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: 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: 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: 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 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: Process for manufacturing ZPGM catalysts systems that may allow the prevention of formation or the conversion of corrosion causing compounds, such as hexavalent chromium compounds, within ZPGM catalyst systems is disclosed. In one embodiment, disclosed ZPGM catalysts systems, may include metallic substrate, which may include alloys of iron and chromium, a washcoat and an overcoat. Disclosed manufacturing process may include a thermal decomposition of hexavalent chromium compounds which may allow the decomposition of such compounds into trivalent chromium compounds, and may also produce metallic catalyst, such as silver. Such conversion may prevent corrosion formation, such as red color corrosion within ZPGM catalyst system. An embodiment of the disclosed process may include a reducing agent, which may be present in exhaust conditions, which may convert hexavalent chromium compounds into trivalent chromium compounds as well as produce metallic catalyst, such as silver.

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 present disclosure relates to selecting the layer of applying ZPGM active phase in washcoat, or applying ZPGM active phase in overcoat, for achieving optimized performance and enhanced thermal stability. Applying ZPGM active phase catalyst in overcoat shows improvements compare to applying ZPGM active phase in washcoat. The selected active phase material may include a chemical composition that is substantially free from PGM, including a formulation of stoichiometric Cu—Mn spinel structure active phase deposited on Niobium-Zirconium support oxide. The selected active phase layer applied in overcoat may include a washcoat of alumina coated on a suitable ceramic substrate. The disclosed active phase may be applied in overcoat to maximize efficiency of catalyst systems, which may exhibit enhanced catalytic activity properties, which may stable after aging and under steady state and oscillating condition, showing optimized performance purifying gases in TWC condition.

Abstract: The present disclosure relates to selecting support oxide for ZPGM catalyst for optimal performance under TWC condition, for achieving enhanced catalyst activity, and improved thermal stability during aging. The selected active phase material may include a chemical composition that is substantially free from PGM, including a formulation of stoichiometric Cu—Mn spinel structure active phase with Niobium-Zirconium support oxide, which may include a washcoat of pure alumina coated on a suitable ceramic substrate. The disclosed Cu—Mn spinel structure active phase with Niobium-Zirconium support oxide may be applied in overcoat to maximize efficiency of ZPGM catalyst systems, which may exhibit enhanced catalytic activity properties that may increase with temperature, showing optimized performance purifying gases in TWC condition, and enhanced stability during aging.

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: 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: 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: 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: 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: Systems and Methods for manufacturing ZPGM catalysts systems that may allow the prevention of formation or the conversion of corrosion causing compounds, such as hexavalent chromium compounds, within ZPGM catalyst systems are disclosed. ZPGM catalysts systems, may include metallic substrate, which may include alloys of iron and chromium, a washcoat and an overcoat. Disclosed manufacturing processes may include a thermal decomposition of hexavalent chromium compounds which may allow the decomposition of such compounds into trivalent chromium compounds, and may also produce metallic catalyst, such as silver.

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: The present disclosure provides identification techniques on platinum group metal (PGM) and zero platinum group metal (ZPGM) catalyst systems, in order to identify responsible materials for the formation of corrosion products, such as hexavalent chromium compounds. Identification analyses, such as X-ray diffraction analysis (XRD) and X-ray fluorescence (XRF) may be performed on various thermally treated PGM and ZPGM catalyst systems. Results of identification analyses may show that for both PGM and ZPGM catalysts, hexavalent chromium (Cr6+) may be formed during thermal aging at range of 600C to 900C. This may be due to the high concentration of chromium in substrate alloys. Therefore, occurrence of corrosion and production of hexavalent chromium may initiate from elements found in the substrate and not from elements within the PGM and ZPGM catalysts.