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

Gu, Yuntao; Liu, Fudong; Li, Wei; Xie, Shaohua; Li, Yuejin; Zheng, Xiaolai

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

Abstract

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% CeO₂/Al₂O₃, 20% CeO₂—Al₂O₃ (20CeAlOy), 30% CeO₂—Al₂O₃ (30CeAlOy), Al₂O₃, and MOx-Al₂O₃, wherein M is one of copper, iron, manganese, titanium, zirconium, magnesium, strontium, and barium. The palladium catalyst material includes a layer of CeO₂ material disposed upon the support material, wherein the layer of CeO₂ material 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 CeO₂ material and a layer of palladium particles disposed upon and dispersed across the surface of the layer of CeO₂ material at locations each corresponding to a respective location of each of the praseodymium particles.

Inventors:: Gu, Yuntao; Liu, Fudong; Li, Wei; Xie, Shaohua; Li, Yuejin; Zheng, Xiaolai

Issue Date:: 2023-10-31

Research Org.:: GM Global Technology Operations LLC, Detroit, MI (United States); Univ. of Central Florida, Orlando, FL (United States); BASF Corporation, Iselin, NJ (United States)

Sponsoring Org.:: USDOE

OSTI Identifier:: 2293787

Patent Number(s):: 11801491

Application Number:: 17/725,828

Assignee:: GM Global Technology Operations LLC (Detroit, MI); University of Central Florida Research Foundation, Inc. (Orlando, FL); BASF Corporation (Iselin, NJ)

Patent Classifications (CPCs):: B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01D - SEPARATION

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

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B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01D - SEPARATION
B01D2255/1023 - Palladium
B01D2255/2065 - Cerium
B01D2255/2066 - Praseodymium
B01D2255/2092 - Aluminium
B01D53/945 - {characterised by a specific catalyst}

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY
B01J21/04 - Alumina
B01J23/10 - of rare earths
B01J23/44 - Palladium
B01J23/63 - with rare earths or actinides
B01J37/0201 - {Impregnation}
B01J37/0215 - {Coating}
B01J37/0236 - {Drying, e.g. preparing a suspension, adding a soluble salt and drying}
B01J37/0244 - {Coatings comprising several layers}
B01J37/0248 - {Coatings comprising impregnated particles}
B01J37/031 - {Precipitation}
B01J37/035 - {Precipitation on carriers}
B01J6/001 - {Calcining}

F - MECHANICAL ENGINEERING F01 - MACHINES OR ENGINES IN GENERAL F01N - GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL
F01N2570/10 - Carbon or carbon oxides
F01N2570/12 - Hydrocarbons
F01N2570/14 - Nitrogen oxides
F01N3/101 - {Three-way catalysts}

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02T - CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
Y02T10/12 - Technologies for the improvement of indicated efficiency of a conventional ICE

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DOE Contract Number:: EE0009196

Resource Type:: Patent

Resource Relation:: Patent File Date: 04/21/2022

Country of Publication:: United States

Language:: English

Citation Formats


                    Gu, Yuntao, Liu, Fudong, Li, Wei, Xie, Shaohua, Li, Yuejin, and Zheng, Xiaolai. Three-way catalyst with reduced palladium loading and method of making the three-way catalyst.  United States: N. p., 2023. 
        Web.

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                    Gu, Yuntao, Liu, Fudong, Li, Wei, Xie, Shaohua, Li, Yuejin, & Zheng, Xiaolai. Three-way catalyst with reduced palladium loading and method of making the three-way catalyst.  United States.

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                    Gu, Yuntao, Liu, Fudong, Li, Wei, Xie, Shaohua, Li, Yuejin, and Zheng, Xiaolai. Tue .  
        "Three-way catalyst with reduced palladium loading and method of making the three-way catalyst".  United States.  https://www.osti.gov/servlets/purl/2293787.

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@article{osti_2293787,

  title        = {Three-way catalyst with reduced palladium loading and method of making the three-way catalyst},

  author       = {Gu, Yuntao and Liu, Fudong and Li, Wei and Xie, Shaohua and Li, Yuejin and Zheng, Xiaolai},

  abstractNote = {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% CeO2/Al2O3, 20% CeO2—Al2O3 (20CeAlOy), 30% CeO2—Al2O3 (30CeAlOy), Al2O3, and MOx-Al2O3, wherein M is one of copper, iron, manganese, titanium, zirconium, magnesium, strontium, and barium. The palladium catalyst material includes a layer of CeO2 material disposed upon the support material, wherein the layer of CeO2 material 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 CeO2 material and a layer of palladium particles disposed upon and dispersed across the surface of the layer of CeO2 material at locations each corresponding to a respective location of each of the praseodymium particles.},

  doi          = {},

  journal      = {},
number       = ,

  volume       = ,

  place        = {United States},

  year         = {2023},

  month        = {10}

}

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

Abstract

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Catalyst support for purification of exhaust gas, catalyst for purification of exhaust gas using the same, and method for producing the catalyst support for purification of exhaust gas
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