Zero PGM catalyst including Cu—Co—Mn ternary spinel for TWC applications

• US 9,468,912 B2
• Filed: 11/17/2014
• Issued: 10/18/2016
• Est. Priority Date: 11/17/2014
• Status: Active Grant

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: Clean Diesel Technologies, Inc.
• Inventors: Nazarpoor, Zahra, Yaglidere, Oguzhan Selim, Golden, Stephen J.
• Primary Examiner(s): Zimmer, Anthony J
• Application Number:
  US14/543,448
• Publication Number:
  US 20160136620A1
• Time in Patent Office: 701 Days
• US Class Current: 1/1
• CPC Class Codes: B01D 2255/2066 Praseodymium
• CPC Class Codes: B01D 2255/207 Transition metals
• CPC Class Codes: B01D 2255/20715 Zirconium
• CPC Class Codes: B01D 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20746 Cobalt
• 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 23/10 of rare earths
• 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 2523/56 Niobium
• CPC Class Codes: B01J 2523/72 Manganese
• CPC Class Codes: B01J 2523/845 Cobalt
• CPC Class Codes: B01J 37/035 : Precipitation on carriers
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

Variations of ZPGM bulk powder catalyst materials, including Cu—Co—Mn ternary spinel systems for TWC applications are disclosed. Bulk powder catalyst samples are prepared employing a plurality of molar ratio variations, including disclosed Cu—Co—Mn spinel on Praseodymium-Zirconia support oxide made by incipient wetness method, or Cu—Co—Mn spinel on Niobium-Zirconia support oxide, which may be synthesized by co-precipitation method. A plurality of bulk powder catalyst samples may be tested by performing isothermal steady state sweep test, employing a flow reactor at inlet temperature of about 450° C., and testing a gas stream from lean to rich condition and influence on TWC performance measured/analyzed, which may lead into significant improvements in the manufacturing of ZPGM bulk powder catalyst materials for TWC applications.

Claims

1. A catalytic composition, comprising:

an oxygen storage material, comprising;

Cu—

Co—

Mn 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; and

wherein the doped zirconia comprises Pr₆O₁₁—

ZrO₂.

3. The composition of claim 1 or 2, wherein the Cu—

Co—

Mn spinel has the general formula (Cu_1-xCo_x)Mn_2.0O₄ where 0.1≦

X≦

0.3.

4. The composition of claim 1 or 2, wherein the Cu—

Co—

Mn spinel has the formula Cu_0.7Co_0.3Mn_2.0O₄.

5. The composition of claim 1 or 2, wherein the Cu—

Co—

Mn spinel has the formula (Cu_0.8Co_0.2)Mn₂O₄.

6. The composition of claim 1 or 2, wherein the Mn of the Cu—

Co—

Mn spinel is in the spinel B site.

7. The composition of claim 1 or 2, wherein the oxygen storage material is calcined at about 800°

C.

8. The composition of claim 1 or 2, wherein the oxygen storage material is calcined at about 600°

C.

9. The composition of claim 1 or 2, wherein the spinel A site of Cu—

Co—

Mn is selected from Cu or Co.

2. A catalytic composition, comprising:

an oxygen storage material, comprising;

Cu—

Co—

Mn 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; and

wherein the doped zirconia comprises Nb₂O₅—

ZrO₂.