Influence of Type of Support Oxide on Stability of Copper-Manganese Zero-PGM Catalyst

• US 20150352529A1
• Filed: 06/05/2014
• Published: 12/10/2015
• Est. Priority Date: 06/05/2014
• Status: Abandoned Application

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: Clean Diesel Technologies, Inc.
• Inventors: Nazarpoor, Zahra, Golden, Stephen
• Application Number:
  US14/297,358
• Publication Number:
  US 20150352529A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B01D 2255/204 Alkaline earth metals
• CPC Class Codes: B01D 2255/2047 Magnesium
• CPC Class Codes: B01D 2255/2063 Lanthanum
• CPC Class Codes: B01D 2255/2065 Cerium
• CPC Class Codes: B01D 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20761 Copper
• CPC Class Codes: B01D 2255/2092 Aluminium
• CPC Class Codes: B01D 2255/30 Silica
• CPC Class Codes: B01D 2255/405 Spinels
• CPC Class Codes: B01D 2255/65 Catalysts not containing noble metals
• CPC Class Codes: B01D 2255/9207 Specific surface
• 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 2523/22 Magnesium
• CPC Class Codes: B01J 2523/24 Strontium
• CPC Class Codes: B01J 2523/25 Barium
• CPC Class Codes: B01J 2523/31 Aluminium
• CPC Class Codes: B01J 2523/3706 : Lanthanum
• CPC Class Codes: B01J 2523/3712 : Cerium
• CPC Class Codes: B01J 2523/41 : Silicon
• CPC Class Codes: B01J 2523/72 : Manganese
• CPC Class Codes: B01J 35/30 : characterised by their physical properties
• CPC Class Codes: B01J 35/612 : less than 10 m2/g
• CPC Class Codes: B01J 35/613 : 10-100 m2/g
• CPC Class Codes: B01J 37/0201 : Impregnation
• CPC Class Codes: B01J 37/0248 : Coatings comprising impregnated particles
• CPC Class Codes: B01J 37/08 : Heat treatment B01J37/0009, B01J37/0018 take precedence
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

Variations of metal oxide materials used as support oxide for Cu—Mn spinel powder for ZPGM TWC applications are disclosed. Bulk powder catalyst samples of Cu—Mn spinel structure on MgAl₂O₄, Al₂O₃-9% BaO, Al₂O₃—SrO, Al₂O₃—CeO, CeO₂—ZrO₂ support oxides and among others are prepared using incipient wetness method. BET-surface area analysis is performed for selected support oxides before and after deposition of Cu—Mn spinel to analyze thermal stability. XRD analysis is performed for bulk powder catalyst samples to investigate Cu—Mn spinel phase formation, and phase stability for a plurality of temperatures to about 1000° C. Activity measurements under isothermal steady state sweep test condition may be performed under rich condition to lean condition for different aging temperature at about 800° C. and about 1000° C. Catalytic activity of samples may be compared to analyze the influence that selected support oxides may have on thermal stability and TWC performance of ZPGM materials for a plurality of TWC applications.

Claims

1. A zero platinum group metal (ZPGM) material composition comprising a copper-manganese (Cu—

Mn) spinel structure on a plurality of support oxides.

2. The ZPGM material composition of claim 1, wherein the Cu—

Mn structure is of the formula CuxMn3-xO4, where X is about 0.02 to about 1.5.

3. The ZPGM material composition of claim 2, wherein the formula is CuMn2O4.

4. The ZPGM material composition of claim 1, wherein the support structure is selected from the group consisting of MgAl2O4, Al2O3-BaO, Al2O3-La2O3, ZrO2-CeO2-Nd2O3-Y2O3, CeO2-ZrO2, CeO2, SiO2, ZrO2-Y2O3-SiO2, Al2O3-CeO2, Al2O3-SrO, TiO2-10% ZrO2, TiO2-10% Nb2O5, SnO2-TiO2, ZrO2-SnO2- TiO2, BaZrO3, BaTiO3, BaCeO3, ZrO2-P6O11, ZrO2-Y2O3, ZrO2-Nb2O5, and combinations thereof.

5. The ZPGM material composition of claim 4, wherein the Al2O3-SrO is Al2O3-5% SrO or Al2O3-15% SrO.

6. The ZPGM material composition of claim 1, wherein the support structure is Al2O3-5% SrO.

7. The ZPGM material composition of claim 4, wherein the Al2O3-BaO is Al2O3-9% BaO.

8. The ZPGM material composition of claim 4, wherein the Al2O3-CeO2 is Al2O3-8% CeO2.

9. The ZPGM material composition of claim 1, wherein the support structure is an alumino silicate.

10. The ZPGM material composition of claim 1, wherein the composition is a bulk powder.

11. The ZPGM material composition of claim 10, wherein the bulk powder is a fine grain bulk powder.

12. The ZPGM material composition of claim 1, wherein the Cu—

Mn spinel structure is calcined material of Cu—

Mn binary spinel structure.

13. The ZPGM material composition of claim 1, wherein the support oxides have a surface area of about 80 to about 200 m2/g after aging.

15. A ZPMG catalyst comprising ZPGM material composition of claim 1.

16. The ZPMG catalyst of claim 15, wherein the catalyst is a three-way catalyst.

14. A zero platinum group metal (ZPGM) material composition comprising a CuMn2O4 spinel structure on a plurality of Al2O3-SrO support oxides.

17. A method of producing a zero platinum group metal (ZPGM) material composition comprising ageing the material at a temperature of about 1000°

C., wherein the ZPGM material composition comprises a copper-manganese (Cu—

Mn) spinel structure on a plurality of support oxides.

18. The method of claim 17, wherein the ageing is about 5 hours.

19. The method of claim 17, wherein the support structure is selected from the group consisting of MgAl2O4, Al2O3-BaO, Al2O3-La2O3, ZrO2-CeO2-Nd2O3-Y2O3, CeO2-ZrO2, CeO2, SiO2, ZrO2-Y2O3- SiO2, Al2O3-CeO2, Al2O3-SrO, TiO2-10% ZrO2, TiO2-10% Nb2O5, SnO2-TiO2, ZrO2-SnO2-TiO2, BaZrO3, BaTiO3, BaCeO3, ZrO2-P6O11, ZrO2-Y2O3, ZrO2-Nb2O5, and combinations thereof.

20. The method of claim 17, wherein the support oxides have a surface area of about 80 to about 200 m2/g after aging.