Three-way Catalyst Systems Including Nb-Zr-Al-Mixed Oxide Supports, Ba-Pd, and Rh-Fe Material Compositions

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.

主权项

1. A close-coupled converter system, comprising:
a first catalyst zone; and a second catalyst zone; wherein the first catalyst zone is configured to receive exhaust gases, process the received exhaust gases into first treated gases, and expel the first treated gases into the second catalyst zone; wherein the second catalyst zone is configured to receive the first treated cases from the first catalyst zone, process the received first treated gases into second treated gases, and expel the second treated gases; wherein the first catalyst zone comprises:
a first catalyst zone substrate;a first catalyst zone washcoat deposited on the first catalyst zone substrate;at least one first catalyst zone impregnation layer; anda first catalyst zone overcoat; wherein the first catalyst zone washcoat comprises a first catalyst zone first oxygen storage material including Cerium, Zirconium-Hafnium, Neodymium, and Yttrium, and a first catalyst zone support oxide; wherein the at least one first catalyst zone impregnation layer comprises Pd, Ba, Ce, and Nd; wherein the first catalyst zone overcoat comprises a first catalyst zone second oxygen storage material comprising Cerium, Zirconium-Hafnium, Neodymium, and Yttrium, and a first catalyst zone oxide mixture comprising Niobium, Zirconium-Hafnium, Alumina and Rhodium; wherein the second catalyst zone comprises:
a second catalyst zone substrate;a second catalyst zone washcoat deposited on the second catalyst zone substrate;at least one second catalyst zone impregnation layer; anda second catalyst zone overcoat; wherein at the second catalyst zone overcoat comprises rhodium and iron.