System and Methods for using Copper- Manganese- Iron Spinel as Zero PGM Catalyst for TWC Applications

• US 20140271384A1
• Filed: 12/05/2013
• Published: 09/18/2014
• Est. Priority Date: 03/15/2013
• Status: Abandoned Application

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: CDTI
• Inventors: Nazarpoor, Zahra, Golden, Stephen J.
• Application Number:
  US14/098,084
• Publication Number:
  US 20140271384A1
• Time in Patent Office: Days
• US Class Current: 422/168
• CPC Class Codes: B01D 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20738 Iron
• CPC Class Codes: B01D 2255/20761 Copper
• CPC Class Codes: B01D 2255/405 Spinels
• CPC Class Codes: B01D 53/945 characterised by a specific catalyst
• CPC Class Codes: B01J 21/066 Zirconium or hafnium; Oxides or hydroxides thereof
• CPC Class Codes: B01J 23/005 Spinels
• CPC Class Codes: B01J 23/8892 Manganese
• CPC Class Codes: B01J 37/038 to form slurries or suspensions, e.g. a washcoat
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

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.

Claims

1. A catalyst component, comprising:

at least one oxygen storage material having a general formula of Cu_xMn_1-xFe₂O₄.

2. The catalyst component of claim 1, wherein the catalyst component is substantially free of rare earth metals.

3. The catalyst component of claim 1, wherein the at least one oxygen storage material is spinel form.

4. The catalyst component of claim 1, further comprising at least one support oxide.

5. The catalyst component of claim 4, wherein the at least one support oxide comprises ZrO₂.

6. The catalyst component of claim 4, wherein the at least one support oxide comprises Nb₂O₅—

ZrO₂.

7. The catalyst component of claim 1, wherein the at least one oxygen storage material is stable at temperatures greater than 600°

C.

8. The catalyst component of claim 1, wherein the at least one oxygen storage material is stable at temperatures less than 900°

C.

9. The catalyst component of claim 1, wherein x is 0.5.

10. The catalyst component of claim 1, wherein NO conversion is about 78%.

11. The catalyst component of claim 1, wherein the at least one oxygen storage material is non-stoichiometric.

12. The catalyst component of claim 1, wherein the at least one oxygen storage material is non-stoichiometric.

20. The catalyst system of claim 1, wherein rein the at least one oxygen storage material is stable at about 900°

C.

21. The catalyst system of claim 1, wherein the at least one oxygen storage material is stable at about 800°

C.

13. A catalyst system, comprising:

at least one substrate;

at least one first coating applied to the at least one substrate comprising at least one oxygen storage material; and

wherein the at least one oxygen storage material comprises Cu—

Fe—

Mn spinel having a niobium-zirconia support oxide; and

wherein the Cu—

Fe—

Mn spinel has a general formula of Cu_xMn_1-xFe₂O₄, wherein the Cu molar ratio is from about x=0.5 to about x=1.0.

14. The catalyst system of claim 13, further comprising at least one second coating comprising Al₂O₃.

15. The catalyst system of claim 13, wherein the at least one first coating is substantially free of platinum group metals.

16. The catalyst system of claim 13, wherein the at least one first coating is substantially free of rare earth metals.

17. The catalyst system of claim 13, wherein the at least one first coating is a washcoat.

18. The catalyst system of claim 13, wherein the T50 of NO is less than 400°

C.

19. The catalyst system of claim 13, wherein the T50 of CO is 200°

C.