ZPGM Catalyst Including Co-Mn-Fe and Cu-Mn-Fe Materials for TWC Applications

• US 20160167023A1
• Filed: 12/11/2014
• Published: 06/16/2016
• Est. Priority Date: 12/11/2014
• Status: Abandoned Application

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: Clean Diesel Technologies, Inc.
• Inventors: Yaglidere, Oguzhan S., Nazarpoor, Zahra, Golden, Stephen J.
• Application Number:
  US14/567,836
• Publication Number:
  US 20160167023A1
• 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 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20738 Iron
• CPC Class Codes: B01D 2255/20746 Cobalt
• 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 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 2523/3718 Praseodymium
• CPC Class Codes: B01J 2523/48 Zirconium
• CPC Class Codes: B01J 2523/72 Manganese
• CPC Class Codes: B01J 2523/842 Iron
• CPC Class Codes: B01J 2523/845 Cobalt
• CPC Class Codes: B01J 37/0201 Impregnation
• 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 bulk powder catalyst materials, including a plurality of formulations for stoichiometric and non-stoichiometric Co_Mn—Fe spinel and Cu—Mn—Fe spinel, which may be prepared by incipient wetness method, employing variations of molar ratio and general formulation (Co_xFe_zMn_2z)_3-δO₄, and Co_1-xMn_xFe₂O₄ spinel supported on doped ZrO₂ support oxide. According to principles in present disclosure, a plurality of formulations for fine grain bulk powder compositions of Cu—Mn—Fe spinel with general formulation of Cu_xMn_yFe_zO₄, may provide solutions for enhanced NOx, CO, and HC conversion performance for TWC applications, employing ZPGM materials for a plurality of TWC applications. Additionally, these types of ternary ZPGM fine grain bulk powder spinel compositions may have a cost effective manufacturing advantage.

Claims

1. A catalytic composition, comprising:

an oxygen storage material, comprising;

Co_Mn—

Fe spinel on a doped zirconia support oxide;

wherein the oxygen storage material converts at least one of NO, CO and HC through oxidation or reduction.

2. The composition of claim 1, wherein the Co_Mn—

Fe spinel is stoichiometric.

3. The composition of claim 1, wherein the Co_Mn—

Fe spinel is non-stoichiometric.

4. The composition of claim 1, wherein the Co_Mn—

Fe spinel is applied to the support oxide by incipient wetness (IW) method.

5. The composition of claim 1, wherein the Co_Mn—

Fe spinel has the general formula (Co_xFe_zMn_2z)_3δ

O₄, wherein Fe/Mn=0.5, x+3z=1, and 0≦

δ

≦

0.2.

6. The composition of claim 1, wherein the Co_Mn—

Fe spinel has the general formula Co_1-xMn_xFe₂O₄ wherein 0≦

x≦

1.

7. The composition of claim 1, wherein the Co_Mn—

Fe spinel has the general formula Cu_xMn_yFe_zO₄ wherein x+y+z=3.

8. The composition of claim 1, wherein the doped zirconia comprises Pr₆O₁₁—

ZrO₂.

9. The composition of claim 1, wherein the Fe of the Co_Mn—

Fe spinel is in the spinel B site.

10. The composition of claim 1, wherein the oxygen storage material is calcined at about 800°

C.

11. The composition of claim 10, wherein the oxygen storage material is calcined for about 5 hours.

12. The composition of claim 1, wherein the Mn of the Co_Mn—

Fe spinel is in the spinel B site.

13. A method for making a catalytic composition, comprising:

preparing a solution comprising Co nitrate solution Co(NO₃)₂, Fe nitrate solution (Fe(NO₃)₃) and Mn nitrate solution (Mn(NO₃)₂) with water wherein Co_Mn—

Fe spinel is formed;

adding the solution drop-wise to doped Zirconia powder via an incipient wetness method to create a mixture;

drying the mixture at 120°

C. for more than 4 hours; and

calcining the mixture at about 800°

C. for about 5 hours

14. The method of claim 13, further comprising grounding the mixture into a fine grain powder.

15. The method of claim 13, wherein the Co_Mn—

Fe spinel is stoichiometric.

16. The method of claim 13, wherein the Co_Mn—

Fe spinel is non-stoichiometric.

17. The method of claim 13, wherein the Co_Mn—

Fe spinel has the general formula (Co_xFe_zMn_2z)_3δ

O₄, wherein Fe/Mn=0.5, x+3z=1, and 0≦

δ

≦

0.2.

18. The method of claim 13, wherein the Co_Mn—

Fe spinel has the general formula Co_1-xMn_xFe₂O₄ wherein 0≦

x≦

1.

19. The method of claim 13, wherein the Co_Mn—

Fe spinel has the general formula Cu_xMn_yFe_zO₄ wherein x+y+z=3.

20. The method of claim 13, wherein the doped zirconia comprises Pr₆O₁₁—

ZrO₂.

21. The method of claim 13, wherein the Fe of the Co_Mn—

Fe spinel is in the spinel B site.