摘要:
Bimetallic Synergized Platinum Group Metals (SPGM) catalyst systems for TWC application are disclosed. Disclosed bimetallic SPGM catalyst systems may include a washcoat with a Cu—Mn spinel structure and an overcoat that includes PGMs, such as Pd/Rh or Pt/Rh supported on carrier material oxides, such as alumina. Bimetallic SPGM catalyst systems show significant improvement in nitrogen oxide reduction performance under lean operating conditions, which allows a reduced consumption of fuel. Additionally, disclosed bimetallic SPGM catalyst systems exhibit enhanced catalytic activity for carbon monoxide conversion. Furthermore, bimetallic SPGM catalyst systems are found to have enhanced catalytic activity for fresh, hydrothermally aged and fuel cut aged conditions compared to PGM catalyst system, showing that there is a synergistic effect between PGM catalyst and Cu—Mn spinel within the disclosed SPGM catalyst system which help in performance and thermal stability of disclosed SPGM catalyst systems.
摘要:
Close-coupled catalysts (CCC) for TWC applications are disclosed. The novel CCCs are implemented using light-weighted ceramic substrates in which a thin coating employing a low loading of Iron (Fe)-activated Rhodium (Rh) material composition, with Iron loadings and an OSM of Ceria-Zirconia, are deposited onto the substrates. Different CCC samples are produced to determine and/or verify improved light-off (LO) and NOX conversion of the CCCs. Other CCC samples produced are a CCC including a standard (non-activated) Rh thin coating and a heavily loaded CCC with a single coating of Pd/Rh material composition. The CCC samples are aged under dyno-aging using the multi-mode aging cycle and their performance tested using a car engine with ports on the exhaust to measure the emissions, according to the testing protocol in the Environmental Protection Agency Federal Test Procedure 75. During testing, the thin coatings of Fe-activated Rh exhibit improved light-off and NOx conversion efficiency.
摘要:
Synergized platinum group metals (SPGM) with ultra-low PGM loadings employed as underfloor (UF) three-way catalyst (TWC) systems with varied material compositions and configurations are disclosed. SPGM UF catalysts in which ZPGM compositions of binary and ternary spinel structures supported onto support oxides are coupled with commercialized PGM close-coupled (CC) catalysts and tested under Federal Test Procedure FTP-75 within TGDI and PI engines. The performance of the TWC systems including commercialized PGM CC and SPGM UF (with ultra-low PGM loadings) catalysts is compared to the performance of commercialized PGM CC and PGM UF catalysts. The disclosed TWC systems indicate that SPGM UF TWC catalytic performance is comparable or even exceeds high PGM-based conventional TWC catalysts, with reduced tailpipe emissions.
摘要:
The present disclosure describes zero-platinum group metals (ZPGM) material compositions including binary Cu—Mn spinel oxide powders having stable reduction/oxidation (redox) reversibility useful for TWC and oxygen storage material applications. The behavior of Cu—Mn spinel oxide powder is analyzed under oxidation-reduction environments to determine redox reversibility, catalytic activity, and spinel structure stability. Characterization of spinel powder is performed employing X-ray diffraction analysis, hydrogen temperature-programmed reduction technique, transmission electron microscopy analysis, and X-ray photoelectron spectroscopy analysis. Test results confirm the phase and structural stability of the Cu—Mn spinel oxide during redox reaction, thereby indicating that the Cu—Mn spinel oxide can be employed in a plurality of TWC applications.
摘要:
The effect of firing (calcination) cycle on metallic substrates in ZPGM catalyst systems is disclosed. ZPGM catalyst samples with washcoat and overcoat are separately fired in a normal, slow and fast firing cycles to determine the optimal firing cycling that may provide an enhanced catalyst performance, as well as the minimal loss of washcoat adhesion from the samples.
摘要:
Variations of ZPGM catalyst material compositions including cerium-cobalt spinel oxide systems for ZPGM DOC applications are disclosed. The disclosed ZPGM catalyst compositions include CexCo3−xO4 spinel and effect of adding copper to Ce-Co as CuxCe1−xCo2O4 spinel systems supported on doped zirconia support oxide, which are produced by the incipient wetness (IW) methodology. ZPGM catalyst compositions are subjected to BET-surface area and XRD analyses to determine the thermal stability and spinel phase formation of supported spinal systems, respectively. DOC performance of ZPGM catalyst compositions is determined under steady state DOC light off test condition to verify/compare oxidation activity of disclosed spinel compositions, desirable and suitable for ZPGM catalyst materials in DOC applications.
摘要:
The present disclosure relates to selecting the layer of applying ZPGM active phase in washcoat, or applying ZPGM active phase in overcoat, for achieving optimized performance and enhanced thermal stability. Applying ZPGM active phase catalyst in overcoat shows improvements compare to applying ZPGM active phase in washcoat. The selected active phase material may include a chemical composition that is substantially free from PGM, including a formulation of stoichiometric Cu—Mn spinel structure active phase deposited on Niobium-Zirconium support oxide. The selected active phase layer applied in overcoat may include a washcoat of alumina coated on a suitable ceramic substrate. The disclosed active phase may be applied in overcoat to maximize efficiency of catalyst systems, which may exhibit enhanced catalytic activity properties, which may stable after aging and under steady state and oscillating condition, showing optimized performance purifying gases in TWC condition.
摘要:
Synergized Platinum Group Metals (SPGM) catalyst system for TWC application is disclosed. Disclosed SPGM catalyst system may include a washcoat with a Cu—Mn spinel structure and an overcoat that includes PGM supported on carrier material oxides, such as alumina. SPGM catalyst system shows significant improvement in nitrogen oxide reduction performance under stoichiometric operating conditions and especially under lean operating conditions, which allows a reduced consumption of fuel. Additionally, disclosed SPGM catalyst system also enhances the reduction of carbon monoxide and hydrocarbon within catalytic converters. Furthermore, disclosed SPGM catalyst systems are found to have enhanced catalyst activity compared to commercial PGM catalyst system, showing that there is a synergistic effect among PGM catalyst and Cu—Mn spinel within the disclosed SPGM catalyst system.
摘要:
The present disclosure describes rhodium iron catalysts of use in catalyst systems. Disclosed here are TWCs configured to include a substrate and one or more of a washcoat layer, an impregnation layer, and/or an overcoat layer. Disclosed herein are one or more of a washcoat layer and/or an overcoat layer formed using a slurry that includes one or more of an oxygen storage material, a refractory support oxide, iron, and rhodium. Disclosed herein are methods of preparing catalysts wherein a washcoat layer is deposited onto the substrate, one or more impregnation layers may be deposited onto the washcoat layer, one or more overcoat layers may be deposited onto the impregnation washcoat layer, and one or more additional impregnation layers may be deposited onto the one or more washcoat layers.
摘要:
The present disclosure describes zoned three way catalyst (TWC) systems including Rhodium-iron overcoat layers and Nb—Zr—Al Oxide overcoat layers. Disclosed herein are TWC sample systems that are configured to include a substrate and one or more of a washcoat layer, an impregnation layer, and/or an overcoat layer. In catalyst systems disclosed herein, closed-coupled catalysts include a first catalyst zone with an overcoat layer formed using a slurry that includes an oxide mixture and an Oxygen Storage Material (OSM). In catalyst systems disclosed herein, oxide mixtures include niobium oxide (Nb2O5), zirconia, and alumina. Further, catalyst systems disclosed herein include a second catalyst zone with an overcoat layer formed to include a rhodium-iron catalyst. Yet further, catalyst systems disclosed herein include impregnation layers that include one or more of Palladium, Barium, Cerium, Neodymium, and Rhodium.