Thermally stable compositions of OSM free of rare earth metals

• US 8,853,121 B1
• Filed: 10/16/2013
• Issued: 10/07/2014
• Est. Priority Date: 10/16/2013
• Status: Expired due to Fees

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: Clean Diesel Technologies, Inc.
• Inventors: Nazarpoor, Zahra, Golden, Stephen J.
• Primary Examiner(s): Nguyen, Cam N.
• Application Number:
  US14/055,411
• Time in Patent Office: 356 Days
• Field of Search: 502/324, 502/345, 502/349, 502/353, 502/524
• US Class Current: 502/324
• CPC Class Codes: B01D 2255/20715 Zirconium
• CPC Class Codes: B01D 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20761 Copper
• CPC Class Codes: B01D 2255/40 Mixed oxides
• CPC Class Codes: B01D 2255/405 Spinels
• 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 23/20 Vanadium, niobium or tantalum
• CPC Class Codes: B01J 23/8892 Manganese
• CPC Class Codes: B01J 35/30 characterised by their physical properties
• CPC Class Codes: B01J 37/035 Precipitation on carriers
• CPC Class Codes: C01G 45/1242 of the type [Mn2O4]-, e.g. LiMn2O4, Li[MxMn2-x]O4
• CPC Class Codes: C01P 2006/90 Other properties not specified above
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

The effect of aging temperature on oxygen storage materials (OSM) substantially free from platinum group (PGM) and rare earth (RE) metals is disclosed. Samples of ZPGM-ZRE metals OSM, hydrothermally aged at a plurality of high temperatures are found to have significantly high oxygen storage capacity (OSC) and phase stability than conventional PGM catalysts with Ce-based OSM. ZPGM-ZRE metals OSM includes a formulation of Cu—Mn stoichiometric spinel structure deposited on Nb—Zr oxide support and may be converted into powder to be used as OSM application or coated onto catalyst substrate. ZPGM-ZRE metals OSM, after aging condition, presents enhanced level of thermal stability and OSC property which shows improved catalytic activity than conventional PGM catalysts including Ce-based OSM. ZPGM-ZRE metals OSM may be suitable for a vast number of applications, and more particularly in underfloor catalyst systems.

Claims

1. A catalytic composition, comprising:

an oxygen storage material, comprising;

Cu—

Mn spinel and Niobium-Zirconia support oxide dried and calcined at about 600°

C.;

wherein the oxygen storage material is hydrothermally aged.

2. The catalytic composition of claim 1, wherein the hydrothermal aging occurs at about 800°

C. to about 1000°

C.

3. The catalytic composition of claim 1, wherein the hydrothermal aging occurs for about 20 hours.

4. The catalytic composition of claim 1, wherein the calcining produces a spinel structure.

5. The catalytic composition of claim 1, wherein the oxygen storage material is substantially free of platinum group metals.

6. The catalytic composition of claim 1, wherein the oxygen storage material is substantially free of rare earth metals metals.

7. The catalytic composition of claim 1, wherein the oxygen storage material is a powder.

8. The catalytic composition of claim 7, wherein the powder is formed by co-precipitation.

9. The catalytic composition of claim 1, wherein the Cu—

Mn spinel has the formula Cu_1.0Mn_2.0O₄.

10. The catalytic composition of claim 1, wherein the Niobium-Zirconia support oxide has the formula Nb₂O₅—

ZrO₂.

11. The catalytic composition of claim 1, wherein the oxygen storage material is coated on a substrate.

12. The catalytic composition of claim 11, wherein the substrate comprises cordierite.

13. The catalytic composition of claim 11, wherein the substrate comprises a honeycomb structure.

14. The catalytic composition of claim 1, wherein the oxygen storage material is in an aqueous slurry.

15. The catalytic composition of claim 1, wherein the Cu—

Mn spinel comprises about 10 g/L to about 15 g/L of Cu.

16. The catalytic composition of claim 1, wherein the Cu—

Mn spinel comprises about 20 g/L to about 25 g/L of Mn.

17. The catalytic composition of claim 1, wherein the niobium-zirconia support oxide is present at about 80 g/L to about 90 g/L.