Abstract: Sulfur-resistant synergized platinum group metals (SPGM) catalysts with significant oxidation capabilities are disclosed. Catalytic layers of SPGM catalyst samples are prepared using conventional synthesis techniques to build a washcoat layer completely or substantially free of PGM material. The SPGM catalyst includes a washcoat layer comprising YMn2O5 (pseudobrookite) and an overcoat layer including a Pt/Pd composition with total PGM loading of at or below 5.0 g/ft3. Resistance to sulfur poisoning and catalytic stability is observed under 5.2 gS/L condition to assess significant improvements in NO oxidation, and HC and CO conversions.

Abstract: Synergized platinum group metals (SPGM) with ultra-low PGM loadings employed as close-coupled (CC) three-way catalysts (TWC) systems with varied material compositions and configurations are disclosed. SPGM CC catalysts in which ZPGM compositions of binary or ternary spinel structures supported onto support oxides are coupled with commercialized PGM UF catalysts and tested under Federal Test Procedure FTP-75 within TGDI and PI engines. The performance of the TWC systems including SPGM CC (with ultra-low PGM loadings) catalyst and commercialized PGM UF catalyst is compared to the performance of commercialized PGM CC and PGM UF catalysts. The disclosed TWC systems indicate that SPGM CC TWC catalytic performance is comparable or even exceeds high PGM-based conventional TWC catalysts, with reduced tailpipe emissions.

Abstract: Synergized platinum group metals (SPGM) with ultra-low PGM loadings employed as underfloor (UF) three-way catalyst (TWC) systems with varied material compositions and configurations are disclosed. SPGM UF catalysts in which ZPGM compositions of binary and ternary spinel structures supported onto support oxides are coupled with commercialized PGM close-coupled (CC) catalysts and tested under Federal Test Procedure FTP-75 within TGDI and PI engines. The performance of the TWC systems including commercialized PGM CC and SPGM UF (with ultra-low PGM loadings) catalysts is compared to the performance of commercialized PGM CC and PGM UF catalysts. The disclosed TWC systems indicate that SPGM UF TWC catalytic performance is comparable or even exceeds high PGM-based conventional TWC catalysts, with reduced tailpipe emissions.

Abstract: Zero-PGM (ZPGM) catalyst materials including pseudo-brookite compositions for use in diesel oxidation catalyst (DOC) applications are disclosed. The disclosed doped pseudo-brookite compositions include A-site partially doped pseudo-brookite compositions, such as, Sr-doped and Ce-doped pseudo-brookite compositions, as well as B-site partially doped pseudo-brookite compositions, such as, Fe-doped, Co-doped Ni-doped, and Ti-doped pseudo-brookite compositions. The disclosed doped pseudo-brookite compositions, including calcination at various temperatures, are subjected to a DOC standard light-off (LO) test methodology to assess/verify catalyst activity as well as to determine the effect of the use of a dopant in an A-site cation or a B-site cation within a pseudo-brookite composition.

Abstract: Multi-zoned synergized-platinum group metals (SPGM) catalysts with significant catalytic capabilities are disclosed. The multi-zoned SPGM catalysts are produced according to catalyst configurations including OC layers of ultra-low PGM loadings, alone or in combination with a base metal oxide, which are deposited onto either mixtures of doped ZrO2 and oxygen storage materials (OSM) or OSM alone. Further, the multi-zoned SPGM catalysts further include zoned impregnation layers with PGM, alone or in combination with Ba loadings. Additionally, three-zoned SPGM catalysts are produced including front and back zone catalysts that include binary spinel oxide compositions. Conversion performance of the aged SPGM catalysts and an aged PGM-based OEM catalyst are tested employing TWC low perturbation isothermal oscillating, isothermal steady-state sweep, and light-off test methodologies.

Abstract: Modified calibration strategies for controlling an internal combustion engine and monitoring catalyst performance are disclosed. The modified calibration strategies are implemented using an engine and test cell/catalyst chamber setup wherein the engine is a Euro V 1.2 L turbo gasoline direct injection engine and test cells/catalyst chamber are implemented as substantially free of platinum group metals (PGM) catalysts, herein referred as ZPGM catalysts, and synergized PGM (SPGM) catalysts including a stoichiometric spinel structure within the catalyst configuration. The utilization of an open ECU enables the modified calibration of the engine out targeted AFR. The conventional ECU AFR control strategies are not modified to have the ECU AFR control strategies to continue running normally and only the final engine out targeted AFR values are modified by applying offset AFR values.

Abstract: The present disclosure relates to zero-PGM (ZPGM) catalysts including variations of Nickel-doped Copper-Manganese spinel for improved catalyst performance at the stoichiometric condition for use within three-way catalyst (TWC) applications. The ZPGM catalyst material compositions within the aforementioned ZPGM catalysts are expressed with general formulas of Cu1-XNiXMn2O4 (A-site substitution) and Cu1Mn2-XNiXO4 (B-site substitution). The ZPGM catalysts are subjected to a TWC isothermal steady-state sweep test to assess the catalytic performance (e.g., NO conversion). Test results indicate the ZPGM catalysts exhibit higher NO conversions, at stoichiometric condition and lean conditions, when Ni substituted the B-site cation of the Cu—Mn spinel as compared to Ni substituted the A-site cation of the Cu—Mn spinel. Additionally, NO conversions of the ZPGM catalysts are significantly affected, at the stoichiometric condition, by the molar ratio of the Ni dopant within the A or B-site cation of the Cu—Mn spinel.

Abstract: Zero-Rare Earth Metal (ZREM) and Zero-platinum group metals (ZPGM) compositions of varied binary spinel oxides are disclosed as oxygen storage material (OSM) to be used within TWC systems. The ZREM-ZPGM OSM systems comprise binary non-Cu spinel oxides of Co—Fe, Fe—Mn, Co—Mn, or Mn—Fe. The oxygen storage capacity (OSC) property associated with the non-Cu ZREM-ZPGM OSM systems is determined employing isothermal OSC oscillating condition testing. Further, the OSC test results compare the OSC properties of a ZREM-ZPGM reference OSM system including a Cu—Mn binary spinel oxide and PGM reference catalysts including Ce-based OSMs. The non-Cu spinel oxides ZREM-ZPGM OSM systems exhibit significantly improved OSC properties, which are greater than the OSC property of the Ce-based OSM PGM reference systems.

Abstract: Synergized platinum group metals (SPGM) with ultra-low PGM loadings employed as close-coupled (CC) three-way catalysts (TWC) systems with varied material compositions and configurations are disclosed. SPGM CC catalysts in which ZPGM compositions of binary or ternary spinel structures supported onto support oxides are coupled with commercialized PGM UF catalysts and tested under Federal Test Procedure FTP-75 within TGDI and PI engines. The performance of the TWC systems including SPGM CC (with ultra-low PGM loadings) catalyst and commercialized PGM UF catalyst is compared to the performance of commercialized PGM CC and PGM UF catalysts. The disclosed TWC systems indicate that SPGM CC TWC catalytic performance is comparable or even exceeds high PGM-based conventional TWC catalysts, with reduced tailpipe emissions.

Abstract: Synergized platinum group metals (SPGM) with ultra-low PGM loadings employed as underfloor (UF) three-way catalyst (TWC) systems with varied material compositions and configurations are disclosed. SPGM UF catalysts in which ZPGM compositions of binary and ternary spinel structures supported onto support oxides are coupled with commercialized PGM close-coupled (CC) catalysts and tested under Federal Test Procedure FTP-75 within TGDI and PI engines. The performance of the TWC systems including commercialized PGM CC and SPGM UF (with ultra-low PGM loadings) catalysts is compared to the performance of commercialized PGM CC and PGM UF catalysts. The disclosed TWC systems indicate that SPGM UF TWC catalytic performance is comparable or even exceeds high PGM-based conventional TWC catalysts, with reduced tailpipe emissions.

Abstract: Effect of the type of ZPGM material composition to improve thermal stability of ZPGM catalyst systems for TWC application is disclosed. ZPGM catalyst system samples are prepared and configured with washcoat on ceramic substrate, overcoat including doped Zirconia support oxide, and impregnation layer including either Cu1Mn2O4 spinel or Cu1Co1Mn1O4 spinel. Testing of ZPGM catalyst samples including variations of aging temperatures and different impregnation layer materials are developed under isothermal steady state sweep test condition for ZPGM catalyst systems to evaluate performance especially NOx conversions and level of thermal stability. As a result disclosed ZPGM catalyst systems with most suitable spinel that includes Cu1Co1Mn1O4 in impregnation layer exhibit high NOx conversion and significant improved thermal stability compare to Cu1Mn2O4 spinel, which is suitable for under floor and close coupled TWC application.

Abstract: Variations of ZPGM catalyst material compositions including doped Cu—Mn spinel supported on doped zirconia support oxide are disclosed. The disclosed ZPGM catalyst compositions include a small substitution of Ni within the A-site or B-site cation of a Cu—Mn spinel supported on doped zirconia support oxide, and produced by the incipient wetness (IW) methodology. Bulk powder ZPGM catalyst compositions are subjected to XRD analyses to determine the spinel phase formation and stability. Additionally, bulk powder ZPGM catalyst compositions are subjected to a steady-state isothermal sweep test to determine NO, CO, and THC conversion. The ZPGM catalyst material compositions including Ni-doped Cu—Mn spinel supported on doped zirconia support oxide exhibit improved levels in NO and CO conversions, 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: The present disclosure describes bulk powder Zero-PGM material compositions including a CuMn2O4 spinel structure supported on doped zirconia support oxides powders, including Ba, Sr, and Ti at different dopant loadings produced by different conventional synthetic methods. BET-surface area and XRD analysis are performed for a plurality of doped zirconia support oxides to compare the thermal stability, before and after deposition of Cu—Mn spinel. Additionally, bulk powder ZPGM catalyst compositions are subjected to a steady-state isothermal sweep test to determine NO conversion capabilities. The selected support oxide material compositions are capable of providing increased surface areas for improved thermal stability leading to a more effective utilization of ZPGM catalyst materials with enhanced NO conversion and improved thermal stability for TWC applications.

Abstract: The present disclosure describes ZPGM catalyst material compositions having significantly high oxygen storage capacity for a plurality of TWC applications. The disclosed ZPGM catalyst material compositions include a Cu—Mn spinel deposited on doped Zirconia support oxide. The disclosed ZPGM catalyst material compositions exhibit significant high OSC stability properties after fuel cut aging. The improved thermal stability and OSC properties of the disclosed ZPGM catalyst material compositions are determined by performing a standard isothermal oscillating OSC tests. Fresh and aged ZPGM catalyst material compositions are employed within the standard isothermal oscillating OSC test, over multiple reducing/oxidizing cycles at a temperature of about 575° C.

Abstract: Zero-PGM (ZPGM) catalyst materials including pseudo-brookite compositions for use in diesel oxidation catalyst (DOC) applications are disclosed. The disclosed doped pseudo-brookite compositions include A-site partially doped pseudo-brookite compositions, such as, Sr-doped and Ce-doped pseudo-brookite compositions, as well as B-site partially doped pseudo-brookite compositions, such as, Fe-doped, Co-doped, Ni-doped, and Ti-doped pseudo-brookite compositions. The disclosed doped pseudo-brookite compositions, including calcination at various temperatures, are subjected to a DOC standard light-off (LO) test methodology to assess/verify catalyst activity as well as to determine the effect of the use of a dopant in an A-site cation or a B-site cation within a pseudo-brookite composition.

Abstract: Sulfur-resistant synergized platinum group metals (SPGM) catalysts with significant oxidation capabilities are disclosed. Catalytic layers of SPGM catalyst samples are produced using conventional synthesis techniques to build a washcoat layer completely or substantially free of PGM material. The SPGM catalyst includes a washcoat layer comprising YMnO3 perovskite and an overcoat layer including a Pt composition deposited on a plurality of support oxides with total PGM loading of about 5 g/ft3. Resistance to sulfur poisoning and catalytic stability is observed under 1.3 gS/L condition to assess the influence that selected support oxides have on the DOC performance of the SPGM catalysts. The results indicate SPGM catalysts produced to include a layer of low amount of PGM catalyst material deposited on a plurality of support oxides added to a layer of ZPGM catalyst material are capable of providing significant improvements in sulfur resistance of SPGM catalyst 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 present disclosure describes zoned three way catalyst (TWC) systems including Rhodium-iron overcoat layers and Nb—Zr—Al Oxide overcoat layers. Disclosed herein are TWC sample systems that are configured to include a substrate and one or more of a washcoat layer, an impregnation layer, and/or an overcoat layer. In catalyst systems disclosed herein, closed-coupled catalysts include a first catalyst zone with an overcoat layer formed using a slurry that includes an oxide mixture and an Oxygen Storage Material (OSM). In catalyst systems disclosed herein, oxide mixtures include niobium oxide (Nb2O5), zirconia, and alumina. Further, catalyst systems disclosed herein include a second catalyst zone with an overcoat layer formed to include a rhodium-iron catalyst. Yet further, catalyst systems disclosed herein include impregnation layers that include one or more of Palladium, Barium, Cerium, Neodymium, and Rhodium.

Abstract: Synergized Platinum Group Metals (SPGM) catalyst system for TWC application is disclosed. Disclosed SPGM catalyst system may include a washcoat that includes stoichiometric Cu—Mn spinel structure, supported on doped ZrO2, and an overcoat that includes PGM, such as platinum (Pt) supported on carrier material oxides, such as alumina. SPGM catalyst system shows significant improvement in nitrogen oxide reduction performance under lean and also rich operating conditions. Additionally, disclosed SPGM catalyst system exhibits enhanced catalytic activity for carbon monoxide conversion. Furthermore, disclosed SPGM catalyst systems are found to have enhanced catalytic activity compared to PGM catalyst system, showing that there is a synergistic effect between PGM catalyst, such as Pt, and Cu—Mn spinel within disclosed SPGM catalyst system, which help in activity and thermal stability of disclosed SPGM catalyst.

Abstract: The present disclosure refers to a plurality of process employed for optimization of Zero-PGM washcoat and overcoat loadings on metallic substrates. According to an embodiment a substantial increase in conversion of HC and CO may be achieved by optimizing the total washcoat and overcoat loadings of the catalyst. According to another embodiment, the present disclosure may provide solutions to determine the optimum total washcoat and overcoat loadings for minimizing washcoat adhesion loss. As a result, may increase the conversion of HC and CO from discharge of exhaust gases from internal combustion engines, optimizing performance of Zero-PGM catalyst systems.