Thermally Stable Zero-PGM Three Way Catalyst with High Oxygen Storage Capacity

摘要

The present disclosure describes ZPGM catalyst material compositions having significantly high oxygen storage capacity for a plurality of TWC applications. The disclosed ZPGM catalyst material compositions include a Cu—Mn spinel deposited on doped Zirconia support oxide. The disclosed ZPGM catalyst material compositions exhibit significant high OSC stability properties after fuel cut aging. The improved thermal stability and OSC properties of the disclosed ZPGM catalyst material compositions are determined by performing a standard isothermal oscillating OSC tests. Fresh and aged ZPGM catalyst material compositions are employed within the standard isothermal oscillating OSC test, over multiple reducing/oxidizing cycles at a temperature of about 575° C.

主权项

1. A method of manufacturing a catalyst system comprising:
coating a washcoat on a substrate followed by firing at a first firing temperature for a first firing period, after the first firing period, coating an overcoat on the washcoat followed by firing at a second firing temperature for a second firing period, mixing Cu nitrate and Mn nitrate solutions for a mixing period to form a Cu—Mn mixture, after the second firing period, impregnating the Cu-Mn mixture onto the overcoat followed by firing at a third firing temperature for a third firing period to form an impregnation layer, wherein
the overcoat includes at least one support oxide selected from the group consisting of MgAl2O4, Al2O3—BaO, Al2O3—La2O3, ZrO2—CeO2—Nd2O3—Y2O3, CeO2—ZrO2, CeO2, SiO2, Alumina silicate, ZrO2—Y2O3—SiO2, Al2O3—CeO2, Al2O3—SrO, TiO2-ZrO2, TiO2—Nb2O5, SnO2—TiO2, ZrO2—SnO2—TiO2, BaZrO3, BaTiO3, BaCeO3, ZrO2—Pr6O11, ZrO2—Y2O3, ZrO2—Nb2O5, Al—Zr—Nb, and Al—Zr—La, and whereinthe impregnation layer includes CuxMn3-xO4 spinel.