Systems and Methods for Zero-PGM Binary Catalyst Having Cu, Mn, and Fe For TWC Applications

• US 20160082422A1
• Filed: 12/07/2015
• Published: 03/24/2016
• Est. Priority Date: 03/22/2013
• Status: Abandoned Application

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: Clean Diesel Technologies, Inc.
• Inventors: Nazarpoor, Zahra, Golden, Stephen J.
• Application Number:
  US14/960,837
• Publication Number:
  US 20160082422A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B01D 2255/2066 Praseodymium
• CPC Class Codes: B01D 2255/20715 Zirconium
• 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 2255/65 Catalysts not containing noble metals
• CPC Class Codes: B01D 53/945 characterised by a specific catalyst
• CPC Class Codes: B01J 23/005 Spinels
• CPC Class Codes: B01J 23/745 Iron
• CPC Class Codes: B01J 23/8892 Manganese
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y10S 502/52712 Plural layers on a support, each layer having a distinct function

Abstract

Variations of bulk powder catalyst material including Cu—Mn, Cu—Fe, and Fe—Mn spinel systems for ZPGM TWC applications are disclosed. The disclosed bulk powder catalyst samples include stoichiometric and non-stoichiometric Cu—Mn, Cu—Fe, and Fe—Mn spinels on Pr₆O₁₁—ZrO₂ support oxide, prepared using incipient wetness method. Activity measurements under isothermal steady state sweep test condition may be performed under rich to lean condition. Catalytic activity of samples may be compared to analyze the influence that different binary spinel system bulk powders may have on TWC performance of ZPGM materials for a plurality of TWC applications. Stoichiometric Cu—Mn, Cu—Fe, and Fe—Mn spinel systems exhibit higher catalytic activity than non-stoichiometric Cu—Mn, Cu—Fe, and Fe—Mn spinel systems. The influence of prepared Cu—Mn, Cu—Fe, and Fe—Mn spinel systems may lead into cost effective manufacturing solutions for ZPGM TWC systems.

Claims

1. A catalytic system, comprising:

a catalyst having the general formula A_XB_3-XO₄, wherein X may be less than or equal to 1.5 and wherein A and B are selected from the group consisting of Cu, Mn, and Fe; and

wherein the catalyst is substantially free of platinum group metals.

2. The catalytic system of claim 1, wherein the catalyst is in spinel form.

3. The catalytic system of claim 1, wherein the catalyst has the general formula Cu_XMn_3-XO₄ where 1.0≦

X≦

1.5.

4. The catalytic system of claim 1, wherein the catalyst has the general formula Cu_XFe_3-XO₄ where 0.5≦

X≦

1.0.

5. A catalytic system, comprising a catalyst having the general formula A_XB_3-XO₄, wherein A and B are selected from the group consisting of Cu, Mn, and Fe.

6. The catalytic system of claim 5, wherein the catalyst is in spinel form.

7. The catalytic system of claim 5, wherein the catalyst has the general formula Cu_XMn_3-XO₄ where 1.0≦

X≦

1.5.

8. The catalytic system of claim 5, wherein the catalyst has the general formula Cu_XFe_3-XO₄ where 0.5≦

X≦

1.0.