Thermally Stable Compositions of OSM Free of Rare Earth Metals

• US 20150105246A1
• Filed: 07/17/2014
• Published: 04/16/2015
• Est. Priority Date: 10/16/2013
• Status: Active Grant

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: Clean Diesel Technologies, Inc.
• Inventors: Nazarpoor, Zahra, Golden, Stephen J.
• Granted Patent: US 9,486,784 B2
• Time in Patent Office: Days
• US Class Current: 502/324
• 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 2255/40 Mixed oxides
• CPC Class Codes: B01D 2255/405 Spinels
• CPC Class Codes: B01D 2255/908 O2-storage component incorporated in the catalyst
• CPC Class Codes: B01D 53/945 characterised by a specific catalyst
• CPC Class Codes: B01J 23/005 Spinels
• CPC Class Codes: B01J 23/20 Vanadium, niobium or tantalum
• CPC Class Codes: B01J 23/8892 Manganese
• CPC Class Codes: B01J 35/30 characterised by their physical properties
• CPC Class Codes: B01J 37/035 Precipitation on carriers
• CPC Class Codes: C01G 45/1242 of the type [Mn2O4]-, e.g. LiMn2O4, Li[MxMn2-x]O4
• CPC Class Codes: C01P 2006/90 Other properties not specified above
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

The effect of aging temperature on oxygen storage materials (OSM) substantially free from platinum group (PGM) and rare earth (RE) metals is disclosed. Samples of ZPGM-ZRE metals OSM, hydrothermally aged at a plurality of high temperatures are found to have significantly high oxygen storage capacity (OSC) and phase stability than conventional PGM catalysts with Ce-based OSM. ZPGM-ZRE metals OSM includes a formulation of Cu—Mn stoichiometric spinel structure deposited on Nb—Zr oxide support and may be converted into powder to be used as OSM application or coated onto catalyst substrate. ZPGM-ZRE metals OSM, after aging condition, presents enhanced level of thermal stability and OSC property which shows improved catalytic activity than conventional PGM catalysts including Ce-based OSM. ZPGM-ZRE metals OSM may be suitable for a vast number of applications, and more particularly in underfloor catalyst systems.

Claims

1. A catalytic composition, comprising:

an oxygen storage material, comprising Cu—

Mn spinel.

2. The catalytic composition of claim 1, wherein the oxygen storage material is substantially free of platinum group metals.

3. The catalytic composition of claim 1, wherein the oxygen storage material is substantially free of rare earth metals metals.

4. The catalytic composition of claim 1, wherein the Cu—

Mn spinel has a structure has the formula Cu_1.0Mn_2.0O₄.

5. The catalytic composition of claim 1, wherein the Cu—

Mn spinel comprises about 10 g/L to about 15 g/L of Cu.

6. The catalytic composition of claim 1, wherein the Cu—

Mn structure comprises about 20 g/L to about 25 g/L of Mn.

7. A catalytic composition, comprising:

an oxygen storage material, comprising Cu—

Mn spinel with Niobium-Zirconia support oxide.

8. The catalytic composition of claim 7, wherein the oxygen storage material is substantially free of platinum group metals.

9. The catalytic composition of claim 7, wherein the oxygen storage material is substantially free of rare earth metals metals.

10. The catalytic composition of claim 7, wherein the Cu—

Mn spinel has a structure has the formula Cu_1.0Mn_2.0O₄.

11. The catalytic composition of claim 7, wherein the Niobium-Zirconia support oxide has the formula Nb₂O₅—

ZrO₂.

12. The catalytic composition of claim 7, wherein the Cu—

Mn spinel comprises about 10 g/L to about 15 g/L of Cu.

13. The catalytic composition of claim 7, wherein the Cu—

Mn structure comprises about 20 g/L to about 25 g/L of Mn.

14. The catalytic composition of claim 7, wherein the niobium-zirconia support oxide is present at about 80 g/L to about 90 g/L.