System and Method for Optimized Oxygen Storage Capacity and Stability of OSM Without Rare Metals

• US 20140274677A1
• 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
• Application Number:
  US14/097,853
• Publication Number:
  US 20140274677A1
• Time in Patent Office: Days
• US Class Current: 502/324
• CPC Class Codes: B01D 2255/207 Transition metals
• CPC Class Codes: B01D 2255/20715 Zirconium
• CPC Class Codes: B01D 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20761 Copper
• CPC Class Codes: B01D 2255/405 Spinels
• CPC Class Codes: B01D 2255/65 Catalysts not containing noble metals
• CPC Class Codes: B01D 2255/908 O2-storage component incorporated in the catalyst
• CPC Class Codes: B01D 2258/012 Diesel engines and lean burn gasoline engines
• CPC Class Codes: B01D 53/945 characterised by a specific catalyst
• CPC Class Codes: B01J 23/005 Spinels
• CPC Class Codes: B01J 23/8892 Manganese
• CPC Class Codes: B01J 2523/00 Constitutive chemical elements of heterogeneous catalysts
• CPC Class Codes: B01J 2523/17 Copper
• CPC Class Codes: B01J 2523/48 Zirconium
• CPC Class Codes: B01J 2523/56 Niobium
• CPC Class Codes: B01J 2523/72 Manganese
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

It is an object of the present disclosure, to provide an oxygen storage material which may include optimum composition and structure of Cu—Mn spinel as OSM, with a suitable doped zirconia, including Niobium-Zirconia support oxide for OSM applications, which may include a chemical composition substantially free from rare metals. The OSC properties of Cu—Mn spinel with a suitable doped zirconia, including Niobium-Zirconia support oxide as OSM may be determined by comparing variations of Cu—Mn composition for determination of the optimum structure of spinel to achieve optimal OSC properties and thermal stability, which may be particularly useful for treating exhaust gases produced by internal combustion engines, where lean/rich fluctuations in operating conditions may produce high variation in exhaust contaminants that may be removed, achieving optimal OSC property of spinel at different temperatures, as well as thermal stability behavior of OSM.

Claims

1. A catalyst component, comprising:

at least one oxygen storage material having a general formula of Cu_xMn_3-xO₄.

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 niobium-zirconia.

6. The catalyst component of claim 1, wherein the at least one oxygen storage material is aged at about 900°

C.

7. The catalyst component of claim 1, wherein the at least one oxygen storage material is aged at about 1000°

C.

8. The catalyst component of claim 1, wherein x is selected from the group consisting of 1 and 0.75.

9. The catalyst component of claim 1, wherein CO conversion that occurs under isothermal oscillating conditions.

10. The catalyst component of claim 1, wherein the O₂ delay time is greater than 40 seconds.

11. The catalyst component of claim 1, wherein the O₂ delay time is greater than 10 seconds.

12. The catalyst component of claim 1, wherein the CO delay time is greater than 40 seconds.

13. The catalyst component of claim 1, wherein the CO delay time is greater than 10 seconds.

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

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

16. A catalyst system, comprising:

a substrate;

an overcoat comprising at least one oxygen storage material substantially free of rare earth metals; and

wherein the at least one oxygen storage material comprises Cu—

Mn spinel having a niobium-zirconia support oxide; and

wherein the Cu—

Mn spinel has the general formula Cu_0.75Mn_2.25O₄.

17. The catalysts system of claim 16, wherein the at least one oxygen storage material is aged at about 900°

C.

18. The catalysts system of claim 16, wherein the at least one oxygen storage material is aged at about 1000°

C.

19. The catalysts system of claim 16, wherein CO conversion that occurs under isothermal oscillating conditions.

20. The catalysts system of claim 16, wherein the O₂ delay time is greater than 40 seconds.

21. The catalysts system of claim 16, wherein the O₂ delay time is greater than 10 seconds.

22. The catalysts system of claim 16, wherein the CO delay time is greater than 40 seconds.

23. The catalysts system of claim 16, wherein the CO delay time is greater than 10 seconds.