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Abstract

A method of manufacturing a layered catalyst for purifying an exhaust gas stream includes introducing a mixture of colloidal ceria, alumina particles, and a liquid medium into a drying chamber via an atomizer to form atomized droplets of the mixture. A drying gas is introduced into the drying chamber such that the atomized droplets contact the drying gas, the liquid medium is removed from the atomized droplets, and ceria nanoparticles deposit on the alumina particles to form composite catalyst support particles. A catalyst precursor including a rhodium precursor and colloidal ceria is applied to the composite catalyst support particles. The composite catalyst support particles and the catalyst precursor are heated to form the layered catalyst. The layered catalyst includes an alumina substrate, a ceria nanoparticle layer extending substantially continuously over the alumina substrate, and a rhodium catalyst layer including an atomic dispersion of rhodium adsorbed on the ceria nanoparticle layer.

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First Claim