Abstract: Sulfur-resistant SPGM catalysts with significant oxidation capabilities are disclosed. Catalytic layers of SPGM samples may be prepared using incipient wetness and metallizing techniques to structure a washcoat layer of ZPGM material of YMnO3 perovskite , and an overcoat layer including Pt/Pd composition on alumina-silica support oxide. Loading of PGM in OC layer is less than 5 g/ft3. A testing methodology for samples may be enabled including of DOC light-off, and soaking under isothermal DOC and sulfated DOC conditions to assess synergistic influence of adding ZPGM to PGM catalyst samples. Resistance to sulfur and catalytic stability may be observed under 5.2 gS/L condition to assess significant improvements in NO oxidation, HC conversion, and CO selectivity. Resistance to sulfur of disclosed SPGM catalyst may be compared with performance of an equivalent PGM control catalyst for DOC applications.

Abstract: Bimetallic Synergized Platinum Group Metals (SPGM) catalyst systems for TWC application are disclosed. Disclosed bimetallic SPGM catalyst systems may include a washcoat with a Cu—Mn spinel structure and an overcoat that includes PGMs, such as Pd/Rh or Pt/Rh supported on carrier material oxides, such as alumina. Bimetallic SPGM catalyst systems show significant improvement in nitrogen oxide reduction performance under lean operating conditions, which allows a reduced consumption of fuel. Additionally, disclosed bimetallic SPGM catalyst systems exhibit enhanced catalytic activity for carbon monoxide conversion. Furthermore, bimetallic SPGM catalyst systems are found to have enhanced catalytic activity for fresh, hydrothermally aged and fuel cut 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 performance and thermal stability of disclosed SPGM catalyst systems.

Abstract: Sulfur-resistant SPGM catalysts with significant oxidation capabilities are disclosed. A plurality of catalyst samples may be prepared including ZPGM material compositions of YMnO3 perovskite supported on doped Zirconia and cordierite substrate, and front zoned with Pd and Pt/Pd compositions. Incipient wetness and metallizing techniques may be used for the catalytic layers. Testing of samples may be performed under standard and sulfated DOC conditions to assess influence of adding PGM to ZPGM catalyst samples. Levels of NO oxidation and HC oxidation may be compared. Resistance to sulfur and catalytic stability may be observed under long-term sulfated DOC condition to determine SPGM catalyst samples for DOC applications which may provide the most significant improvements in NO oxidation, HC conversion, CO selectivity, and long-term resistance to sulfur.

Abstract: Variations of ZPGM bulk powder catalyst materials, including Cu—Co—Mn ternary spinel systems for TWC applications are disclosed. Bulk powder catalyst samples are prepared employing a plurality of molar ratio variations, including disclosed Cu—Co—Mn spinel on Praseodymium-Zirconia support oxide made by incipient wetness method, or Cu—Co—Mn spinel on Niobium-Zirconia support oxide, which may be synthesized by co-precipitation method. A plurality of bulk powder catalyst samples may be tested by performing isothermal steady state sweep test, employing a flow reactor at inlet temperature of about 450° C., and testing a gas stream from lean to rich condition and influence on TWC performance measured/analyzed, which may lead into significant improvements in the manufacturing of ZPGM bulk powder catalyst materials for TWC applications.

Abstract: Effect of the type of material composition employed within overcoat in conjunction with ZPGM composition in impregnation layer on thermal stability and TWC performance of ZPGM catalyst systems is disclosed. Effect of aging temperature on thermal stability of disclosed ZPGM catalyst systems is also described. Testing of ZPGM catalyst samples including isothermal steady state sweep test condition and isothermal oscillating TWC test on disclosed ZPGM catalyst systems show that ZPGM catalyst system that includes combination of Cu1Mn2O4 spinel and YMnO3 perovskite exhibit higher level of thermal stability at temperature higher than temperatures registered for under floor application of TWC.

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: Sulfur tolerant oxidation catalysts with significant oxidation capabilities are disclosed. A plurality of catalyst samples may be prepared including ZPGM material compositions of YMnO3 perovskite, CuxMn3-xO4 spinel, and a combination of both, supported on doped Zirconia and cordierite substrate, and front zoned with sulfur getters of Pd, Ba acetate, and Ce nitrate. Testing of samples may be performed under standard and sulfated DOC conditions to assess influence of adding front zoned sulfur getters to ZPGM catalyst samples. Levels of NO oxidation and HC conversion may be compared, and resistance to sulfur and catalytic stability may be observed to determine ZPGM samples zoned with sulfur getter which may provide the most significant improvements in NO oxidation, HC conversion, CO selectivity, and resistance to sulfur for use in DOC applications.

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: 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: YMn2O5 pseudo-brookite compositions with improved thermal stability and catalytic activity as Zero-PGM (ZPGM) catalyst systems for DOC application are disclosed. Testing of YMn2O5 pseudo-brookite catalysts and YMnO3 perovskite catalysts, including variations of calcination temperatures, are performed under DOC light-off (LO) tests at wide range of space velocity to evaluate catalytic performance, especially level of NO oxidation. The presence of YMn2O5 pseudo-brookite oxides in disclosed ZPGM catalyst compositions is analyzed by x-ray diffraction (XRD) analysis. XRD analyses and LO tests confirm that YMn2O5 pseudo-brookite catalysts exhibit higher catalytic activity and significant improved thermal stability when compared to conventional YMnO3 perovskite catalysts.

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: 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: 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: 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: 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: 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: Variations of metal oxide materials used as support oxide for Cu—Mn spinel powder for ZPGM TWC applications are disclosed. Bulk powder catalyst samples of Cu—Mn spinel structure on MgAl2O4, Al2O3-9% BaO, Al2O3—SrO, Al2O3—CeO, CeO2—ZrO2 support oxides and among others are prepared using incipient wetness method. BET-surface area analysis is performed for selected support oxides before and after deposition of Cu—Mn spinel to analyze thermal stability. XRD analysis is performed for bulk powder catalyst samples to investigate Cu—Mn spinel phase formation, and phase stability for a plurality of temperatures to about 1000° C. Activity measurements under isothermal steady state sweep test condition may be performed under rich condition to lean condition for different aging temperature at about 800° C. and about 1000° C.

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: A diesel oxidation catalyst (DOC) system for the treatment of exhaust gas emissions, including oxidation of nitrogen oxides (NO), unburned hydrocarbons (HC), and carbon monoxide (CO) is disclosed. Fresh and hydrothermally aged Zero-PGM (ZPGM) DOC samples are prepared and configured with an alumina-based washcoat on ceramic substrate, overcoat including doped Zirconia support oxide, and impregnation layer of Cu—Mn spinel of selected base metal loadings. Testing of fresh and hydrothermally aged ZPGM DOC system samples including Cu—Mn spinel is developed to evaluate the performance of Cu—Mn spinel active phase in oxidation CO, HC, and NO, as well as production of NO2. Key to improvement in light-off performance and NO oxidation is to have a diesel oxidation catalyst that is substantially PGM-free and available for a plurality of applications in lean burn engine operations.

Abstract: Synergized platinum group metals (SPGM) oxidation catalyst systems are disclosed. Disclosed SPGM oxidation catalyst systems may include a washcoat with a Cu—Mn spinel structure and an overcoat including PGM, such as palladium (Pd), platinum (Pt), rhodium (Rh), or combinations thereof, supported on carrier material oxides. SPGM systems show significant improvement in abatement of unburned hydrocarbons (HC) and carbon monoxide (CO), and the oxidation of NO to NO2, which allows reduction of fuel consumption. Disclosed SPGM oxidation catalyst systems exhibit enhanced catalytic activity compared to PGM oxidation systems, showing that there is a synergistic effect between PGM and Cu—Mn spinel composition within the disclosed SPGM oxidation catalyst systems. Disclosed SPGM oxidation catalyst systems may be available for a plurality of DOC applications.