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: The effect of firing (calcination) cycle on metallic substrates in ZPGM catalyst systems is disclosed. ZPGM catalyst samples with washcoat and overcoat are separately fired in a normal, slow and fast firing cycles to determine the optimal firing cycling that may provide an enhanced catalyst performance, as well as the minimal loss of washcoat adhesion from the samples.

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: 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 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: The present disclosure refers to variation of compositions for catalytic converters free of platinum group metals, which may be employed to manufacture ZPGM oxidation catalyst systems, to remove main pollutants from exhaust of diesel engines, by oxidizing toxic gases. 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 may be used. Materials suitable for use as ZPGM catalysts include Lanthanum (La), Yttrium (Y), Silver (Ag), Manganese (Mn) and combinations thereof. The disclosed ZPGM DOC systems may include perovskite structures with the characteristic formulation ABO3 or related structures. A plurality of methods may be employed for production of ZPGM diesel oxidation catalyst systems substantially free of PGM, which may include a substrate, a washcoat, and an impregnation layer.

Abstract: A Cu—Mn—Fe spinel on a plurality of support oxides is disclosed as ZPGM catalyst. The active phase for ZPGM samples may be Cu—Mn—Fe spinel on ZrO2 or Niobium-Zirconia support oxide. TWC activity may be increased and the effect of support oxide on performance of Cu—Mn—Fe spinel optimized to provide enhanced levels of NO, CO, and HC conversion even when compared to materials used for binary systems of Cu—Mn spinel. Cu—Mn—Fe spinel on support oxide provides optimal and stable spinel phase at a range of temperatures below 900° C. Bulk powder material including the disclosed ternary system may provide active catalyst for TWC applications having a chemical composition substantially free from PGM for cost effective manufacturing.