drying the resultant mixture, and calcining the dry mixture in the air at 500C for two hours.

Then, a mixed powder comprising of 25 g of the 30 Ce-ZrO2 powder mentioned above and 115 g of a activated alumina containing 3% by weight of ceria and 1% by weight of iron oxide and having a specific surface area of 123 m /g was impregnated with a mixed aqueous solution of containing 0.2 g of rhodium nitrate as 35 rhodium and 1 g of palladium nitrate as palladium. The impregnated powder was dried and then calcined in the air at 500C to prepare a catalyst composition.

- ~ 133g962 This catalyst composition was converted into a slurry. In the same manner as in Example 8, monolithic carriers were coated with the slurry to obtain a finished catalyst carrying 9.2 g of the catalyst 5 composition.

Example 11 A Ce-ZrO2 powder containing 23% by weight of ceria was prepared by treating a mixed aqueous solution of cerium nitrate and zirconium nitrate with aqua 10 ammonia thereby inducing coprecipitation of the salts, removing the coprecipitate, drying and calcining in the air at 500C for two hours. This Ce-ZrO2 powder was found to have a specific surface area of 91 m2/g.

Then, a finished catalyst carrying 9.2 g of a 15 catalyst composition was obtained by following the procedure of Example 10, except that the Ce-ZrO2 powder prepared by the coprecipitation method was used instead.

Example 12 A finished catalyst was obtained by following 20 the procedure of Example 10, except that amorphous zirconia having a specific surface area of 82 m2/g was used as the zirconia source for the Ce-ZrO2 powder.

Control 12 A finished catalyst was obtained by following 25 the procedure of Example 10, except that a zirconia powder having a specific surface area of 42 m2/g was impregnated with cerium nitrate and a Ce-ZrO2 powder containing 28% by weight of ceria based on zirconia was prepared instead.

30 Control 13 A catalyst composition was prepared by mixing a mixed powder comprising 115 g of activated alumina containing 5% by weight of ceria and 1% by weight of iron oxide and having a specific surface area of 123 35 m2/g and 18 g of amorphous zirconia powder having a specific surface area of 82 m2/g and 7g of cerium nitrate as ceria, 0.2 g of rhodium nitrate as rhodium, - 23 ~ 13~4962 and 1 g of palladium nitrate as palladium, drying the resultant mixture, and calcining the dry mixture in the air at 500C for two hours.

From this catalyst composition, a finished 5 catalyst carrying 9.2 g of the catalyst composition was obtained by coating monolithic carriers with the catalyst composition in the same manner as in Example 10 .

The amounts of catalyst components carried per 10 liter of each of the finished catalysts of Examples 8 to 12 and Controls 7 to 13 were as shown in Table 6.

- 24 1334962 ,~ a) h ~,~ooooo a ~ O O O O O O O ., o o o o o o o ~r ~ d' U~ o C3 ~ . . . .

O ¦ O O O O O OU~ N ~ In CO ~D00N00 0 0 0 0 0 O a ~1 o l 00 ~ ~It`l .... .

E~ aJ ~ .

.

a ~o . .......

i N N r~ N N11') 1` O'~' . .. .

O 1~) 1~ N N ~ N N C~l Ul ~1 ~1 ~ ~~ N N t~l N N O O O O O O O O O O O O o OOOOO . .

O --1 0 r~l N N t~ u, a ~ ~ ,1 ~ ~ ~ a a a ~ ~ ~ 4 ~ J - 25 ~, , 133q962 Example 13 The catalyst of Example 8 to 12 and the catalysts of Controls 7 to 13 were tested for catalytic activity after a durability test in an engine.

5The durability test was formed by use of a commercially available electronically controlled engine (8 cylinders 4,400 cc), with a multi-converter filled with a sample catalyst and connected to the exhaust system of the engine.

The engine was operated by a mode 10 of 6~ seconds' steady driving and 6 seconds' decelerated driving (druing which period the fuel was cut and the catalyst was exposed to harsh conditions of an oxidizing atmosphere at elevated temperature), to age the catalyst for 50 hours under conditions such that the catalyst 15 inlet gas temperature during the steady driving would reach 800C.

The evaluation of the aged catalyst for catalytic performance was carried out by use of a commercially available electronically controlled engine 20 (4 cylinders, 1,800 cc), with a multi-converter filled with a sample catalyst and connected to the exhaust system of the engine. The performance of the catalyst was evaluated under the conditions of catalyst inlet gas temperature of 450C and a space velocity of 90,000 25 hr 1. ln this case, a l-Hz sine wave form signal from an external oscillator was fed into a control unit of the engine to effect continuous change of the average air/fuel ratio, with the air/fuel ratio (A/F) fluctuated within the range of + 0.5 A/F and 1 Hz. In the 30 meantime, the gas sampled at the inlet and outlet of the catalyst was analyzed to find the ratios of removal of CO, HC, and NOX for the average air/fuel ratio, A/F, in the range of 15.1 to 14.1 A three way characteristic curve was obtained 35 by plotting on a graph the data of the ratio of removal of CO, HC, and NO~ obtained as described above vs. the inlet air/fuel ratio. The ratio of purification at the - 26 133~9~2 intersection of the curves of ratios of removal of CO and NOX (hereinafter referred to as "crossover point") and the ratio of removal of HC at the A/F value of that crossover point were found from the three way 5 characterisitc curve to be used as criteria for the evaluation of the three way performance of the catalyst.

The evaluation of the catalyst with respect to the purification capcity at low temperatures was carried out by operating the engine with the average air/fuel 10 ratio, A/F, fixed at 14.6 and the air/fuel ratio fluctuated within the range of + 0.5 A/F and 1 Hz, continuously changing the catalyst inlet gas temperature from 200 to 500C by means of a heat-exchanger disposed before the catalyst converter in the exhaust system of 15 the engine, simultaneously analyzing the gas sampled at the inelt and outlet of the catalyst, and determining the ratios of removal of CO, HC, and NOX.

The data consequently obtained on the ratios of removal of CO, HC, and NOX vs. the catalyst inlet gas 20 temperature were plotted on a graph. The catalyst inlet gas temperature at which the ratio of purification reached 50% (R50) was found from the curve of the graph and used as a criterion for the evaluation of the catalyst's purification ability at low temperatures.

The results of the evaluation of catalyst performance obtained by the method described above were as shown in Table 7.

Table 7 Results of evaluation of catalyst performance after durability test with engine Three way performance Purification ability at low temperature Crossover point Ratio of Ratio of Raio of Catalyst removal of CO removal of HC removal of NOx Ratios of removal Ratlo of removal T 50 (~C) T 50(UC) T 50(~C)of CO and NO (%) of HC (%) Example 8 96.5 92.6 345 349 343 Example 9 95.8 91.6 351 357 349 Control 7 50.8 51.2 ~ 428 425 436 Control 8 60.5 58.6 415 416 424 Control 9 45.6 48.2 424 418 415 oo Control 10 72.5 65.8 ~ 408 412 401 Control 11 61.8 57.4 414 417 409 Example 10 98.1 95.3 342 341 330 Example 11 98.8 98.2 328 334 319 Example 12 ! 99.2 96.8 336 343 321 Control 12 82.8 83.5 421 427 409 Control 13 85.6 82.1 404 406 409 ~V 133~962 It is clearly noted from Table 7 that the catalysts of this invention containing a ceria-zirconia compound having a platinum-family metal and ceria incorporated in the form of a solid solution in zirconia 5 in a concentration in the range of 10 to 50% by weight as contemplated by the present invention exhibit highly satisfactory catalyst performance as compared with the conventional catalyst using ceria and zirconia.

From the results described above, it is noted 10 that the catalyt offered by the present invention possesses an outstanding purification ability and, at the same time, retains high durability even under such harsh conditions as experienced in an oxidizing atmosphere at an elevated temperature.

15 Example 14 Wit-h a solution in 100 ml of water of 50 g of cerium nitrate ~Ce(NO3)3 6H2O], 50 g of minute particles of ziuconia having a specific surface area of 97 m2/g were impregnated. The impregnated particles 20 were thoroughly dried and then calcined at 500C for one hour. (The product was labelled as Sample No. 6) Example 15 With a solution in 100 ml of water of 50 g of cerium nitrate ~Ce(NO3)3 6H2O~ and 1.7 g of yttrium 25 nitrate ~Y(No3)3 . 6H2O], 50 g of the same minute particles of zirconia as in Example 14 were impregnated.

The impregnated particles were thoroughly dried and then calcined at 500C for one hour. (The product was labelled as Sample No. 7.) 30 Example 16 With a solution in 100 ml of water of 50 g of cerium nitrate [Ce(NO3)3~ 6H2O] and 3.4 g of yttrium nitrate ~Y(NO3)3- 6H2O)~, 50 g of minute particles of zirconia having a specific surface area o 97 m /g were 35 impregnated. The impregnated particles were thoroughly dried and then calcined at 500C for one hour. (The product was labelled as Sample No. 8.) - 29 1334962 Example 17 Sample No. 9 was obtained by following the procedure of Example 16, except that the amount of yttrium nitrate was changed to 6.8 g.

5 Example 18 Sample No. 10 was obtained by following the procedure of Example 16, except that 8.4 g of calcium nitrate [Ca(NO3)2, 4H2O] was used in place of yttrium nitrate.

10 Example 19 With solution in 100 ml of water of 50 g of cerium nitrate, 3.4 g of yttrium nitrate and 8.4 g of calcium nitrate, 50 g of the same minute particles of zirconia as in Example 14 was impregnated. The 15 impregnated particles were thoroughly dried and then calcined at 5~0C for 1 hour. (The product was labelled as Sample No. 11) Control 14 Sample g was obtained by following the 20 procedure of Example 16, except that zirconia having a specific surface area of 40 m2/g was used instead.

Control 15 Sample h was obtained by following the procedure of Example 17, except that the addition of 25 cerium nitrate was omitted.

Control 16 Sample i was obtained by folloiwng the procedure of Example 16, except that 50 g of ~ -alumina having a specific surface area of 150 m2/g was used in 30 place of zirconia.

Example 20 ~ 1] The cerium oxide-containing powders of Samples No. 6 to 11 and Samples g to i obtained respectively in Examples 14 to 19 and Controls 14 to 16 35 and a commercially available ceria of a large specific surface area (85 m2/g) were treated in an electric oven - 30 ~3349B2 at l,000C for ten hours and subjected to X-ray diffraction and tested for B~T surface area. The results were as shown in Table 8.

The cerium oxide-containing powders of Example 5 14 to 19 showed no growth of CeO2 crystal even after the treatment at the elevated temperatre and further exhibited stable BET surface area due to addition of yttrium and/or calcium.

[2) The samples Nos. 8 and 9, the sample i, 10 and commercially available cerium oxide were tested for XPS. The results were as shown in Fig. 5. It is noted from Fig. 5 that the cerium oxides obtained in the working examples of this invention show a shift from the ordinary 3d peak of Ce toward the lower bond energy 15 side. The fact that the bond energy is shifted toward the lower energy side means that the oxidation number of Ce is increased. It is, therefore, logical to infer that the addition of yttrium results in the formation of a Ce seed of an enhanced state of oxidation.

- 31 ~ 133~9~2 E~ l .D ~ r i a~ ~r Ltl ~r ~ o~ ~t o ~ ~ u~ o ~ r ~ r l N r ~ m u~ rl a~ o u~ ` aJ ~, _ -- -- -- _ -- _ rc ~ r r r r- rl r ~i ~ o r x ~ ~ ~ c ~ ~~ o c ) r t~ ~ ~ I 0 3 ~ r t~ a) ~ ~ t r t~ c~ n ~ I C -- O r ~1 ~ ~ ~ ~ J J t O ~ o r~ rl ~ J I ~ ~) J ~ ~3 _ 1¢ :) O O O O O O O O ~ t~ r c ) o ri ; ~ ~ x ~ ~ r c ) c~ x o o o o ~ ~ u u rl ~) r l ~ ~r N N dt Ul O O O O I O O O N N N ~ ~` J N O O O O O O O O O N N ~I N N N ~1 N S~ O N N N N N N N I O ~1 0 0 0 o o o o a rl U U U U U U U Q~ O s~ ~ o o o o o o o o In X U N N N N N N N N O O O O O O O O O N O h S~ ~ h S~ ri m r,. r-l ~'J ~ a~ ~D rl r~ p rt Qt CO ~ Or l t:Sl ,~ '-rl a) r tl~ r I r-l ~ ~ N O ' O' ~ ~D U - 133~62 Example 21 An alumina powder containing platinum and rhodium was obtained by impregnating 200 g of activated alumina having a specific surface area of 150 m2/g with 5 a mixture of an aqueous solution of dinitrodianmine platinic nitrate containing 1.5 g of platinum and an aqueous solution of rhodium nitrate containing 0.3 g of rhodium, thoroughly drying the impregnated activated alumina, and calcining the dry alumina in the air at 10 400C for two hours.

Then, in a ball mill, the platinum-family metal containing alumina obtained as described above and 100 g of the cerium oxide-containing powder obtained in Example 14 were blended with water and nitric acid to 15 prepare an aqueous slurry.

A finished catalyst No. 12 was obtained by coating monolithic carriers (33 mm in diameter and 110 mm in length~ of cordielite with the aqueous slurry and then drying the coated carriers at 130C for three 20 hours. The amount of the slurry coting of the finished catalyst was 150 g/liter.

Examples 22 to 26 and Controls 17 to 19 Finished catalyst Nos. 13 to 17 and No. j to 1 were obtained by following the procedure of Example 21, 25 except that the c,e,rium oxide-containing powder obtained in Examples 15 to 19 and Controls 14 to 16 were used in such amounts as shown in Table 8.

Control 20 A finished catalyst No. m was obtained by 30 following the procedure of Example 21, except that 100 g of a commercially awailable ceria (85 m2/g) was used instead.

Example 20 The catalysts Nos. 12 - 17, and the catalysts 35 Nos. j - m of Controls were sujbected to the durability test with an engine and then tested, for catalytic performance. ,' - 33 13349~2 The durability test was performed by use of an electronically controlled engine (8 cylinders, 4,400 cc). The engine was operated by a mode of 60 seconds' steady driving and 6 seconds' decelerated driving 5 (during which period the fuel was cut and the sample catalyst was exposed to an oxidizing atmosphere at an elevated temperature) and the sample catalyst as aged for 50 hours under the conditions such that the catalyst temperature reached 900C in the steady driving.

The evaluation of the catalyst was performed by use of an electronically controlled engine by continuously changing the temperature from 200C to 450C by means of a heat-exchanger and simultaneously determining the catalyst inlet gas temperature for the 15 ratios of removal of CO, HC, and NOX to reach 50~ (T50) and the ratlo of removal of the components at 450C.

The results were as shown in Table 9.

It is clearly noted from Table 9 that the catalysts according to the present invention retain 20 highly desirable durability even under harsh conditions as experienced in an oxidizing atmosphere at elevated temperatures owing to the stabilization of cerium oxide.

~ 34 1334962 Table 9 Catalyst 50% conversion temperature Ratio of purification at No. (C) 450C (%) CO HC NO CO HC NO 12 358 363 356 88 85 89 13 341 348 338 92 86 93 14 337 341 332 94 86 94 329 334 322 95 90 94 16 334 340 329 94 86 94 17 327 331 319 95 90 94 j 389 394 382 79 80 81 . k 365 367 360 68 75 69 1 397 403 395 63 72 66 m 403 --412 401 72 68 73 Air/fuel ratio of exhaust gas from engine, A/F, = 14.6 + 0.5, 1 Hz. Temperature increasing speed 10C/min.

- 35