# US 11,439,983 B2 · Active perovskite-type catalysts stable to high temperature aging for gasoline exhaust gas applications

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- Number: US 11,439,983 B2
- Document ID: US11439983B2
- Status: Granted
- Kind: B2
- Application number: 16/832,018
- Filed: 2020-03-27
- Published: 2020-10-01
- Granted: 2022-09-13
- Earliest claimed: 2019-03-29
- Assignees: Johnson Matthey Public Limited Company
- Applicants: Johnson Matthey Public Limited Company
- Inventors: Shuhei Nagaoka; Kerry Simmance; Andrea Eva Pascui; Emily Price
- Web page: https://patentgrep.com/patent/US11439983B2

## CPC

- B01J 23/002: {Mixed oxides other than spinels, e.g. perovskite}
- B01D 53/945: {characterised by a specific catalyst}
- B01J 21/04: Alumina
- B01J 21/066: {Zirconium or hafnium; Oxides or hydroxides thereof}
- B01J 23/10: of rare earths
- B01J 23/34: Manganese
- B01J 23/83: with rare earths or actinides
- B01J 35/45: Nanoparticles
- B01J 35/613: {10-100 m2/g}
- B01J 35/733: {Perovskite-type}
- B01J 35/77: Compounds characterised by their crystallite size
- B01J 37/0072: {Preparation of particles, e.g. dispersion of droplets in an oil bath}
- B01J 37/04: Mixing {(B01J37/0009, B01J37/0018 take precedence)}
- B01J 37/14: with gases containing free oxygen
- B01J 37/349: {making use of flames, plasmas or lasers}
- F01N 3/101: {Three-way catalysts}
- F01N 3/28: Construction of catalytic reactors
- B01D 2255/2063: Lanthanum
- B01D 2255/20715: Zirconium
- B01D 2255/2073: Manganese
- B01D 2255/20738: Iron
- B01D 2255/2092: Aluminium
- B01D 2255/402: Perovskites
- B01D 2255/9202: Linear dimensions
- B01D 2255/9207: Specific surface
- B01J 35/30: characterised by their physical properties
- B01J 2235/00: Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties
- B01J 2235/15: X-ray diffraction
- B01J 2235/30: Scanning electron microscopy; Transmission electron microscopy
- B01J 2523/00: Constitutive chemical elements of heterogeneous catalysts
- B01J 2523/31: Aluminium
- B01J 2523/3706: Lanthanum
- B01J 2523/48: Zirconium
- B01J 2523/72: Manganese
- B01J 2523/842: Iron
- F01N 2370/04: Zeolitic material
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- F01N: GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES (arrangements in connection with gas exhaust of propulsion units in vehicles B60K13/00; combustion-air intake silencers specially adapted for, or arranged on, internal-combustion engines F02M35/00; protecting against, or damping, noise in general G10K11/16)

## Abstract

Compositions, articles, and methods related to a three-way-catalyst composition comprising a perovskite-type compound of formula (I): LazB1-qB′qO3±δ or formula (II):[BOx]y:[LazBO3±δ]1-y and a non-redox active component; wherein B or B′ is Fe, Mn, Co, Ni, Cu, Ti, or Zr; q is in a range from about 0 to about 0.5; x is from about 1 to about 2.5; y is from about 1 to about 30 wt %; z is about 0.6 to about 1.1; δ is in a range from about 0 to about 0.6.

## Claims

### Claim 1

A three-way catalyst composition comprising a perovskite-type compound of formula (I): LazB1-qB′qO3±δ or formula (II): [BOx]y:[LazBO3±δ]1-y and a non-redox active component; wherein
B or B′ is Fe, Mn, Co, Ni, Cu, Ti, or Zr;
q is in a range from 0 to 0.5;
δ is in a range from 0 to 0.6;
x is from 1 to 2.5;
y is from 1 to 30 wt %;
z is 0.6 to 1.1; and
wherein the perovskite-type compound has high surface area of at least 40 m2/g.

### Claim 2 (depends on 1)

The three-way catalyst composition of claim 1, wherein the perovskite-type compound is the compound of formula (I): LazBO3±δ.

### Claim 3 (depends on 2)

The three-way catalyst composition of claim 2, wherein B is Fe.

### Claim 4 (depends on 2)

The three-way catalyst composition of claim 2, wherein B is Mn.

### Claim 5 (depends on 1)

The three-way catalyst composition of claim 1, wherein the perovskite-type compound is the compound of formula (II): [BOx]y:[LazBO3±δ]1-y.

### Claim 6 (depends on 5)

The three-way catalyst composition of claim 5, wherein B is Mn.

### Claim 7 (depends on 1)

The three-way catalyst composition of claim 1, wherein the non-redox active component comprises an oxide.

### Claim 8 (depends on 1)

The three-way catalyst composition of claim 1, wherein the non-redox active component comprises alumina.

### Claim 9 (depends on 1)

The three-way catalyst composition of claim 1, wherein the non-redox active component comprises ZrO2.

### Claim 10 (depends on 9)

The three-way catalyst composition of claim 9, wherein the ZrO2 is doped.

### Claim 11 (depends on 1)

The three-way catalyst composition of claim 1, wherein the catalyst is substantially free of platinum group metals.

### Claim 12 (depends on 1)

The three-way catalyst composition of claim 1, wherein the catalyst is free of platinum group metals.

### Claim 13 (depends on 1)

The three-way catalyst composition of claim 1, wherein the perovskite-type compound is present in an amount of 5 wt % to 75 wt % of the catalyst composition.

### Claim 14 (depends on 1)

The three-way catalyst composition of claim 1, wherein the non-redox active component is present in an amount of 25 wt % to 95 wt % of the catalyst composition.

### Claim 15 (depends on 1)

The three-way catalyst composition of claim 1, wherein the perovskite-type compound and the non-redox active component are present in a weight ratio of 0.5:1 to 3:1.

### Claim 16 (depends on 1)

A catalyst article for treating exhaust gas, comprising:
a. a substrate; and
b. the three-way-catalyst composition of claim 1.

### Claim 17 (depends on 1)

A method of treating an exhaust gas from an internal combustion engine, comprising contacting the exhaust gas with a catalyst article comprising a substrate and the three-way-catalyst composition of claim 1.

### Claim 18 (depends on 17)

The method of claim 17, wherein the three-way-catalyst composition provides:
(1) a fresh NO conversion at 500-600° C., and
(2) an aged NO conversion at 500-600° C. after aging the catalyst at a temperature of at least 700° C. for 20 hours in the presence of steam,
wherein a delta between the fresh NO conversion and the aged NO conversion is a decrease of less than 20%.

### Claim 19 (depends on 17)

The method of claim 17, wherein the three-way-catalyst composition provides:
(1) a fresh HC or CO conversion at 500° C., and
(2) an aged HC or CO conversion at 500° C. after aging the catalyst at a temperature of at least 700° C. for 20 hours in the presence of steam,
wherein a delta between the fresh HC or CO conversion and the aged HC or CO conversion is a decrease of less than 50%.