Patent Application
20160361711
Field of the Disclosure
This disclosure relates generally to zero-PGM (ZPGM) catalyst materials, and more particularly, to reversible redox properties of spinel oxide materials for use in a plurality of catalyst applications.
Background Information
Conventional gasoline exhaust systems employ three-way catalysts (TWC) technology and are referred to as TWC systems. TWC systems convert the toxic CO, HC and NOx into less harmful pollutants. Typically, TWC systems include a substrate structure upon which a layer of supporting and sometimes promoting oxides are deposited. Catalysts, based on platinum group metals (PGM), are then deposited upon the supporting oxides. Conventional PGM materials include platinum (Pt), palladium (Pd), rhodium (Rh), iridium (Ir), or combinations thereof.
Although PGM catalyst materials are effective for toxic emission control and have been commercialized by the emissions control industry, PGM materials are scarce and expensive. This high cost remains a critical factor for widespread applications of PGM catalyst materials. As changes in the formulation of catalysts continue to increase the cost of TWC systems, the need for catalysts of significant catalytic performance has directed efforts toward the development of catalytic materials capable of providing the required synergies to achieve greater catalytic performance. Additionally, compliance with ever stricter environmental regulations and the need for lower manufacturing costs require new types of TWC systems. Therefore, there is a continuing need to provide TWC systems exhibiting catalytic properties substantially similar to or exceeding the catalytic properties exhibited by conventional TWC systems employing high PGM catalyst materials.
The present disclosure describes zero-platinum group metals (ZPGM) material compositions including binary spinel oxide powders to develop suitable ZPGM catalyst materials. Further, the present disclosure describes reduction/oxidation (redox) reversibility, catalytic performance, and thermal stability of the aforementioned ZPGM catalyst materials. These ZPGM catalyst materials can be employed for a variety of catalyst applications, such as, for example oxygen storage material (OSM) applications, and ZPGM and ultra-low loading synergized-PGM (SPGM) three-way catalyst (TWC) systems, amongst others.
In some embodiments, the ZPGM catalyst materials include binary spinel oxide compositions, which are synthesized using conventional synthesis methodologies to produce spinel oxide powders. In these embodiments, the binary spinel oxide composition is implemented as copper (Cu)-manganese (Mn) spinel oxide compositions. Further to these embodiments, the Cu—Mn spinel oxide is produced using a general formulation CuXMn3−XO4 in which X is a variable representing molar ratios within a range from about 0.01 to about 2.99. In an example, X takes a value of about 1.0 for a stoichiometric CuMn2O4 spinel oxide powder.
In some embodiments, the redox behavior of the Cu—Mn spinel oxide powder is analyzed within oxidation-reduction environments. In these embodiments, functional testing and chemical characterization of Cu—Mn spinel powder are conducted to assess the formation of the spinel phase, the reversible redox property, thermal stability, and the catalytic activity of the Cu—Mn spinel powder. Further to these embodiments, the chemical characterization of the Cu—Mn spinel powder is performed during a redox cycling process employing X-ray diffraction (XRD) analysis, hydrogen temperature-programmed reduction (H2-TPR) technique, transmission electron microscopy (TEM) analysis, and X-ray photoelectron spectroscopy (XPS) analysis.
The chemical characterization of the spinel powder confirms the significant redox property and reversibility of the Cu—Mn spinel oxide under reduction/oxidation environments. In other words, the Cu—Mn spinel structure, which is free of PGM and rare-earth metals, exhibits significant redox stability and reversibility that can enable catalyst materials in bulk powder format for the development of a plurality of TWC systems and other catalyst applications.
Numerous other aspects, features, and benefits of the present disclosure may be made apparent from the following detailed description taken together with the drawing figures.
The present disclosure can be better understood by referring to the following figures. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosure. In the figures, reference numerals designate corresponding parts throughout the different views.
The present disclosure is described herein in detail with reference to embodiments illustrated in the drawings, which form a part hereof Other embodiments may be used and/or other modifications may be made without departing from the scope or spirit of the present disclosure. The illustrative embodiments described in the detailed description are not meant to be limiting of the subject matter presented.
Definitions
As used here, the following terms have the following definitions:
“Calcination” refers to a thermal treatment process applied to solid materials, in presence of air, to bring about a thermal decomposition, phase transition, or removal of a volatile fraction at temperatures below the melting point of the solid materials.
“Catalyst” refers to one or more materials that may be of use in the conversion of one or more other materials.
“Conversion” refers to the chemical alteration of at least one material into one or more other materials.
“Energy-dispersive X-ray spectroscopy (EDS, EDX, or XEDS) analysis” refers to an analytical technique used for the elemental or chemical compositional analysis of a material, based on the fundamental principle that each element has a unique atomic structure, thereby allowing a unique set of peaks on its X-ray emission spectrum.
“High-resolution transmission electron microscopy or HRTEM testing” refers to an imaging mode of the transmission electron microscope (TEM) that allows for direct imaging of the atomic structure of the sample to study properties of materials on the atomic scale, such as, for example metals, nanoparticles, graphene, and C nanotubes, amongst others.
“Lattice matching” refers to a matching of a unit cell of an unknown material against a database of known materials represented by their respective standard unit cell dimensions to determine the unknown materials lattice parameters and identify the unknown material.
“Lattice parameter or lattice constant” refers to the physical dimension of unit cells in a crystal lattice. Lattices in three dimensions have three lattice constants, referred to as a, b, and c. However, in the special case of cubic crystal structures, all of the constants are equal and only referred to a.
“Platinum group metals (PGM)” refers to platinum, palladium, ruthenium, iridium, osmium, and rhodium.
“Scanning transmission electron microscope (STEM)” refers to a type of transmission electron microscope (TEM) testing in which the electrons pass through a sufficiently thin specimen by focusing an electron beam into a narrow spot which is scanned over the sample raster.
“Spinel” refers to any minerals of the general formulation AB2O4 where the A ion and B ion are each selected from mineral oxides, such as, for example magnesium, iron, zinc, manganese, aluminum, chromium, titanium, cobalt, nickel, or copper, amongst others.
“Support oxide” refers to porous solid oxides, typically mixed metal oxides, which are used to provide a high surface area that aids in oxygen distribution and exposure of catalysts to reactants, such as, for example NOX, CO, and hydrocarbons.
“Temperature-programmed reduction (TPR)” refers to a technique for the characterization of solid materials often used in the field of heterogeneous catalysis to find the most efficient reduction conditions, in which a catalyst precursor is submitted to a programmed temperature rise, while a reducing gas mixture is flowed over it.
“Three-way catalyst (TWC)” refers to a catalyst that performs the three simultaneous tasks of reduction of nitrogen oxides to nitrogen and oxygen, oxidation of carbon monoxide to carbon dioxide, and oxidation of unburnt hydrocarbons to carbon dioxide and water.
“X-ray diffraction (XRD) analysis” refers to an analytical technique for identifying crystalline material structures, including atomic arrangement, crystalline size, and imperfections in order to identify unknown crystalline materials (e.g., minerals, inorganic compounds).
“X-ray photoelectron spectroscopy (XPS) analysis” refers to a surface-sensitive quantitative spectroscopy technique that measures the elemental composition at the parts per thousand range, empirical formula, chemical state, and electronic state of the elements that exist within a material.
The present disclosure describes zero-platinum group metals (ZPGM) material compositions including binary spinel oxide powders to develop suitable ZPGM catalyst materials. Further, the present disclosure describes reduction/oxidation (redox) reversibility, catalytic performance, and thermal stability of the aforementioned ZPGM catalyst materials using various chemical characterization and catalyst functional testing. These ZPGM catalyst materials can be employed for a variety of catalyst applications, such as, for example oxygen storage material (OSM) applications, and ZPGM and ultra-low loading synergized PGM (SPGM) three-way catalyst (TWC) systems, amongst others.
ZPGM Catalyst Material Composition and Preparation
In some embodiments, the ZPGM catalyst materials include binary spinel oxide compositions, which are synthesized using conventional synthesis methodologies to produce spinel oxide powders.
In these embodiments, the binary spinel oxide composition is implemented as copper (Cu)-manganese (Mn) spinel oxide compositions. Further to these embodiments, the Cu—Mn spinel oxide is produced using a general formulation CuXMn3−XO4 spinel in which X is a variable representing molar ratios within a range from about 0.01 to about 2.99. In an example, X takes a value of about 1.0 for a stoichiometric CuMn2O4 spinel oxide powder. Still further to these embodiments, bulk powder of CuMn2O4 spinel is produced as described in U.S. patent application Ser. No. 13/891,617. In these embodiments, bulk powder Cu—Mn spinel is calcined at a plurality of temperatures within a range from about 600° C. to about 1000° C.
X-ray Diffraction Analysis for CuMn2O4 Spinel Phase Formation
In some embodiments, XRD spectrum 102 illustrates diffraction peaks of a fresh Cu—Mn spinel powder. In these embodiments and after calcination, pure CuMn2O4 spinel phase is produced, as illustrated by spectral lines 104. Further to these embodiments, pure CuMn2O4 spinel includes no contaminant and no secondary oxide phases. This result confirms the presence of pure and single phase CuMn2O4 spinel oxide within the produced spinel powder.
In
Functional Testing and Characterization of CuMn2O4 Spinel Powder
In some embodiments, the behavior of the Cu—Mn spinel oxide powder is analyzed within oxidation-reduction environments to determine the reduction/oxidation (redox) reversibility, catalytic activity, and thermal stability of the Cu—Mn spinel oxide powder that result from the associated metal-oxygen-metal interactions during the oxidation-reduction cycling process. In these embodiments, functional testing and chemical characterization of Cu—Mn spinel powder are conducted to assess the formation of the spinel phase, the reversible redox property, thermal stability, and the catalytic activity of the Cu—Mn spinel powder. Further to these embodiments, the catalytic activity of the Cu—Mn spinel powder is determined employing a TWC light-off testing during a redox condition cycling process.
In some embodiments, the chemical characterization of the Cu—Mn spinel powder is performed during a redox condition cycling process. In these embodiments, the redox condition cycling process employs X-ray diffraction (XRD) analysis, hydrogen temperature-programmed reduction (H2-TPR) technique, transmission electron microscopy (TEM) analysis, and X-ray photoelectron spectroscopy (XPS) analysis.
HRTEM-EDS Analysis of Fresh CuMn2O4 Spinel Powder
In some embodiments, the crystal structure of a fresh CuMn2O4 spinel powder is assessed by high-resolution transmission electron microscopy (HRTEM) in combination with an energy-dispersive X-ray spectroscopy (EDS) analysis. In these embodiments, the HRTEM-EDS analysis is employed to confirm the spinel oxide elemental composition.
In some embodiments, the CuMn2O4 spinel spectra from the XRD data is verified by diffraction imaging and EDS measurements, which indicate minor variations in the Mn:Cu ratio. In these embodiments, all grains identified as CuMn2O4 spinel exhibit superlattice reflections. Further to these embodiments, detailed EDS measurements of different parts of a singular grain is illustrated by EDS spectrum 204. Still further to these embodiments, minor deviations in the Mn:Cu ratio are indicated by the EDS data. In these embodiments, electron diffraction pattern 206 verifies a CuMn2O4 spinel grain. Further to these embodiments, the small and weak, but very sharp spots arranged around the major reflections are seen as superlattice reflections. Still further to these embodiments, all grains identified as CuMn2O4 spinel exhibit aforementioned superlattice reflections in all orientations.
Reversibility of Cu—Mn Spinel Oxide Under Reduction/Oxidation Conditions
In some embodiments, partial reduction step 302 is a partial reduction reaction of the Cu—Mn spinel oxide powder performed by means of a reducing gas. In these embodiments and after partial reduction step 302, Cu—Mn spinel oxide powder is characterized by means of an XRD analysis to detect the phases formed as a result of partial reduction step 302. Further to these embodiments, partial reduction step 302 is followed by a full reduction step 304 employing a substantially similar reducing gas as previously used in partial reduction step 302, above. Still further to these embodiments, Cu—Mn spinel oxide powder is then characterized by means of an XRD analysis to detect the phases formed as a result of full reduction step 304. In these embodiments, full reduction step 304 is followed by oxidation step 306 performed by employing an 02 gas composition to restore the Cu—Mn spinel oxide powder to an oxidized state. Further to these embodiments and after oxidation step 306, Cu—Mn spinel oxide powder is characterized by means of an XRD analysis to detect the phases formed and to confirm that the Cu—Mn spinel oxide exhibits a redox reversibility property.
In some embodiments, at the beginning of the redox reversibility cycle a pure CuMn2O4 spinel oxide phase within the bulk powder spinel is detected (spinel phase 308). In these embodiments, the redox reversible cycle continues during partial reduction step 302, in which partial reduction is performed employing a reducing gas having about 0.5% CO at about 600° C. for a duration of about 20 minutes. Further to these embodiments and after partial reduction step 302, mixed phases of CuO/MnO/spinel 310 are detected.
In some embodiments, the redox reversible cycle continues during full reduction step 304, in which full reduction is performed employing a reducing gas having about 0.5% CO at about 600° C. for a duration of about 120 minutes. In these embodiments, after full reduction step 304, mixed phases of Cu/MnO 312 are detected.
In some embodiments, the redox reversible cycle continues during oxidation step 306, in which oxidation is performed employing an oxidizing gas having about 0.5% 02 at about 600° C. for a duration of about 120 minutes. In these embodiments and after oxidation step 306, CuMn2O4 spinel oxide phase 308 is detected.
In some embodiments and after partial reduction step 302, XRD spectrum 412 of XRD analysis 410 illustrates diffraction peaks for separate phases of CuO, MnO, and Cu—Mn spinel, as illustrated by spectral line 414, spectral lines 416, and spectral lines 104, respectively. In these embodiments and after full reduction step 304, XRD spectrum 422 of XRD analysis 420 illustrates diffraction peaks for separate phases of Cu and MnO, as illustrated by spectral lines 424 and 426, respectively. Further to these embodiments and after oxidation step 306, XRD spectrum 102 of XRD analysis 100 illustrates diffraction peaks of bulk powder Cu—Mn spinel. The results in
In some embodiments, XRD analysis 500 indicates that after the oxidation step the Cu—Mn spinel is fully returned, as illustrated by XRD spectrum 502 and spectral line 104. In these embodiments, spectral line 104 represents the phase intensity of Cu—Mn spinel that is exhibiting an associated diffraction peak within XRD spectrum 502 that confirms the Cu—Mn spinel possesses a redox reversibility property during the oxidation-reduction process, as previously described in
Temperature-Programmed Reduction (TPR) Test of Cu—Mn Spinel Powder
In some embodiments, TPR spectrum 602, TPR spectrum 604, and TPR spectrum 606 illustrate the results of the H2-TPR testing employed to characterize the reduction property of the Cu—Mn spinel oxide during the oxidation-reduction process. In these embodiments, the TPR test is performed employing a reducing gas mixture of about 10% H2 diluted in argon (Ar), and the reversibility cycle (described in
In some embodiments, TPR spectrum 602 illustrates the result of the H2 consumption per gram of fresh Cu—Mn spinel as a function of temperature. In these embodiments, TPR spectrum 604 illustrates the result of the H2 consumption per gram of a full reduced Cu—Mn spinel as a function of temperature. Further to these embodiments, TPR spectrum 606 illustrates the result of the H2 consumption per gram of a re-oxidized Cu—Mn spinel as a function of temperature.
In some embodiments, the integration of the area under the associated curve provides the total hydrogen consumption (mL/g spinel) that occurs during the H2-TPR test on a Cu—Mn spinel at various stages of the redox cycle. In these embodiments, H2 consumption of TPR spectrum 602 is about 141.9 mL/g, TPR spectrum 604 is about 7.1 mL/g, and TPR spectrum 606 is about 149.1 mL/g. Further to these embodiments, the H2 consumption of fresh spinel and spinel after redox reaction exhibit substantially similar H2 consumption, thereby confirming that the Cu—Mn spinel phase is reversible.
Activity of Cu—Mn Spinel Powder
In some embodiments, NO conversion curve 702, NO conversion curve 704, and NO conversion curve 706 illustrate the NO conversion percentage results before the reduction step (fresh), after the reduction step, and after the oxidation step, respectively.
In some embodiments, NO conversion curve 704 illustrates that NO conversion occurs at higher temperatures within a range from about 400° C. to about 600° C. under LO condition after the full reduction step. In these embodiments, the aforementioned NO conversion is attributed to Cu metal and MnO. Further to these embodiments, NO conversion curve 706 indicates that the re-oxidation of the Cu and MnO phases regenerates to Cu—Mn spinel, which exhibits slightly increased activity when compared with NO conversion curve 702 associated with the fresh Cu—Mn spinel. In summary, these results indicate that the Cu—Mn spinel structure exhibits stability towards oxidation-reduction during redox cycle.
Characterization of Cu—Mn Spinel Powder Employing XPS Analysis
In some embodiments, XPS spectrum 802 illustrates the Cu2p3/2 de-convoluted peaks associated with a fresh Cu—Mn spinel before the reduction step of the reversibility cycle. In these embodiments, Cu+ peak 810 of XPS spectrum 802 possesses significantly less Cu+ cations than the total Cu cations possessed by Cu2+ peak 812 and Cu2+ peak 814 of XPS spectrum 802. Further to these embodiments, XPS spectrum 804 illustrates the Cu2p3/2 de-convoluted peaks associated with CuO/MnO/spinel phases during the reduction step of the reversibility cycle. In these embodiments, Cu+ peak 816 of XPS spectrum 804 possesses significantly more Cu+ cations than the Cu2+ cations possessed by Cu2+ peak 818 of XPS spectrum 804. Still further to these embodiments, XPS spectrum 806 illustrates the Cu2p3/2 de-convoluted peaks associated with a re-oxidized Cu—Mn spinel after the oxidation step of the reversibility cycle. In these embodiments, Cu+ peak 820 of XPS spectrum 806 possesses significantly less Cu cations than the total Cu2+ cations possessed by Cu2+ peak 822 and Cu2+ peak 824 of XPS spectrum 806.
In some embodiment and after full reduction step 304, Cu metal is not detected in XPS spectrum 804, and the intensity of Cu cations indicate that Cu2+ is significantly reduced. In these embodiments, CO2+ is reduced to Cu1+. Further to these embodiments and after oxidation step 306, the intensity of Cu cations indicates that a re-oxidation of Cu1+ to Cu2+ is detected in the reversibility cycle, as described in XPS spectrum 806.
In some embodiments and for the fresh Cu—Mn spinel powder, the Cu2+ concentration is higher than the Cu+ concentration, therefore majority of Cu cations within Cu—Mn spinel oxide is in form of Cu2+ . In these embodiments and after complete reduction cycle, the Cu+ concentration is higher than the Cu2+ concentration, thereby indicating that majority of the Cu cations are reduced to Cu+. Further to these embodiments and after re-oxidation (complete redox cycle) of the spinel oxide powder, the Cu—Mn spinel oxide powder exhibits again a higher concentration of Cu2+ than Cu+ concentration, thereby indicating the re-oxidation of Cu+ to Cu2+. Still further to these embodiments, the oxidation state of Cu within the Cu—Mn spinel oxide powder resulting from the XPS analysis confirms that the Cu—Mn spinel exhibit a reversible oxidation-reduction property.
TEM Analysis of Cu—Mn Spinel Powder after Reduction in a CO Environment
In some embodiments and referring to
In some embodiments, spinel phase 912 illustrates the distribution of CuO/MnO/ spinel phases associated with a Cu—Mn spinel powder after partial reduction step 302. In these embodiments, CuO phase 914 illustrates Cu-rich phases associated with a Cu—Mn spinel powder after partial reduction step 302. Further to these embodiments, MnO phase 916 illustrates Mn-rich phases associated with a Cu—Mn spinel powder after partial reduction step 302.
In some embodiments, as illustrated by STEM images 906 and 908, the Cu-map exhibits significantly defined and separate Cu-rich phases (CuO phase 914) surrounded by Mn-rich phases (MnO phase 916). In these embodiments, these results confirm the phase separation of Cu and Mn surrounded by spinel phase 912 particles in a partial reduced sample. Further to these embodiments and referring to XRD data, the Mn- and Cu-phases are found to be MnO and CuO. Still further to these embodiments, the STEM-EDS mapping exhibits a phase separation of Cu and Mn surrounded by spinel phase 912 particles. The presence of spinel crystals around the CuO/MnO is confirmed in
In some embodiments, many nano-sized crystals of a second phase cover the surface of the MnO crystals as illustrated by the particular diffraction patterns that related to CuMn spinet. In these embodiment and referring to electron diffraction pattern 206, the Mn-rich phase has the MnO crystal structure. Further to these embodiments, a pattern of weak reflections in the background reveals a second phase as it is described in CuO/MnO/spinel phases diagram 920. In these embodiments, dark field image 1004 confirms the existence of nano-sized crystals on the surface of MnO grains.
In summary, XRD, XPS, TPR, and activity measurements confirm the significant redox reversibility property of the Cu—Mn spinel oxide during the complete redox cycle. In other words, the Cu—Mn spinel oxide, which is free of PGM and rare-earth metals, exhibits significant redox stability and reversibility that can enable catalyst materials in bulk powder format for the development of a plurality of TWC systems and other catalyst applications.
While various aspects and embodiments have been disclosed, other aspects and embodiments are contemplated. The various aspects and embodiments disclosed are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
This application claims priority to U.S. Provisional Application Ser. No. 62/175,956, filed Jun. 15, 2015, which is hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62175956 | Jun 2015 | US |
