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 stoichiometric spinel structure and an overcoat that includes PGM, such as palladium (Pd) supported on carrier material oxides, such as alumina. SPGM catalyst system shows significant improvement in nitrogen oxide reduction performance under lean operating conditions, which allows a reduced consumption of fuel. Additionally, disclosed SPGM catalyst system also exhibits enhanced catalytic activity for carbon monoxide conversion. Furthermore, disclosed SPGM catalyst systems are found to have enhanced catalytic activity for fresh and aged conditions compared to PGM catalyst system, showing that there is a synergistic effect between PGM catalyst and Cu—Mn spinel within the disclosed SPGM catalyst system which help in thermal stability of disclosed SPGM catalyst.

Abstract: Disclosed are three-way catalysts that are able to simultaneously convert nitrogen oxides, carbon monoxide, and hydrocarbons in exhaust gas emissions into less toxic compounds. Also disclosed are three-way catalyst formulations comprising palladium (Pd)-containing oxygen storage materials. In some embodiments, the three-way catalyst formulations of the invention do not contain rhodium. Further disclosed are improved methods for making Pd-containing oxygen storage materials. The relates to methods of making and using three-way catalyst formulations of the invention.

Abstract: The present disclosure describes ZPGM material compositions including LaMnO3 perovskite structure mixed with a plurality of support oxide powders to develop suitable ZPGM catalyst materials. Bulk powder ZPGM catalyst compositions are produced by physically mixing bulk powder LaMnO3 perovskite with different support oxide powders calcined at about 1000° C. XRD analyses are performed for bulk powder ZPGM catalyst compositions to determine La—Mn perovskite phase formation and phase stability for a plurality of temperatures to about 1000° C. ZPGM catalyst material compositions including La—Mn perovskite structure mixed with doped zirconia, La2O3, cordierite, and ceria-zirconia support oxides present phase stability, which can be employed in ZPGM catalysts for a plurality of DOC applications, thereby leading to a more effective utilization of ZPGM catalyst materials with high thermal and chemical stability in DOC products.

Abstract: The present disclosure describes ZPGM material compositions including a CuMn2O4 spinel structure mixed with a plurality of support oxide powders to develop suitable ZPGM catalyst materials. Bulk powder ZPGM catalyst compositions are produced by physically mixing bulk powder CuMn2O4 spinel with different support oxide powders calcined at about 1000° C. XRD analyses are performed for bulk powder ZPGM catalyst compositions to determine Cu—Mn spinel phase formation and phase stability for a plurality of temperatures to about 1000° C. ZPGM catalyst material compositions including CuMn2O4 spinel mixed with La2O3, cordierite, and ceria-zirconia support oxides exhibit phase stability, which can be employed in ZPGM catalysts for a plurality of TWC applications, thereby leading to a more effective utilization of ZPGM catalyst materials with high thermal and chemical stability in TWC products.

Abstract: Synergized PGM (SPGM) catalyst systems including ZPGM material compositions and formulations are disclosed. Variations of catalyst systems are tested to determine the synergistic effect of adding ZPGM material to PGM catalysts. The synergistic effect is determined under isothermal oscillating condition from which enhanced OSC property indicates enhanced catalytic behavior of disclosed SPGM catalyst systems as compared with commercial PGM catalysts with OSM for TWC applications. Disclosed SPGM catalyst systems is free of rare earth metals and especially Ce and may have an optimal OSC property and optimal thermal stability that increases with the temperature, showing acceptable level of O2 storage even at low temperatures.

Abstract: Spinels having a general formula of AB2O4, where A and B are a transition metal but not the same transition metal are disclosed. Spinel and spinel compositions of the application are useful in various applications and methods as further described.

Abstract: Synergized Platinum Group Metals (SPGM) catalyst systems for TWC application are disclosed. Disclosed SPGM catalyst systems may include a washcoat with a Cu—Mn spinel structure, Cu1.0Mn2.0O4, supported on Nb2O5—ZrO2 and an overcoat that includes PGM supported on carrier material oxides, such as alumina. SPGM catalyst system that includes the spinel structure of Cu1.0Mn2.0O4 show 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 with spinel structure of Cu1.0Mn2.0O4 also enhances the reduction of carbon monoxide and hydrocarbon within catalytic converters.

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: Synergies resulting from combinations of catalyst systems including Copper-Manganese material compositions and PGM catalysts are disclosed. Variations of catalyst system configurations are tested to determine most effective material composition, formulation, and configuration for an optimal synergized PGM (SPGM) catalyst system. The synergistic effect of the selected SPGM catalyst system is determined under steady state and oscillating test conditions, from which the optimal NO/CO cross over R-value indicates enhanced catalytic behavior of the selected SPGM catalyst system as compared with current PGM catalysts for TWC applications. According to principles in the present disclosure, application of Pd on alumina-based support as overcoat and Cu—Mn spinel structure supported on Nb2O5—ZrO2 as washcoat on suitable ceramic substrate, produce higher catalytic activity, efficiency, and better performance in TWC condition, especially under lean condition, than commercial PGM catalysts.

Abstract: The invention generally relates to three-way catalysts and catalyst formulations capable of simultaneously converting nitrogen oxides, carbon monoxide, and hydrocarbons into less toxic compounds. Such three-way catalyst formulations contain ZrO2-based mixed-metal oxide support oxides doped with an amount of lanthanide. Three-way catalyst formulations with the support oxides of the present invention demonstrate higher catalytic activity, efficiency and longevity than comparable catalysts formulated with traditional support oxides.

Abstract: Disclosed are three-way catalysts that are able to simultaneously convert nitrogen oxides, carbon monoxide, and hydrocarbons in exhaust gas emissions into less toxic compounds. Also disclosed are three-way catalyst formulations comprising palladium (Pd)-containing oxygen storage materials. In some embodiments, the three-way catalyst formulations of the invention do not contain rhodium. Further disclosed are improved methods for making Pd-containing oxygen storage materials. The relates to methods of making and using three-way catalyst formulations of the invention.

Abstract: Influence of a plurality of base metal loadings on TWC performance of ZPGM catalysts for TWC applications is disclosed. ZPGM catalyst samples are prepared and configured with washcoat on ceramic substrate, overcoat including doped Zirconia support oxide, and impregnation layer of Cu—Mn spinel with different base metal loadings. Testing of ZPGM catalyst samples including variations of base metal loadings is developed under isothermal steady state sweep test condition to evaluate the influence of variations of base metal loadings on TWC performance in NOX conversion. As a result of increasing Cu—Mn base metal loadings, improvements of lean NOX conversion and oxygen storage capacity may be realized at higher base metal loading ratios. The ZPGM catalyst samples exhibiting higher NOX conversion and OSC are compared with commercial PGM catalyst samples under lean condition.

Abstract: Variations of bulk powder catalyst material including Cu—Mn, Cu—Fe, and Fe—Mn spinel systems for ZPGM TWC applications are disclosed. The disclosed bulk powder catalyst samples include stoichiometric and non-stoichiometric Cu—Mn, Cu—Fe, and Fe—Mn spinels on Pr6O11—ZrO2 support oxide, prepared using incipient wetness method. Activity measurements under isothermal steady state sweep test condition may be performed under rich to lean condition. Catalytic activity of samples may be compared to analyze the influence that different binary spinel system bulk powders may have on TWC performance of ZPGM materials for a plurality of TWC applications. Stoichiometric Cu—Mn, Cu—Fe, and Fe—Mn spinel systems exhibit higher catalytic activity than non-stoichiometric Cu—Mn, Cu—Fe, and Fe—Mn spinel systems. The influence of prepared Cu—Mn, Cu—Fe, and Fe—Mn spinel systems may lead into cost effective manufacturing solutions for ZPGM TWC systems.

Abstract: Variations of coating processes of Cu—Mn—Fe ZPGM catalyst materials for TWC applications are disclosed. The disclosed coating processes for Cu—Mn—Fe spinel materials are enabled in the preparation ZPGM catalyst samples according to a plurality of catalyst configurations, which may include an alumina only washcoat layer coated on a suitable ceramic substrate, and an overcoat layer with or without an impregnation layer, including Cu—Mn—Fe spinel and doped Zirconia support oxide, prepared according to variations of disclosed coating processes. Activity measurements are considered under variety of lean condition to rich condition to analyze the influence of disclosed coating processes on TWC performance of ZPGM catalysts for a plurality of TWC applications. Different coating processes may substantially increase thermal stability and TWC activity, providing improved levels of NOx conversion that may lead to cost effective manufacturing solutions for ZPGM-TWC systems.

Abstract: The effect of aging temperature on oxygen storage materials (OSM) substantially free from platinum group (PGM) and rare earth (RE) metals is disclosed. Samples of ZPGM-ZRE metals OSM, hydrothermally aged at a plurality of high temperatures are found to have significantly high oxygen storage capacity (OSC) and phase stability than conventional PGM catalysts with Ce-based OSM. ZPGM-ZRE metals OSM includes a formulation of Cu—Mn stoichiometric spinel structure deposited on Nb—Zr oxide support and may be converted into powder to be used as OSM application or coated onto catalyst substrate. ZPGM-ZRE metals OSM, after aging condition, presents enhanced level of thermal stability and OSC property which shows improved catalytic activity than conventional PGM catalysts including Ce-based OSM. ZPGM-ZRE metals OSM may be suitable for a vast number of applications, and more particularly in underfloor catalyst systems.

Abstract: ZPGM-ZRE catalyst system substantially free from platinum group (PGM) and rare earth (RE) metals for TWC application is disclosed. Disclosed ZPGM-ZRE catalyst system may include pure alumina as washcoat and a Cu—Mn stoichiometric spinel with Nb2O5—ZrO2 support oxide, as ZPGM-ZRE catalyst in overcoat. Disclosed ZPGM-ZRE catalyst systems are found to have high thermal stability, catalyst activity, and high oxygen storage capacity compared to commercial PGM catalyst system that includes Ce-based oxygen storage material (OSM).

Abstract: The present disclosure relates to an enhanced oxygen storage material (OSM) that may be converted into powder form and used as a raw material for a vast number of applications, and more particularly in catalyst systems. The disclosed OSM, substantially free from PGM and rare earth (RE) metals, has significantly higher oxygen storage capacity (OSC) than conventional OSM including PGM and RE metals. The disclosed OSM may be converted into powder, including a formulation of Cu—Mn spinel structure deposited on Nb—Zr oxide support. The disclosed OSM may also be coated onto a ceramic substrate as washcoat layer for characterization under OSC isothermal oscillating condition. The disclosed OSM may have an optimal OSC property that increases with the temperature, showing acceptable level of O2 storage even at low temperatures.

Abstract: Influence of a plurality of base metal loadings on TWC performance and thermal stability of ZPGM catalysts for TWC applications is disclosed. ZPGM catalyst samples are prepared and configured with washcoat on ceramic substrate, overcoat including doped Zirconia support oxide, and impregnation layer of Cu—Mn spinel with different base metal loadings. Testing of ZPGM catalyst samples including variations of base metal loadings is developed under isothermal steady state sweep test condition for fresh and aged ZPGM catalysts to evaluate the influence of variations of base metal loadings on TWC performance specially NOx conversions and level of stability of NOx conversion. As a result disclosed ZPGM catalyst systems with an optimum base metal loadings exhibit high and stable NOx conversion which is suitable for under floor TWC application.

Abstract: Disclosed here are variations of carrier material oxide formulations to create Cu—Mn spinel, where the formulations may include Ti1-xNbxO2, TiO2, SiO2, Doped alumina, Nb2O5—ZrO2, Nb2O5—ZrO2—CeO2, Doped ZrO2 and combinations thereof. The formation of type of Cu—Mn oxide phase depends on type of carrier material oxide. The crystallite size of Cu—Mn spinel, NO and CO conversion rate of Cu—Mn Spinel may vary according to the carrier material oxide and condition treatment used to form the spinel during co-precipitation method.

Abstract: Variations of synthesis methods for Zero Platinum Group Metal (ZPGM) catalyst systems are disclosed herein. The methodologies of influence of synthesis methods on Cu—Mn catalyst systems which may include a variation of carrier metal oxides are disclosed. The XRD characterization and activity measurements of a series of stoichiometric and non-stoichiometric Cu—Mn spinels with different support oxide are discussed.