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: 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: Solutions to the problem of washcoat and/or overcoat adhesion loss of ZPGM catalyst on metallic substrates are disclosed. Present disclosure provides an enhanced process for improving WCA to metallic substrates of ZPGM catalyst systems. Reduction of WCA loss and improved catalyst activity may be enabled by the selection of processing parameters determined from variation of rheological properties by the solid content of the overcoat slurry and variation of the overcoat slurry particle size distribution to produce desirable homogeneity, specific loading, and adherence of the coating on metallic substrates. Processing parameters may be applied to a plurality of metallic substrates of different geometries and cell densities.

Abstract: The present disclosure refers to processes and formulations employed for optimization of variations of Zero-PGM catalyst coated on metallic substrates. Deposition of a uniform and well-adhered layer of catalyst on the metallic substrate may be enabled by the selection of a washcoat loading resulting from variation of metal loadings. Characterization of catalysts may be performed using a plurality of catalytic tests, including but not limited to washcoating adherence test, back pressure test, inspection of textural characteristics, and catalyst activity. Optimized variations may be applied to a plurality of metallic substrates for achieving coating uniformity, desired level of WCA loss, and optimized performance of catalyst activity.

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.

Abstract: Solutions to the problem of washcoat and/or overcoat adhesion loss of ZPGM catalyst on metallic substrates are disclosed. Present disclosure provides a novel process for improving WCA to metallic substrates of ZPGM catalyst systems. Reduction of WCA loss and improved catalyst activity may be enabled by the selection of processing parameters determined from variations of pH and addition of binder to overcoat slurry, and particle size of washcoat. Processing parameters may be applied to a plurality of metallic substrates of different geometries and cell densities.

Abstract: Present disclosure provides a novel process for optimization of Zero-PGM catalyst systems using metallic substrate. Deposition of a homogeneous and well-adhered layer of catalyst on the metallic substrate may be enabled by the selection of a washcoat loading resulting from variation of metal loadings. Characterization of catalysts may be performed using a plurality of catalytic tests, including but not limited to washcoating adherence test, back pressure test, inspection of textural characteristics, and catalyst activity. Optimization may be applied to a plurality of metallic substrates of different geometries and cell densities.

Abstract: The present disclosure provides an identification process which may employ various identification techniques on Zero platinum group metal (ZPGM) catalyst systems, in order to identify responsible materials for the formation of corrosion material, such as hexavalent chromium compounds. Identification analysis, such as X-ray diffraction analysis (XRD), X-ray fluorescence (XRF), and X-ray Photoelectron Spectroscopy (XPS) may be performed on various thermally treated ZPGM catalyst systems, such as in bare substrate, substrate with one type of ZPGM in washcoat, a substrate with one type of ZPGM in overcoat and substrate combination of ZPGM metals in both washcoat and overcoat. Results of identification analysis may show that regardless of metal catalyst (for example Ag, Cu, Ce), hexavalent chromium (Cr6+) may be formed on aged catalysts systems, which may be due to the high concentration of chromium in substrate.

Abstract: The present disclosure refers to a plurality of process employed for optimization of Zero-PGM metal loading in Washcoat and Overcoat on metallic substrates. According to an embodiment a substantial increase in conversion of HC and CO may be achieved by optimizing the metal loading of the catalyst. According to another embodiment, the present disclosure may provide solutions to determine the optimum metal loading in washcoat 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.

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: Diesel oxidation ZPGM catalyst systems using Y1-x AgxMnO3 perovskite are disclosed. The ZPGM catalyst system compositions may include Y1-x AgxMnO3perovskite in impregnation component and at least one carrier material oxide in washcoat. The ZPGM catalyst system compositions may also include Y1-x AgxMnO3 perovskite co-precipitated in a carrier material oxide as washcoat. The catalyst activity is measured with an inlet gas mixture containing diesel exhaust composition and characterized according to performance in NO oxidation, NO2 production, NO storage capability and diesel oxidation applications.

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.

Abstract: Disclosed here are material formulations of use in the conversion of exhaust gases. A catalyst is formed by using a perovskite structure having the general formula ABO3 or a mullite structure having the general formula of AB2O5 where components “A” and “B” may be any suitable non-platinum group metals. Suitable materials may include Yttrium, Lanthanum, Silver, Manganese and formulations thereof.

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: Diesel oxidation ZPGM catalyst systems are disclosed. ZPGM catalyst systems may oxidize toxic gases, such as carbon monoxide, hydrocarbons and nitrogen oxides that may be included in exhaust gases. ZPGM catalyst systems may include: a substrate, a washcoat, and an impregnation layer. The washcoat may include at least one carrier material oxides. The impregnation layer may include at least one ZPGM catalyst, carrier material oxides and OSMs. 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 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 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: Oxidation ZPGM catalyst systems and three way ZPGM catalyst systems are disclosed. ZPGM catalyst systems may oxidize toxic gases, such as carbon monoxide and hydrocarbons, optionally some ZPGM catalyst systems may as well reduce nitrogen oxides that may be included in exhaust gases. ZPGM catalyst systems may include: a substrate, a washcoat, and an overcoat. The washcoat may include at least one ZPGM catalyst and carrier material oxides. Similarly, overcoat may include at least one ZPGM catalyst, carrier material oxides and OSMs. 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 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: 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.