Abstract: Compositions and methods for the preparation of ZPGM catalytic converters are disclosed. Addition of Mn to ZPGM catalytic converters from prior ZPGM catalytic may create a new ZPGM catalytic converter with greater improvement TWC conditions compared to previous types. Suitable known in the art chemical techniques, deposition methods and treatment systems may be employed in order to form the disclosed ZPGM catalyst systems. Disclosed ZPGM TWC systems in catalytic converters may be employed to decrease the pollution caused by exhaust from various sources, such as automobiles, utility plants, processing and manufacturing plants, airplanes, trains, all-terrain vehicles, boats, mining equipment, and other engine-equipped machines.

Abstract: Disclosed herein is a method of separating variations in the mass flow of gas through a catalyst from the thermal load observed by the temperature control system in a test bench. The method may include separating the temperature control component from the mass flow control component.

Abstract: The present disclosure refers to a plurality of methods employed for production of ZPGM diesel oxidation catalyst systems substantially free of PGM, which may include a substrate, a washcoat, and an impregnation layer. Washcoat may include at least one carrier material oxides. An optional impregnation layer component, which may include at least one ZPGM catalyst. This catalyst system may be free of any oxygen storage material (OSM). Suitable deposition methods and firing systems may be employed in order to form disclosed ZPGM oxidation catalyst systems, which may be able to remove main pollutants from exhaust of diesel engines, by oxidizing toxic gases.

Abstract: Disclosed here are material formulations of use in the conversion of exhaust gases, where the formulations may include Copper (Cu), Manganese (Mn) and combinations thereof. Combinations of use may include Cu—Mn Spinels. Catalysts including these materials may be synthesized by methods including co-precipitation, co-milling, templating, and the sol-gel method, using any suitable carrier material oxide and any suitable oxygen storage material. The properties of the catalysts disclosed may vary according to the calcining temperature, where stoichiometric and non-stoichiometric Cu—Mn Spinels may form when calcining suitable formulations at suitable temperatures.

Abstract: The present disclosure may include a device for testing catalysts, and a method for controlling the flow rate and temperature parameters during the process. The device may separate mass flow control through heating elements from the mass flow through the sample, as well as separate banks for mixing oxidizing elements, carbon dioxide, and diluent gas as well as reducing agents, nitric oxide, and diluent gas. The device disclosed here may also use mass control units of a sufficiently high speed so as to allow the desired testing conditions.

Abstract: The present disclosure may include a method for preparing gas mixtures of use in testing catalysts, where the method may include using separate banks of mass flow controllers for mixing the gas composition to the desired composition and for controlling the flow of the gas composition through the heater. A separate bank may be used for controlling any suitable mix of reducing agents while another separate bank may be used for controlling any suitable mix of oxidizing gases.

Abstract: Disclosed here are material formulations of use in the conversion of exhaust gases, where the formulations may include Iron (Fe), Cobalt (Co), Manganese (Mn), Cerium (Ce), Lanthanum and combinations thereof.

Abstract: A double impregnation method and composition for producing three way catalysts (TWC) are disclosed. The TWC may generally include a substrate, a washcoat, a first and second impregnation compositions, and optionally at least an overcoat over the impregnation compositions. The first impregnation composition may include a composition of a perovskite, base metal oxides, and alkaline earth carbonates. The method for applying the first impregnation composition may include combining all base metals in the composition, adding Pd, drying, and adding a heat treatment. The method for applying the second impregnation composition may include adding a remainder of Pd as a Pd solution over the first impregnation, drying, and applying a heat treatment.

Abstract: Disclosed here are material formulations of use in the conversion of exhaust gases, where the formulations may include Niobium (Nb), Zirconium (Zr) and combinations thereof.

Abstract: Fuel Borne Catalysts of use in High Sulfur Fuels are disclosed, where formulations may include any number of suitable platinum group metals, transition metals, rare earth metals, and alkaline earth metals, including platinum, palladium, iron, manganese, cerium, yttrium, lithium, sodium, calcium, strontium, vanadium, silver and combinations thereof.

Abstract: Compositions and methods for the preparation of ZPGM oxidation catalytic converters are disclosed. ZPGM catalyst systems may be employed within catalytic converters under lean hydrocarbon, air to fuel ratio condition to oxidize toxic gases, such as carbon monoxide and other hydrocarbons that may be included in exhaust gas. ZPGM oxidation catalyst systems are completely free of PGM catalyst and may include: a substrate, a washcoat, and an overcoat. Washcoat may include silver as ZPGM catalyst, and carrier material oxides. Similarly, overcoat may include at least one ZPGM catalyst, carrier material oxides and OSMs. Overcoat of the disclosed ZPGM catalyst system may include copper and cerium as ZPGM catalysts. Suitable known in the art chemical techniques, deposition methods and treatment systems may be employed in order to form the disclosed ZPGM catalyst systems.

Abstract: A diesel oxidation catalyst (DOC) catalytic converter for at least the conversion of carbon monoxide and hydrocarbons, removal of a fraction of particulate matter, and decrease of sulfur trioxide emissions within exhaust gases from an engine and consequently of sulfuric acid, is disclosed. The DOC may include any suitable configuration including at least a substrate and a washcoat, where the substrate has a plurality of channels, suitable porosity, offers a three-dimensional support for the washcoat, and is made of any suitable material. The washcoat may be deposited on the substrate by any suitable method, and may include a mixture of at least one or more carrier material oxides and one or more catalysts. Suitable materials for the carrier material oxides may include titanium dioxide, tin dioxide, and zirconium dioxide, among others, excluding aluminum oxide (Al2O3), which may serve for a decrease of sulfur trioxide emissions and consequently of sulfuric acid mist.

Abstract: Synergized Platinum Group Metals (SPGM) catalyst system for TWC application is disclosed. Disclosed SPGM catalyst system may include a washcoat with a Cu—Mn spinel structure and an overcoat that includes PGM supported on carrier material oxides, such as alumina. SPGM catalyst system shows significant improvement in nitrogen oxide reduction performance under stoichiometric operating conditions and especially under lean operating conditions, which allows a reduced consumption of fuel. Additionally, disclosed SPGM catalyst system also enhances the reduction of carbon monoxide and hydrocarbon within catalytic converters. Furthermore, disclosed SPGM catalyst systems are found to have enhanced catalyst activity compared to commercial PGM catalyst system, showing that there is a synergistic effect among PGM catalyst and Cu—Mn spinel within the disclosed SPGM catalyst system.

Abstract: Compositions and methods for the preparation of ZPGM oxidation catalyst systems are disclosed. ZPGM catalyst systems may be employed within catalytic converters under lean hydrocarbon, air to fuel ratio condition to oxidize toxic gases, such as carbon monoxide and other hydrocarbons that may be included in exhaust gas. ZPGM oxidation catalyst systems are completely free of PGM catalyst and may include: a substrate, a washcoat, and an overcoat. Washcoat may include silver as ZPGM catalyst, and carrier material oxides. Similarly, overcoat may include at least one ZPGM catalyst, carrier material oxides and OSMs. Overcoat of the disclosed ZPGM catalyst system may include copper and cerium as ZPGM catalysts. Suitable known in the art chemical techniques, deposition methods and treatment systems may be employed in order to form the disclosed ZPGM catalyst systems.

Abstract: Disclosed here are methods of preparing zero platinum group metal catalysts systems with different support oxide material. A ZPGM catalyst system may include a substrate and a washcoat and an impregnation layer, wherein said impregnation layer may include the ZPGM pervoskite catalyst and the washcoat layer may include the support oxides material. Suitable support oxides material may include ZrO2, ZrO2 doped with lanthanide group metals, Nb2O5, Nb2O5—ZrO2, Al2O3 and Al2O3 doped with lanthanide group metals, TiO2 and doped TiO2 or mixtures thereof.

Abstract: Optimized Cu—Mn spinel compositions, with optimal spinel phase formation and phase stability properties, for a plurality of ZPGM catalysts in underfloor and closed-loop coupled catalyst applications are disclosed. Plurality of Cu—Mn spinel compositions are prepared with variations of molar ratios. Effect of calcination temperature is analyzed to determine spinel phase formation and phase stability, as well as the effect of calcination temperature on lattice parameter of spinel, as correlated to spinel phase formation and phase stability of optimal Cu—Mn spinel compositions disclosed. Disclosed Cu—Mn spinels with enhanced spinel phase formation and phase stability may be suitable for ZPGM catalyst systems used in a vast number of TWC applications.

Abstract: A Cu—Mn—Fe spinel on a plurality of support oxides is disclosed as ZPGM catalyst. The active phase for ZPGM samples may be Cu—Mn—Fe spinel on ZrO2 or Niobium-Zirconia support oxide. TWC activity may be increased and the effect of support oxide on performance of Cu—Mn—Fe spinel optimized to provide enhanced levels of NO, CO, and HC conversion even when compared to materials used for binary systems of Cu—Mn spinel. Cu—Mn—Fe spinel on support oxide provides optimal and stable spinel phase at a range of temperatures below 900° C. Bulk powder material including the disclosed ternary system may provide active catalyst for TWC applications having a chemical composition substantially free from PGM for cost effective manufacturing.

Abstract: Variations of coating processes of ZPGM catalyst materials for TWC applications are disclosed. The disclosed coating processes for ZPGM materials are enabled in the preparation of ZPGM catalyst samples according to a plurality of catalyst configurations, which may include washcoat and an overcoat layer with or without an impregnation layer, including Cu—Mn spinel and doped Zirconia support oxide, prepared according to variations of disclosed coating processes. Activity measurements under isothermal steady state sweep test condition are considered under lean condition and rich condition close to stoichiometric condition to analyze the influence of disclosed coating processes on TWC performance of ZPGM catalysts. Different coating processes may substantially increase TWC activity, providing improved levels of NO, CO, and HC conversions and cost effective manufacturing solutions.

Abstract: Disclosed here are material formulations of use in the conversion of exhaust gases, where the formulations may include Copper (Cu), Cerium (Ce), Tin (Sn), Niobium (Nb), Zirconium (Zr), Calcium (Ca) and combinations thereof.

Abstract: It is an object of the present disclosure, to provide an optimized catalyst composition with variations of Cu and Mn molar ratio, which may include a formulation CuxMn3-xO4 spinel, with a plurality of molar ratio variations for selecting the optimal Cu—Mn molar ratio for TWC application. The formulation may include a support oxide, such as Nb2O5—ZrO2. Employing this optimized Cu and Mn ratio in spinel as overcoat may achieve optimal NO conversion, high catalyst activity, and enhanced thermal stability, having a chemical composition substantially free from PGM and rare earth metals. According to principles of the present disclosure, the disclosed Cu—Mn spinel on Nb—Zr support oxide for TWC applications may require a washcoat of alumina, and overcoat of Cu—Mn spinel on Nb—Zr support oxide.