Nickel-Doped Copper-Manganese Spinel as Zero-PGM Catalyst for TWC Applications

• US 20170095800A1
• Filed: 10/01/2015
• Published: 04/06/2017
• Est. Priority Date: 10/01/2015
• Status: Abandoned Application

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: Clean Diesel Technologies, Inc.
• Inventors: Nazarpoor, Zahra, Golden, Stephen J.
• Application Number:
  US14/872,609
• Publication Number:
  US 20170095800A1
• Time in Patent Office: Days
• CPC Class Codes: B01D 2255/20715 Zirconium
• CPC Class Codes: B01D 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20753 Nickel
• 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 21/005 Spinels
• CPC Class Codes: B01J 2235/15 X-ray diffraction
• CPC Class Codes: B01J 23/005 Spinels
• CPC Class Codes: B01J 23/755 Nickel
• CPC Class Codes: B01J 23/83 with rare earths or actinides
• CPC Class Codes: B01J 23/8474 Niobium
• CPC Class Codes: B01J 2523/00 Constitutive chemical elements of heterogeneous catalysts
• CPC Class Codes: B01J 2523/17 Copper
• CPC Class Codes: B01J 2523/72 Manganese
• CPC Class Codes: B01J 2523/847 Nickel
• CPC Class Codes: B01J 35/70 characterised by their crystalline properties, e.g. semi-crystalline catalysts comprising carbon B01J21/18; molecular sieves B01J29/00
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

Variations of ZPGM catalyst material compositions including doped Cu—Mn spinel supported on doped zirconia support oxide are disclosed. The disclosed ZPGM catalyst compositions include a small substitution of Ni within the A-site or B-site cation of a Cu—Mn spinel supported on doped zirconia support oxide, and produced by the incipient wetness (IW) methodology. Bulk powder ZPGM catalyst compositions are subjected to XRD analyses to determine the spinel phase formation and stability. Additionally, bulk powder ZPGM catalyst compositions are subjected to a steady-state isothermal sweep test to determine NO, CO, and THC conversion. The ZPGM catalyst material compositions including Ni-doped Cu—Mn spinel supported on doped zirconia support oxide exhibit improved levels in NO and CO conversions, which can be employed in ZPGM catalysts for a plurality of TWC applications, thereby leading to a more effective utilization of ZPGM catalyst materials with high thermal and chemical stability in TWC products.

Claims

1. A catalyst composition comprising a spinel of formula Cu_1-xNi_xMn₂O₄ wherein x is about 0.01 to about 0.5.

2. The catalyst composition of claim 1, wherein x is about 0.01 to about 0.2.

3. The catalyst composition of claim 2, wherein x is about 0.02.

4. The catalyst composition of claim 1, further comprising at least one support oxide, wherein the spinel of formula Cu_1-xNi_xMn₂O₄ is deposited on the at least one support oxide.

5. The catalyst composition of claim 4, wherein the at least one support oxide is selected from the group consisting of MgAl₂O₄, Al₂O₃—

BaO, Al₂O₃—

La₂O₃, ZrO₂—

CeO₂—

Nd₂O₃—

Y₂O₃, CeO₂—

ZrO₂, CeO₂, SiO₂, Alumina silicate, ZrO₂-Y₂O₃-SiO₂, Al₂O₃—

CeO₂, Al₂O₃—

SrO, TiO₂—

ZrO₂, TiO₂—

Nb₂O₅, SnO₂—

TiO₂, ZrO₂—

SnO₂—

TiO₂, BaZrO₃, BaTiO₃, BaCeO₃, ZrO₂—

P₆O₁₁, ZrO₂—

Y₂O₃, ZrO₂—

Nb₂O₅, Al—

Zr—

Nb, and Al—

Zr—

La.

6. The catalyst composition of claim 4, wherein the at least one support oxide includes a doped zirconia support oxide.

7. The catalyst composition of claim 6, wherein the doped zirconia support oxide is ZrO₂—

Pr₆O₁₁ support oxide.

8. The catalyst composition of claim 7, the ZrO₂—

Pr₆O₁₁ support oxide is ZrO₂-10%Pr₆O₁₁ support oxide.

9. The catalyst composition of claim 5, wherein the at least one support oxide includes at least one selected from the group consisting of TiO₂-10%ZrO₂ and TiO₂-10%Nb₂O₅.

10. The catalyst composition of claim 2, further comprising at least one support oxide, wherein the spinel of formula Cu_1-x Ni_xMn₂O₄ is deposited on the at least one support oxide, and wherein the at least one support oxide includes ZrO₂—

Pr₆O₁₁ support oxide.

11. A catalyst component comprising a spinel of formula Cu₁Mn_2-xNi_xO₄ wherein x is about 0.1 to about 1.5.

12. The catalyst composition of claim 11, wherein x is about 0.1 to about 0.5.

13. The catalyst composition of claim 12, wherein x is about 0.5.

14. The catalyst composition of claim 11, further comprising at least one support oxide, wherein the spinel of formula CuMn_2-xNi_xO₄ is deposited on the at least one support oxide.

15. The catalyst composition of claim 14, wherein the at least one support oxide is selected from the group consisting of MgAl₂O₄, Al₂O₃—

BaO, Al₂O₃—

La₂O₃, ZrO₂—

CeO₂—

Nd₂O₃—

Y₂O₃, CeO₂—

ZrO₂, CeO₂, SiO₂, Alumina silicate, ZrO₂—

Y₂O₃—

SiO₂, Al₂O₃—

CeO₂, Al₂O₃—

SrO, TiO₂—

ZrO₂, TiO₂—

Nb₂O₅, SnO₂—

TiO₂, ZrO₂—

SnO₂—

TiO₂, BaZrO₃, BaTiO₃, BaCeO₃, ZrO₂—

P₆O₁₁, ZrO₂—

Y₂O₃, ZrO₂—

Nb₂O₅, Al—

Zr—

Nb, and Al—

Zr—

La.

16. The catalyst composition of claim 14, wherein the at least one support oxide includes a doped zirconia support oxide.

17. The catalyst composition of claim 16, wherein the doped zirconia support oxide is ZrO₂—

Pr₆O₁₁ support oxide.

18. The catalyst composition of claim 17, the ZrO₂—

Pr₆O₁₁ support oxide is ZrO₂-10%Pr₆O₁₁ support oxide.

19. The catalyst composition of claim 15, wherein the at least one support oxide includes at least one selected from the group consisting of TiO₂-10%ZrO₂ and TiO₂-10%Nb₂O₅.

20. The catalyst composition of claim 12, further comprising at least one support oxide, wherein the spinel of formula Cu ₁Mn_2-xNi_xO₄ is deposited on the at least one support oxide, and wherein the at least one support oxide includes ZrO₂—

Pr₆O₁₁ support oxide.