# US 9,433,930 B2 · Methods for selecting and applying a layer of Cu—Mn spinel phase to ZPGM catalyst systems for TWC application > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,433,930 B2 - Document ID: US9433930B2 - Status: Granted - Kind: B2 - Application number: 14/090,809 - Filed: 2013-11-26 - Published: 2015-05-28 - Granted: 2016-09-06 - Earliest claimed: 2013-11-26 - Assignees: Clean Diesel Technologies Inc. (Cdti) - Applicants: Clean Diesel Technologies, Inc. - Inventors: Zahra Nazarpoor - Web page: https://patentgrep.com/patent/US9433930B2 ## CPC - B01J 23/8892: {Manganese} - B01D 53/945: {characterised by a specific catalyst} - B01J 23/005: {Spinels} - B01J 37/0244: {Coatings comprising several layers} - B01D 2255/20715: Zirconium - B01D 2255/2073: Manganese - B01D 2255/20761: Copper - B01D 2255/209: Other metals - B01D 2255/40: Mixed oxides - B01D 2255/65: Catalysts not containing noble metals - B01J 37/035: {Precipitation on carriers} - B01J 37/038: {to form slurries or suspensions, e.g. a washcoat} - B01J 2523/00: Constitutive chemical elements of heterogeneous catalysts - Y02T 10/12: Improving ICE efficiencies - 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) - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract The present disclosure relates to selecting the layer of applying ZPGM active phase in washcoat, or applying ZPGM active phase in overcoat, for achieving optimized performance and enhanced thermal stability. Applying ZPGM active phase catalyst in overcoat shows improvements compare to applying ZPGM active phase in washcoat. The selected active phase material may include a chemical composition that is substantially free from PGM, including a formulation of stoichiometric Cu—Mn spinel structure active phase deposited on Niobium-Zirconium support oxide. The selected active phase layer applied in overcoat may include a washcoat of alumina coated on a suitable ceramic substrate. The disclosed active phase may be applied in overcoat to maximize efficiency of catalyst systems, which may exhibit enhanced catalytic activity properties, which may stable after aging and under steady state and oscillating condition, showing optimized performance purifying gases in TWC condition. ## Claims ### Claim 1 A method for optimizing a catalytic component, comprising: applying to a substrate a first washcoat comprising AL203, applying to the substrate of a second washcoat or an overcoat having at least one active phase catalyst composition comprising Cu—Mn and a support oxide comprising Nb205-Zr02, wherein a loading of Cu—Mn in the catalyst composition is from 25 to 34%, and a loading of the Nb205-Zr02 in the catalyst composition is from 66 to 75%, based on a total loading of the catalyst composition. ### Claim 2 (depends on 1) The method of claim 1, wherein the substrate comprises cordierite. ### Claim 3 (depends on 1) The method of claim 1, wherein the substrate comprises ceramics. ### Claim 4 (depends on 1) The method of claim 1, wherein the substrate comprises a honeycomb structure. ### Claim 5 (depends on 1) The method of claim 1, wherein the at least one active phase catalyst is an aqueous slurry. ### Claim 6 (depends on 1) The method of claim 1, wherein the at least one active phase catalyst comprises at least one spinel structure. ### Claim 7 (depends on 1) The method of claim 1, wherein the Cu—Mn is stoichiometric. ### Claim 8 (depends on 1) The method of claim 1, wherein the at least one active catalyst is calcined at about 600° C. ### Claim 9 (depends on 1) The method of claim 1, wherein the least one active phase catalyst is substantially free from platinum group metals. ### Claim 10 (depends on 1) The method of claim 1, wherein the least one active phase catalyst is made by a co-precipitation method. ### Claim 11 (depends on 1) The method of claim 1, wherein the least one active phase catalyst is applied in the second washcoat. ### Claim 12 (depends on 11) The method of claim 11, wherein the least one active phase catalyst is applied as a powder. ### Claim 13 (depends on 11) The method of claim 11, wherein the least one active phase catalyst is applied as a slurry. ### Claim 14 (depends on 1) The method of claim 1, wherein the least one active phase catalyst has a higher catalytic activity when substantially contained in the overcoat. ### Claim 15 (depends on 1) The method of claim 1, wherein the least one active phase catalyst has a higher stability when substantially contained in the overcoat. ### Claim 16 (depends on 1) The method of claim 1, wherein a loading of Cu in the catalyst composition is from 8 to 13%. ### Claim 17 (depends on 1) The method of claim 1, wherein a loading of Mn in the catalyst composition is from 16 to 21%. ### Claim 18 A method for optimizing a catalytic component, comprising: applying to a substrate a first washcoat comprising AL203, applying to the substrate of a second washcoat or an overcoat having at least one active phase catalyst composition consisting of Cu—Mn and a support oxide of Nb205-Zr02.