Scalable Synthesis Of Ordered Mesoporous Binary Metal Oxide: Cexzr1-Xo2 As Thermally Stable Catalyst For Enhanced Co Oxidation

The scale-up synthesis of mesoporous binary metal oxides with uniform porosity for practical application is still challenging. Here we report an ordered mesoporous CexZr1-xO2 catalyst synthesized by a scalable colloidal solution combustion method, and tested for CO oxidation. The mesoporous CexZr1-xO2 catalyst is durable and demonstrates superior CO oxidation activity with a full conversion at similar to 400 degrees C due to its high surface area of about 141 m(2)/g and pore volumes of 0.55 mL/g. The CexZr1-xO2 catalyst is also active and thermally stable up to 800 degrees C. Its structure is robust with uniform Zr distribution and nano-cavities even after accelerated ageing. We have also realized the practical feasibility by scale-up synthesis of 600 g mesoporous CexZr1-xO2 catalyst. It is then effectively applied as diesel oxidation catalysts in a Diesel Particulate Filter (DPF) in simulated vehicle gas environment. Our DPF prototype allows nearly a full CO to CO2 conversion below 100 degrees C. The synthesis is simple and scalable, allowing full control of composition and porosity to effectively design binary oxides for enhanced catalytic applications.