University of Central Florida Research Foundation Inc

Basf Corporation

Gm Global Technolgoy Operations, Inc.

Basf Mobile Emissions Catalysts LLC

Fudong Liu

Shaohua Xie

Wei Ping Li

Michel Deeba

Yuejin Li

Yuntao Gu

Xiaolai Zheng

A catalyst support structure may include a base material and a metal oxide support structure. The metal oxide support structure may be formed by loading a first concentration of precursors of a metal oxide onto the base material using incipient wetness impregnation (IWI) to form the catalyst support structure, performing a first calcination process on the catalyst support structure at a first temperature to produce first structures of the metal oxide, loading a second concentration of precursors of the metal oxide onto the catalyst support structure using IWI to at least partially cover the first structures of the metal oxide, and performing a second calcination process on the catalyst support structure at a second temperature lower than the first temperature to produce second structures of the metal oxide.

Defect engineering and modification of substrates for supported metal/metal oxide catalysts

The present disclosure provides SCR catalyst compositions capable of reducing nitrogen oxide (NO) emissions in engine exhaust. The catalyst compositions include a reducible metal oxide support containing ceria, one or more transition metal oxides as a redox promotor; and an oxide of niobium, tungsten, silicon, molybdenum, or a combination thereof as an acidic promotor. The redox promotor and the acid promotor are both supported on the reducible metal oxide support. Further provided are SCR catalyst articles coated with such compositions, processes for preparing such catalyst compositions and articles, an exhaust gas treatment system including such catalyst articles, and methods for reducing NOin an exhaust gas stream using such catalyst articles and systems.

Metal oxide-based SCR catalyst composition

Methods for fabricating thermally stable reducible metal oxide catalyst support structures on a base material using a multi-step incipient wetness impregnation (IWI) process are disclosed. For example, reducible metal oxide catalyst support structures having high surface area and high thermal stability may be formed using a multi-step IWI process, where the support structure is generated through high-temperature calcination between IWI steps. The metal or metal oxide catalysts fabricated using the methods are also disclosed. The generation of engineered surface defects on reducible metal oxides using a gas reduction process to serve as anchoring sites for metal or metal oxide catalysts is also disclosed. Generating engineered defects through a gas reduction process may be a relatively low-cost and scalable process suitable for fabricating efficient catalysts using a wide range of materials.

This disclosure is directed to catalyst compositions, catalytic articles for purifying exhaust gas emissions and methods of making and using the same. In particular, the disclosure relates to a catalytic article including a catalytic material on a substrate, wherein the catalytic material has a first layer and a second layer. The first layer includes a platinum group metal (PGM) component impregnated on a porous support material; and the second layer includes a rhodium component impregnated on a support material, wherein the support material is a composite material including zirconia doped with baria, alumina, or combinations thereof, wherein the zirconia-based support material includes zirconia in an amount from about 80 to about 99 wt. %.

Base metal doped zirconium oxide catalyst support materials

A method for fabricating a precious metal catalyst may include depositing a precious metal on a base material to form a catalyst structure, performing a first calcination on the catalyst structure, depositing a metal oxide on the catalyst structure such that the precious metal is at least partially encapsulated by the metal oxide, performing a second calcination on the catalyst structure, and reducing the catalyst structure with a reductive material to induce diffusion of at least a portion of the precious metal to a surface of the metal oxide.

Precious metal catalysts fabricated using reverse loading and metal shuttling

A catalyst may include a base material, a precious metal, and a metal oxide. At least a portion of the precious metal may form catalytically active sites on a surface of the metal oxide. The catalytically active sites may be formed by depositing the precious metal on the base material to form a catalyst structure, performing a first calcination on the catalyst structure, depositing the metal oxide on the catalyst structure, wherein the precious metal is at least partially encapsulated by the metal oxide, performing a second calcination on the catalyst structure, and reducing the catalyst structure with a reductive material, where at least a portion of the precious metal diffuses to a surface of the metal oxide to form the catalytically active sites.

A three-way catalyst for reduced palladium loading is provided. The catalyst includes an inert substrate and a palladium catalyst material coating the substrate. The palladium catalyst material includes a support material formed from one of 10% CeO/AlO, 20% CeO&#x2014;AlO(20CeAlOy), 30% CeO&#x2014;AlO(30CeAlOy), AlO, and MOx-AlO, wherein M is one of copper, iron, manganese, titanium, zirconium, magnesium, strontium, and barium. The palladium catalyst material includes a layer of CeOmaterial disposed upon the support material, wherein the layer of CeOmaterial is dispersed on a surface of the support material. The palladium catalyst material includes an active component including a layer of praseodymium oxide particles dispersed across the surface of the layer of CeOmaterial and a layer of palladium particles disposed upon and dispersed across the surface of the layer of CeOmaterial at locations each corresponding to a respective location of each of the praseodymium particles.

Three-way catalyst with reduced palladium loading and method of making the three-way catalyst

A layered catalyst structure for purifying an exhaust gas stream includes a catalyst support and a palladium catalyst layer including an atomic dispersion of palladium ions electrostatically adsorbed onto an exterior surface of the catalyst support. The catalyst support includes an alumina substrate, a first ceria layer disposed on and extending substantially continuously over the alumina substrate, and a second colloidal ceria layer formed directly on the first ceria layer over the alumina substrate. The palladium catalyst layer is formed on the exterior surface of the catalyst support by applying a palladium-containing precursor solution to the exterior surface of the catalyst support and then heating the catalyst support and the palladium-containing precursor solution. The palladium-containing precursor solution includes a positively charged palladium complex in an aqueous medium and has a pH greater than a point of zero charge of the second colloidal ceria layer.

Layered catalyst structures and methods of making the same

Described are three-way conversion (TWC) catalytic articles effective to abate hydrocarbons (HCs), carbon monoxide (CO), and nitrogen oxides (NO) from an engine exhaust gas containing phosphorous impurities. The disclosed catalytic article has a layered catalytic material, wherein the first layer of the catalytic material is disposed directly on the substrate and a second layer is disposed on top of the first layer. The second layer includes phosphorus resistant materials that prevent catalytic poisoning of the catalytic article by the phosphorous impurities. In particular, the second layer includes a phosphorus trap material having an alkaline earth metal component and a rhodium component impregnated on a phosphorus-resistant support material.

Growing community of inventors

Oviedo, FL, United States of America

Fudong Liu