Three-way catalyst systems including Fe-activated Rh and Ba-Pd material compositions
First Claim
1. A catalyst system, comprising:
- a substrate;
a washcoat deposited on the substrate;
at least one impregnation layer; and
an overcoat;
wherein the washcoat comprises at least one of the group consisting of about 10 (w/w) to about 75 (w/w) cerium oxide, about 25 (w/w) to about 90 (w/w) zirconium-hafnium oxide, about 0 (w/w) to about 15 (w/w) lanthanum oxide, about 0 (w/w) to about 15 (w/w) neodymium oxide, about 0 (w/w) to about 15 (w/w) yttrium oxide, and about 0 (w/w) to about 15 (w/w) praseodymium oxide;
wherein the at least one impregnation layer comprises rhodium at about 1 g/ft3 to about g/ft3 and iron at about 60 g/ft3 to about 630 g/ft3 ; and
wherein the overcoat comprises at least one of the group consisting of an oxygen storage material, support oxides, barium carbonate, doped alumina, strontium carbonate, and combinations thereof.
1 Assignment
0 Petitions
Accused Products
Abstract
Three way catalysts (TWCs) for catalyst systems are disclosed. The disclosed TWC systems include Iron (Fe)-activated Rhodium (Rh) and Barium (Ba)-Palladium (Pd) layers capable of interacting with conventional and/or non-conventional catalyst supports and additives. Variations of TWC system samples are produced including Fe-activated Rh layers deposited onto a washcoat (WC) layer having one or more of an oxygen storage material (OSM). Other TWC system samples are produced including an impregnation (IMPG) layer having loading variations of Ba within a Pd, Ce, and Nd applied onto an OSM WC layer, and a further overcoat layer including Fe-activated Rh is applied onto the IMPG layer. The catalytic performance of disclosed TWC catalysts is evaluated by performing a series of light-off tests, wide pulse perturbation tests, and standard isothermal oxygen storage capacity oscillating tests. Disclosed TWC catalysts exhibit high catalytic performance and significant oxygen storage capacity.
-
Citations
18 Claims
-
1. A catalyst system, comprising:
-
a substrate; a washcoat deposited on the substrate; at least one impregnation layer; and an overcoat; wherein the washcoat comprises at least one of the group consisting of about 10 (w/w) to about 75 (w/w) cerium oxide, about 25 (w/w) to about 90 (w/w) zirconium-hafnium oxide, about 0 (w/w) to about 15 (w/w) lanthanum oxide, about 0 (w/w) to about 15 (w/w) neodymium oxide, about 0 (w/w) to about 15 (w/w) yttrium oxide, and about 0 (w/w) to about 15 (w/w) praseodymium oxide; wherein the at least one impregnation layer comprises rhodium at about 1 g/ft3 to about g/ft3 and iron at about 60 g/ft3 to about 630 g/ft3 ; and wherein the overcoat comprises at least one of the group consisting of an oxygen storage material, support oxides, barium carbonate, doped alumina, strontium carbonate, and combinations thereof. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
-
-
10. A catalyst system, comprising:
-
a substrate; a washcoat deposited on the substrate; at least one impregnation layer impregnated in the washcoat; and an overcoat; wherein the at least one impregnation layer comprises Pd nitrate, Ce nitrate, Nd nitrate, and a Ba salt; wherein the Ba salt is loaded from about 50 g/ft3 to about 700 g/ft3. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18)
-
Specification