Enhancing CO oxidation performance by controlling the interconnected pore structure in porous three-way catalyst particles

Highly ordered porous structured particles comprising three-way catalyst (TWC) nanoparticles have attracted attention because of their remarkable catalytic performance. However, the conditions for controlling their pore arrangement to form interconnected pore structures remain unclear. In particular, the correlation between framework thickness (distance between pores) or macroporosity and the diffusion of gaseous reactants to achieve a high catalytic performance has not been extensively discussed. Here, the interconnected pore structure was successfully controlled by adjusting the precursor components (<i>i.e.</i>, template particle concentration) <i>via</i> a template-assisted spray process. A cross-sectional image analysis was conducted to comprehensively examine the internal structure and porous properties (framework thickness and macroporosity) of the porous TWC particles. In addition, we propose mathematical equations to predict the framework thickness and macroporosity, as well as determine the critical conditions that caused the formation of interconnected pores and broken structures in the porous TWC particles. The evaluation of CO oxidation performance revealed that porous TWC particles with an interconnected pore structure, thin framework, and high macroporosity exhibited a high catalytic performance owing to the effective diffusion and utilization of their internal parts. The study findings provide valuable insights into the design of porous TWC particles with interconnected pore structures to enhance exhaust gas emission control in real-world applications.