Abstract: Catalyst systems that are resistant to high-temperature sintering and methods for preparing such catalyst systems that are resistant to sintering at high temperatures are provided. Methods of forming such catalyst systems include contacting a support having a surface including a catalyst particle with a solution comprising a metal salt and having an acidic pH. The metal salt is precipitated onto the surface of the support. Next, the metal salt is calcined to selectively generate a porous coating of metal oxide on the surface of the support distributed around the catalyst particle.

Abstract: Bimetallic oxidation catalyst devices include a support body, one or more metal A bulk deposits disposed on the support body, and a plurality of metal B atomic clusters disposed on the surface of each of the metal A bulk deposits. Metal A and metal B are different metals each selected from the group consisting of platinum group metals (PGM), Ag, Au, Ni, Co, and Cu, and substantially no metal B is deposited on the support body. At least 85% by weight of the metal B atomic clusters comprise up to 10 atoms and the maximum metal B atomic cluster size is 200 metal B atoms. The combined loading of metal A and metal B can be less than 1.5% by weight relative to the weight of the support body. Metal A can include Pd, Rh, Rh, or Pd, and metal B can include Pt, Pt, Ag, or Ag.

Abstract: Methods of preparing a sinter-resistant catalyst include forming a dual coating system. A surface of a particulate catalyst support contacts a first liquid precursor including a metal salt with an element selected from the group consisting of: aluminum (Al), cerium (Ce), zirconium (Zr), titanium (Ti), silicon (Si), magnesium (Mg), zinc (Zn), and combinations thereof. The first liquid precursor precipitates or is adsorbed as an ion on a portion of the surface forming a first coating including a porous metal oxide on the surface. The surface may be contacted with a second liquid precursor including a metal oxide sol including a metal selected from the group consisting of: aluminum (Al), cerium (Ce), zirconium (Zr), iron (Fe), titanium (Ti), silicon (Si), and combinations thereof. A second coating is formed from the second liquid precursor on a portion of the surface to create the sinter-resistant catalyst system.

Abstract: Catalysts that are resistant to high-temperature sintering and methods for preparing such catalysts that are resistant to sintering at high temperatures are provided. The catalyst may be prepared by contacting a solution comprising an ionic species with one or more charged surface regions of a catalyst support. A surface of the catalyst support further includes one or more catalyst particles disposed adjacent to the one or more charged surface regions. The ionic species has a first charge opposite to a second charge of the one or more charged surface regions. Next, the ionic species is associated with the one or more charged surface regions to form a layer on the one or more select surface regions. The layer is calcined to generate a coating comprising metal oxide on the one or more select surface regions, where the coating is formed adjacent to the one or more catalyst particles.

Abstract: Catalyst systems that are resistant to high-temperature sintering and methods for preparing such catalyst systems that are resistant to sintering at high temperatures are provided. Methods of forming such catalyst systems include contacting a support having a surface including a catalyst particle with a solution comprising a metal salt and having an acidic pH. The metal salt is precipitated onto the surface of the support. Next, the metal salt is calcined to selectively generate a porous coating of metal oxide on the surface of the support distributed around the catalyst particle.

Abstract: Bimetallic oxidation catalyst devices include a support body, one or more metal A bulk deposits disposed on the support body, and a plurality of metal B atomic clusters disposed on the surface of each of the metal A bulk deposits. Metal A and metal B are different metals each selected from the group consisting of platinum group metals (PGM), Ag, Au, Ni, Co, and Cu, and substantially no metal B is deposited on the support body. At least 85% by weight of the metal B atomic clusters comprise up to 10 atoms and the maximum metal B atomic cluster size is 200 metal B atoms. The combined loading of metal A and metal B can be less than 1.5% by weight relative to the weight of the support body. Metal A can include Pd, Rh, Rh, or Pd, and metal B can include Pt, Pt, Ag, or Ag.

Abstract: Catalyst systems that are resistant to high-temperature sintering and methods for preparing such catalyst systems that are resistant to sintering at high temperatures are provided. Methods of forming such catalyst systems include contacting a support having a surface including a catalyst particle with a solution comprising a metal salt and having an acidic pH. The metal salt is precipitated onto the surface of the support. Next, the metal salt is calcined to selectively generate a porous coating of metal oxide on the surface of the support distributed around the catalyst particle.

Abstract: A catalytic converter includes a catalyst. The catalyst includes a non-modified metal oxide support and platinum group metal (PGM) complexes atomically dispersed on the non-modified metal oxide support. The PGM complexes include a PGM species selected from the group consisting of an atom of a platinum group metal, a cluster including from 2 atoms to less than 10 atoms of the platinum group metal, and combinations thereof. An alkali metal or an alkaline earth metal is bonded to the PGM species. The alkali or alkaline earth metal is part of a structure including oxygen atoms and hydrogen atoms.

Abstract: A method of stabilizing a catalyst system includes hydrothermally treating an aluminum oxide catalyst support having ?about 95 volume % of ?-Al2O3 phase by heating to a temperature of about 800° C. to about 1,200° C. in the presence of water. A majority of the ?-Al2O3 is converted to a stable alumina phase selected from the group consisting of: ?-Al2O3, ?-Al2O3, and combinations thereof to form a stabilized porous aluminum oxide support having an average surface area of ?about 50 m2/g to ?about 150 m2/g. A platinum group metal is then bound to a surface of the stable porous aluminum oxide support to form the stabilized catalyst systems.

Abstract: Methods of preparing a sinter-resistant catalyst include forming a dual coating system. A surface of a particulate catalyst support contacts a first liquid precursor including a metal salt with an element selected from the group consisting of: aluminum (Al), cerium (Ce), zirconium (Zr), titanium (Ti), silicon (Si), magnesium (Mg), zinc (Zn), and combinations thereof. The first liquid precursor precipitates or is adsorbed as an ion on a portion of the surface forming a first coating including a porous metal oxide on the surface. The surface may be contacted with a second liquid precursor including a metal oxide sol including a metal selected from the group consisting of: aluminum (Al), cerium (Ce), zirconium (Zr), iron (Fe), titanium (Ti), silicon (Si), and combinations thereof. A second coating is formed from the second liquid precursor on a portion of the surface to create the sinter-resistant catalyst system.

Abstract: A catalytic converter includes a catalyst. The catalyst includes a metal oxide support and platinum group metal (PGM) complexes atomically dispersed on the metal oxide support. The PGM complexes include a PGM species selected from the group consisting of an atom of a platinum group metal, a cluster including from 2 atoms to less than 10 atoms of the platinum group metal, a nanoparticle including 10 or more atoms of the platinum group metal, and combinations thereof. An alkali metal or an alkaline earth metal is bonded to the PGM species. The alkali or alkaline earth metal is part of a structure including oxygen atoms and hydrogen atoms. A barrier is disposed between a first PGM complex and a second PGM complex.

Abstract: Catalysts that are resistant to high-temperature sintering and methods for preparing such catalysts that are resistant to sintering at high temperatures are provided. The catalyst may be prepared by contacting a solution comprising an ionic species with one or more charged surface regions of a catalyst support. A surface of the catalyst support further includes one or more catalyst particles disposed adjacent to the one or more charged surface regions. The ionic species has a first charge opposite to a second charge of the one or more charged surface regions. Next, the ionic species is associated with the one or more charged surface regions to form a layer on the one or more select surface regions. The layer is calcined to generate a coating comprising metal oxide on the one or more select surface regions, where the coating is formed adjacent to the one or more catalyst particles.

Abstract: Catalyst systems that are resistant to high-temperature sintering and methods for preparing such catalyst systems that are resistant to sintering at high temperatures are provided. Methods of forming such catalyst systems include contacting a support having a surface including a catalyst particle with a solution comprising a metal salt and having an acidic pH. The metal salt is precipitated onto the surface of the support. Next, the metal salt is calcined to selectively generate a porous coating of metal oxide on the surface of the support distributed around the catalyst particle.

Abstract: A catalytic converter includes a catalyst. The catalyst includes a non-modified metal oxide support and platinum group metal (PGM) complexes atomically dispersed on the non-modified metal oxide support. The PGM complexes include a PGM species selected from the group consisting of an atom of a platinum group metal, a cluster including from 2 atoms to less than 10 atoms of the platinum group metal, and combinations thereof. An alkali metal or an alkaline earth metal is bonded to the PGM species. The alkali or alkaline earth metal is part of a structure including oxygen atoms and hydrogen atoms.

Abstract: A catalytic converter includes a catalyst. The catalyst includes a metal oxide support and platinum group metal (PGM) complexes atomically dispersed on the metal oxide support. The PGM complexes include a PGM species selected from the group consisting of an atom of a platinum group metal, a cluster including from 2 atoms to less than 10 atoms of the platinum group metal, a nanoparticle including 10 or more atoms of the platinum group metal, and combinations thereof. An alkali metal or an alkaline earth metal is bonded to the PGM species. The alkali or alkaline earth metal is part of a structure including oxygen atoms and hydrogen atoms. A barrier is disposed between a first PGM complex and a second PGM complex.

Abstract: A catalytic converter includes a catalyst. The catalyst includes a support, platinum group metal (PGM) particles dispersed on the support, and metal oxide nanoparticles formed on the support. The metal oxide nanoparticles are dispersed between a first set of the PGM particles and a second set of the PGM particles to suppress aging of the PGM particles.

Abstract: A catalytic converter includes a catalyst. The catalyst includes a support, platinum group metal (PGM) particles dispersed on the support, and metal oxide nanoparticles formed on the support. The metal oxide nanoparticles are dispersed between a first set of the PGM particles and a second set of the PGM particles to suppress aging of the PGM particles.

Abstract: A catalytic converter includes a catalyst. The catalyst includes a support, platinum group metal (PGM) particles dispersed on the support, and a barrier formed on the support. The barrier is disposed between a first set of the PGM particles and a second set of the PGM particles to suppress aging of the PGM particles.

Abstract: Catalysts that are resistant to high-temperature sintering and methods for preparing such catalysts that are resistant to sintering at high temperatures are provided. The catalysts include a metal nanoparticle bound to a metal oxide support, where the metal nanoparticle and support are coated with a porous metal oxide coating layer. The catalyst is prepared by contacting a metal nanoparticle bound to a metal oxide support with a solution of metal salts, drying the solution of metal salts, and calcining the metal salts to generate a porous metal oxide coating on the metal nanoparticle and metal oxide support.

Abstract: A catalytic converter includes a catalyst. The catalyst includes a support, platinum group metal (PGM) particles dispersed on the support, and a barrier formed on the support. The barrier is disposed between a first set of the PGM particles and a second set of the PGM particles to suppress aging of the PGM particles.