Mixed-phase ceramic oxide three-way catalyst formulations and methods for preparing the catalysts
First Claim
1. A multi-phase catalyst for simultaneous conversion of oxides of nitrogen, carbon monoxide, and hydrocarbons represented by the general formula:
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CeyLn1-xAx+sMOz,wherein;
A is an element selected from the group consisting of Mg, Ca, Sr, Ba, Li, Na, K, Cs, Rb, and any combination thereof;
Ln is a mixture of elements originally in the form of single-phase mixed lanthanides collected from natural ores, a single lanthanide, or a mixture of artificial lanthanides;
M is an element selected from the group consisting of Fe, Mn, Cr, Ni, Co, Cu, V, Zr, Pt, Pd, Rh, Ru, Ag, Au, Al, Ga, Mo, W, Ti, and any combination thereof;
x is a number defined by 0≦
x<
1.0;
y is a number defined by 0≦
y<
10;
s is a number defined by 0≦
s<
10; and
z is a number defined by z>
0,where s=0 only when y>
0 and y=0 only when s>
0.
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Abstract
A multi-phase catalyst for the simultaneous conversion of oxides of nitrogen, carbon monoxide, and hydrocarbons is provided. A catalyst composition comprising the multi-phase catalyst and methods of making the catalyst composition are also provided. The multi-phase catalyst may be represented by the general formula of CeyLn1-xAx+sMOZ, wherein Ln is a mixture of elements originally in the form of single-phase mixed lanthanides collected from natural ores, a single lanthanide, or a mixture of lanthanides; A is an element selected from a group consisting of Mg, Ca, Sr, Ba, Li, Na, K, Cs, Rb, or any combination thereof; and M is an element selected from the group consisting of Fe, Mn, Cr, Ni, Co, Cu, V, Zr, Pt, Pd, Rh, Ru, Ag, Au, Al, Ga, Mo, W, Ti, or any combination thereof; x is a number defined by 0≦x<1.0; y is a number defined by 0≦y<10; s is a number defined by 0≦s<10; where s=0 only when y>0 and y=0 only when s>0. The multi-phase catalyst can have an overlayer of an oxide having the fluorite structure with a combination of platinum and/or rhodium.
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Citations
90 Claims
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1. A multi-phase catalyst for simultaneous conversion of oxides of nitrogen, carbon monoxide, and hydrocarbons represented by the general formula:
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CeyLn1-xAx+sMOz,wherein; A is an element selected from the group consisting of Mg, Ca, Sr, Ba, Li, Na, K, Cs, Rb, and any combination thereof; Ln is a mixture of elements originally in the form of single-phase mixed lanthanides collected from natural ores, a single lanthanide, or a mixture of artificial lanthanides; M is an element selected from the group consisting of Fe, Mn, Cr, Ni, Co, Cu, V, Zr, Pt, Pd, Rh, Ru, Ag, Au, Al, Ga, Mo, W, Ti, and any combination thereof; x is a number defined by 0≦
x<
1.0;y is a number defined by 0≦
y<
10;s is a number defined by 0≦
s<
10; andz is a number defined by z>
0,where s=0 only when y>
0 and y=0 only when s>
0. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A catalyst composition, comprising:
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(a) a substrate; (b) a washcoat; and (c) a multi-phase catalyst represented by the general formula;
CeyLn1-xAx+sMOz,wherein; Ln is a mixture of elements originally in the form of single-phase mixed lanthanides collected from natural ores, a single lanthanide, or a mixture of artificial lanthanides; A is an element selected from the group consisting of Mg, Ca, Sr, Ba, Li, Na, K, Cs, Rb, and combinations thereof; M is an element selected from the group consisting of Fe, Mn, Cr, Ni, Co, Cu, V, Zr, Pt, Pd, Rh, Ru, Ag, Au, Al, Ga, Mo, W, Ti, and combinations thereof; x is a number defined by 0≦
x<
1.0;y is a number defined by 0≦
y<
10;s is a number defined by 0≦
s<
10; andz is a number defined by z>
0,where s=0 only when y>
0 and y=0 only when s>
0.- View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50)
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51. A method of making a catalyst composition, the method comprising the steps of:
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(a) providing a substrate; (b) providing at least one carrier material for forming a washcoat on the substrate; (c) providing a solution for forming a multi-phase catalyst supported by the substrate, wherein the solution has a general cation formula of
CeyLn1-xAx+sM, wherein;Ln is a single lanthanide, a mixture of artificial lanthanides, or a mixture of elements originally in the form of single-phase mixed lanthanides collected from natural ores; A is an element selected from the group consisting of Mg, Ca, Sr, Ba, Li, Na, K, Cs, Rb, and combinations thereof; and M is an element selected from the group consisting of Fe, Mn, Cr, Ni, Co, Cu, V, Zr, Pt, Pd, Rh, Ru, Ag, Au, Al, Ga, Mo, W, Ti and combinations thereof; x is a number defined by 0≦
x<
1.0;y is a number defined by 0≦
y<
10;s is a number defined by 0≦
s<
10, andz is a number defined by z>
0,where s=0 only when y>
0 and y=0 only when s>
0;and (d) forming the catalyst composition comprising the substrate, the washcoat, and the multi-phase catalyst. - View Dependent Claims (52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85)
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86. A method for simultaneous conversion of oxides of nitrogen, carbon monoxide, and hydrocarbons in motor vehicle exhaust comprising:
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(a) providing a catalyst composition, wherein said catalyst composition comprises; (i) a substrate; (ii) a washcoat; and (iii) a multi-phase catalyst represented by the general formula;
CeyLn1-xAx+sMOz,wherein; Ln is a mixture of elements originally in the form of single-phase mixed lanthanides collected from natural ores, a single lanthanide, or a mixture of artificial lanthanides; A is an element selected from the group consisting of Mg, Ca, Sr, Ba, Li, Na, K, Cs, Rb, and combinations thereof; M is an element selected from the group consisting of Fe, Mn, Cr, Ni, Co, Cu, V, Zr, Pt, Pd, Rh, Ru, Ag, Au, Al, Ga, Mo, W, Ti, and combinations thereof; x is a number defined by 0≦
x<
1.0;y is a number defined by 0≦
y<
10;s is a number defined by 0≦
s<
10; andz is a number defined by z>
0,where s=0 only when y>
0 and y=0 only when s>
0; and(b) contacting said exhaust with said catalyst composition. - View Dependent Claims (87, 88, 89, 90)
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Specification