[특허]Rhodium-iron catalysts

Clean Diesel Technologies, inc.

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Rhodium-iron catalysts

국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	B01J-027/25 B01J-023/00 B01J-023/02 B01J-023/10 B01J-023/40 B01J-023/42 B01J-023/44 B01J-023/56 B01J-023/58 B01J-023/70 B01J-023/74 B01J-021/04 B01D-053/94 B01J-023/89 B01J-035/04 B01J-023/20 B01J-023/63 B01J-027/232 B01J-035/00
출원번호	US-0732307 (2015-06-05)
등록번호	US-9475004 (2016-10-25)
발명자 / 주소	Hatfield, Randal L. Golden, Stephen J. Ngo, Johnny T.
출원인 / 주소	Clean Diesel Technologies, inc.
대리인 / 주소	Alston & Bird LLP
인용정보	피인용 횟수 : 0 인용 특허 : 60

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The present disclosure describes rhodium iron catalysts of use in catalyst systems. Disclosed here are TWCs configured to include a substrate and one or more of a washcoat layer, an impregnation layer, and/or an overcoat layer. Disclosed herein are one or more of a washcoat layer and/or an overcoat layer formed using a slurry that includes one or more of an oxygen storage material, a refractory support oxide, iron, and rhodium. Disclosed herein are methods of preparing catalysts wherein a washcoat layer is deposited onto the substrate, one or more impreg...

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1. A catalyst system, comprising: a substrate;a washcoat deposited on the substrate;at least one impregnation layer; andan overcoat;wherein the washcoat comprises at least one of the group consisting of about 10 wt % to about 75 wt % cerium oxide, about 25 wt % to about 90 wt % zirconium-hafnium oxide, about 0 wt % to about 15 wt % lanthanum oxide, about 0 wt % to about 15 wt % neodymium oxide, about 0 wt % to about 15 wt % yttrium oxide, and about 0 wt % to about 15 wt % praseodymium oxide;wherein the at least one impregnation layer comprises one or more of the group consisting of rhodium, iron nitrate, cerium, and combinations thereof; andwherein the overcoat comprises at least one of the group consisting of an oxygen storage material, a refractory support oxide, iron, rhodium, and combinations thereof. 2. The catalyst system of claim 1, wherein the washcoat further comprises at least one of the group consisting of a refractory support oxide, iron, rhodium, and combinations thereof. 3. The catalyst system of claim 1, wherein the at least one impregnation layer is loaded with about 2.9 g/ft3 to about 9.8 g/ft3 of rhodium. 4. The catalyst system of claim 3, wherein the at least one impregnation layer is loaded in the washcoat and wherein the washcoat further comprises a second impregnation layer of about 1 wt % to about 4 wt % iron. 5. The catalyst system of claim 3, wherein the at least one impregnation layer is loaded with about 60 g/ft3 to about 630 g/ft3 of iron. 6. The catalyst system of claim 5, wherein the at least one impregnation layer is loaded with about 150 g/ft3 to about 630 g/ft3 of iron. 7. The catalyst system of claim 3, wherein the washcoat comprises at least one of the group consisting of a fluorite phase Cerium Zirconium-Hafnium Lanthanum (CZL) OSM, a Cerium Zirconium-Hafnium Neodymium (CZN) OSM, a Cerium Zirconium-Hafnium Yttrium (CZY) OSM, a Cerium Zirconium-Hafnium Lanthanum Praseodymium (CZLP) OSM, a Cerium Zirconium (CZ) OSM, and a Cerium Zirconium-Hafnium Neodymium Yttrium (CZNY) OSM. 8. The catalyst system of claim 7, wherein said CZL OSM includes 30 wt % Cerium Oxide, 60 wt % Zirconium-Hafnium Oxide, and 10 wt % Lanthanum Oxide; said CZN OSM includes 30 wt % Cerium Oxide, 60 wt % Zirconium-Hafnium Oxide, and 10 wt % Neodymium Oxide; said CZY OSM includes 30 wt % Cerium Oxide, 60 wt % Zirconium-Hafnium Oxide, and 10 wt % Yttrium Oxide; said CZLP OSM includes 30 wt % Cerium Oxide, 60 wt % Zirconium-Hafnium Oxide, 5 wt % Lanthanum Oxide, and 5 wt % Praseodymium Oxide; said CZ OSM includes 75 wt % Cerium Oxide and 30% Zirconium-Hafnium Oxide; and said CZNY OSM includes 31 wt % Cerium, 58.3 wt % Zirconium-Hafnium, 5.5 wt % Neodymium, and 5.2 wt % Yttrium Oxide. 9. The catalyst system of claim 3, wherein the washcoat comprises at least one of the group consisting of a CZL, a CZN, a CZY, a CZLP, and a CZNY. 10. The catalyst system of claim 9, wherein said CZL OSM includes 30 wt % Cerium Oxide, 60 wt % Zirconium-Hafnium Oxide, and 10 wt % Lanthanum Oxide; said CZN OSM includes 30 wt % Cerium Oxide, wt % Zirconium-Hafnium Oxide, and 10 wt % Neodymium Oxide; said CZY OSM includes 30 wt % Cerium Oxide, 60 wt % Zirconium-Hafnium Oxide, and 10 wt % Yttrium Oxide; said CZLP OSM includes 30 wt % Cerium Oxide, 60 wt % Zirconium-Hafnium Oxide, 5 wt % Lanthanum Oxide, and 5 wt % Praseodymium Oxide; and said CZNY OSM includes 31 wt % Cerium, 58.3 wt % Zirconium-Hafnium, 5.5 wt % Neodymium, and 5.2 wt % Yttrium Oxide. 11. The catalyst system of claim 3, wherein the at least one impregnation layer is further loaded with about 150 g/ft3 to about 630 g/ft3 of iron; about 499 g/ft3 to about 1497 g/ft3 Cerium; and 0 g/ft3 to about 317 g/ft3 yttrium. 12. The catalyst system of claim 3, wherein the at least one impregnation layer is further loaded with about 150 g/ft3 to about 630 g/ft3 of iron; 0 g/ft3 to about 1497 g/ft3 Cerium; and about 31.7 g/ft3 to about 317 g/ft3 yttrium. 13. The catalyst system of claim 3, wherein the washcoat comprises about 7.36 wt % iron. 14. The catalyst system of claim 1, wherein the at least one impregnation layer is loaded with about 60 g/ft3 to about 630 g/ft3 of iron. 15. The catalyst system of claim 1, wherein the at least one impregnation layer is loaded with about 499 g/ft3 to about 1497 g/ft3 of cerium. 16. The catalyst system of claim 1, wherein the washcoat comprises iron, rhodium, and CZNY OSM. 17. The catalyst system of claim 16, wherein the washcoat comprises 7.36 wt % iron, rhodium, and CZNY OSM, and wherein the CZNY OSM comprises 31 wt % Cerium, 58.3 wt % Zirconium-Hafnium, 5.5 wt % Neodymium, and 5.2 wt % Yttrium Oxide. 18. The catalyst system of claim 1, wherein the washcoat comprises about 4 wt % to about 20 wt % iron. 19. The catalyst system of claim 1, wherein rhodium is loaded in the washcoat at about 0.1 g/ft3 to about 20 g/ft3. 20. The catalyst system of claim 19, wherein rhodium is loaded in the washcoat at about 4.8 g/ft3.

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Rhodium-iron catalysts

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