Methods and processes of coating zero-PGM catalysts including with Cu, Mn, Fe for TWC applications

摘要

Variations of coating processes of Cu—Mn—Fe ZPGM catalyst materials for TWC applications are disclosed. The disclosed coating processes for Cu—Mn—Fe spinel materials are enabled in the preparation ZPGM catalyst samples according to a plurality of catalyst configurations, which may include an alumina only washcoat layer coated on a suitable ceramic substrate, and an overcoat layer with or without an impregnation layer, including Cu—Mn—Fe spinel and doped Zirconia support oxide, prepared according to variations of disclosed coating processes. Activity measurements are considered under variety of lean condition to rich condition to analyze the influence of disclosed coating processes on TWC performance of ZPGM catalysts for a plurality of TWC applications. Different coating processes may substantially increase thermal stability and TWC activity, providing improved levels of NOx conversion that may lead to cost effective manufacturing solutions for ZPGM-TWC systems.

主权项

1. A process for making a catalytic system, comprising:
providing a substrate; applying a washcoat to said substrate, wherein the substrate comprises alumina; applying an overcoat to said washcoat, said overcoat comprising at least one support oxide comprising doped ZrO2; applying to said overcoat at least one layer of Cu—Mn spinel; and wherein the catalytic system is free of platinum group metals; and wherein the doped ZrO2comprises Nb2O5—ZrO2.