Mixed-phase ceramic oxide three-way catalyst formulations and methods for preparing the catalysts

A catalyst composition, comprising:

• (a) a substrate;
• (b) a washcoat;
• and
• (c) a multi-phase catalyst represented by the general formula:
• CeyLn1-xAx+sMOz,
• wherein:
• Ln is a mixture of elements originally in the form of single-phase mixed lanthanides collected from natural ores, a single lanthanide, or a mixture of artificial lanthanides;
• A is an element selected from the group consisting of Mg, Ca, Sr, Ba, Li, Na, K, Cs, Rb, and combinations thereof;
• M is an element selected from the group consisting of Fe, Mn, Cr, Ni, Co, Cu, V, Zr, Pt, Pd, Rh, Ru, Ag, Au, Al, Ga, Mo, W, Ti, and combinations thereof;
• x is a number defined by 0≦x<1.0;
• y is a number defined by 0≦y<10;
• s is a number defined by 0≦s<10;
• and
• z is a number defined by z>0,
• where s=0 only when y>0 and y=0 only when s>0.

A method of making a catalyst composition, the method comprising the steps of:

• (a) providing a substrate;
• (b) providing at least one carrier material for forming a washcoat on the substrate;
• (c) providing a solution for forming a multi-phase catalyst supported by the substrate, wherein the solution has a general cation formula of
• CeyLn1-xAx+sM, wherein:
• Ln is a single lanthanide, a mixture of artificial lanthanides, or a mixture of elements originally in the form of single-phase mixed lanthanides collected from natural ores;
• A is an element selected from the group consisting of Mg, Ca, Sr, Ba, Li, Na, K, Cs, Rb, and combinations thereof;
• and
• M is an element selected from the group consisting of Fe, Mn, Cr, Ni, Co, Cu, V, Zr, Pt, Pd, Rh, Ru, Ag, Au, Al, Ga, Mo, W, Ti and combinations thereof;
• x is a number defined by 0≦x<1.0;
• y is a number defined by 0≦y<10;
• s is a number defined by 0≦s<10, and
• z is a number defined by z>0,
• where s=0 only when y>0 and y=0 only when s>0;
• and
• (d) forming the catalyst composition comprising the substrate, the washcoat, and the multi-phase catalyst.

A method for simultaneous conversion of oxides of nitrogen, carbon monoxide, and hydrocarbons in motor vehicle exhaust comprising:

• (a) providing a catalyst composition, wherein said catalyst composition comprises:
• (i) a substrate;
• (ii) a washcoat;
• and
• (iii) a multi-phase catalyst represented by the general formula:
• CeyLn1-xAx+sMOz,
• wherein:
• Ln is a mixture of elements originally in the form of single-phase mixed lanthanides collected from natural ores, a single lanthanide, or a mixture of artificial lanthanides;
• A is an element selected from the group consisting of Mg, Ca, Sr, Ba, Li, Na, K, Cs, Rb, and combinations thereof;
• M is an element selected from the group consisting of Fe, Mn, Cr, Ni, Co, Cu, V, Zr, Pt, Pd, Rh, Ru, Ag, Au, Al, Ga, Mo, W, Ti, and combinations thereof;
• x is a number defined by 0≦x<1.0;
• y is a number defined by 0≦y<10;
• s is a number defined by 0≦s<10;
• and
• z is a number defined by z>0,
• where s=0 only when y>0 and y=0 only when s>0;
• and
• (b) contacting said exhaust with said catalyst composition.