ZPGM Catalyst Including Co-Mn-Fe and Cu-Mn-Fe Materials for TWC Applications
Variations of bulk powder catalyst materials, including a plurality of formulations for stoichiometric and non-stoichiometric Co_Mn—Fe spinel and Cu—Mn—Fe spinel, which may be prepared by incipient wetness method, employing variations of molar ratio and general formulation (Co x Fe z Mn 2z ) 3-δ O 4 , and Co 1-x Mn x Fe 2 O 4 spinel supported on doped ZrO 2 support oxide. According to principles in present disclosure, a plurality of formulations for fine grain bulk powder compositions of Cu—Mn—Fe spinel with general formulation of Cu x Mn y Fe z O 4 , may provide solutions for enhanced NOx, CO, and HC conversion performance for TWC applications, employing ZPGM materials for a plurality of TWC applications. Additionally, these types of ternary ZPGM fine grain bulk powder spinel compositions may have a cost effective manufacturing advantage.
1 . A catalytic composition, comprising:
an oxygen storage material, comprising:
Co_Mn—Fe 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.
2 . The composition of claim 1 , wherein the Co_Mn—Fe spinel is stoichiometric.
3 . The composition of claim 1 , wherein the Co_Mn—Fe spinel is non-stoichiometric.
4 . The composition of claim 1 , wherein the Co_Mn—Fe spinel is applied to the support oxide by incipient wetness (IW) method.
5 . The composition of claim 1 , wherein the Co_Mn—Fe spinel has the general formula (Co x Fe z Mn 2z ) 3δ O 4 , wherein Fe/Mn=0.5, x+3z=1, and 0≦δ≦0.2.
6 . The composition of claim 1 , wherein the Co_Mn—Fe spinel has the general formula Co 1-x Mn x Fe 2 O 4 wherein 0≦x≦1.
7 . The composition of claim 1 , wherein the Co_Mn—Fe spinel has the general formula Cu x Mn y Fe z O 4 wherein x+y+z=3.
8 . The composition of claim 1 , wherein the doped zirconia comprises Pr 6 O 11 —ZrO 2 .
9 . The composition of claim 1 , wherein the Fe of the Co_Mn—Fe spinel is in the spinel B site.
10 . The composition of claim 1 , wherein the oxygen storage material is calcined at about 800° C.
11 . The composition of claim 10 , wherein the oxygen storage material is calcined for about 5 hours.
12 . The composition of claim 1 , wherein the Mn of the Co_Mn—Fe spinel is in the spinel B site.
13 . A method for making a catalytic composition, comprising:
preparing a solution comprising Co nitrate solution Co(NO 3 ) 2 , Fe nitrate solution (Fe(NO 3 ) 3 ) and Mn nitrate solution (Mn(NO 3 ) 2 ) with water wherein Co_Mn—Fe spinel is formed;
adding the solution drop-wise to doped Zirconia powder via an incipient wetness method to create a mixture;
drying the mixture at 120° C. for more than 4 hours; and
calcining the mixture at about 800° C. for about 5 hours
14 . The method of claim 13 , further comprising grounding the mixture into a fine grain powder.
15 . The method of claim 13 , wherein the Co_Mn—Fe spinel is stoichiometric.
16 . The method of claim 13 , wherein the Co_Mn—Fe spinel is non-stoichiometric.
17 . The method of claim 13 , wherein the Co_Mn—Fe spinel has the general formula (Co x Fe z Mn 2z ) 3δ O 4 , wherein Fe/Mn=0.5, x+3z=1, and 0≦δ≦0.2.
18 . The method of claim 13 , wherein the Co_Mn—Fe spinel has the general formula Co 1-x Mn x Fe 2 O 4 wherein 0≦x≦1.
19 . The method of claim 13 , wherein the Co_Mn—Fe spinel has the general formula Cu x Mn y Fe z O 4 wherein x+y+z=3.
20 . The method of claim 13 , wherein the doped zirconia comprises Pr 6 O 11 —ZrO 2 .
21 . The method of claim 13 , wherein the Fe of the Co_Mn—Fe spinel is in the spinel B site.