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1. (WO2019043557) PHOSPHORUS RESISTANT THREE-WAY CATALYST
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WHAT IS CLAIMED:

1. A TWC catalytic article with enhanced phosphorus resistance comprising:

a catalytic material on a substrate, the catalytic material comprising a first layer disposed on the substrate and a second layer disposed on the first layer,

wherein the second layer comprises:

a phosphorus trap material comprising an alkaline earth metal component and a metal oxide, wherein the alkaline earth metal component is supported on the metal oxide or is in the form of a composite with the metal oxide, and

a rhodium component impregnated on a phosphorus-resistant support material; and

wherein the catalytic material is effective for three-way conversion to oxidize carbon monoxide and hydrocarbons and reduce nitrogen oxides.

2. The TWC catalytic article of claim 1, wherein the phosphorus-resistant support material is a zirconia-based support material.

3. The TWC catalytic article of claim 2, wherein the zirconia-based support material is zirconia, lanthana-zirconia, titania-zirconia, titania-lanthana-zirconia, alumina-zirconia, baria-zirconia, strontia-zirconia, neodymia-zirconia, praseodymia-zirconia, tungsten oxide -zirconia, niobia-zirconia, yttria-zirconia, or any combination thereof.

4. The TWC catalytic article of claim 3, wherein the zirconia-based support material is lanthana-zirconia.

5. The TWC catalytic article of claim 4, wherein the lanthana-zirconia comprises zirconia in an amount from about 80 to about 99 wt.%.

6. The TWC catalytic article of any of claims 1-5, wherein the second layer contains the rhodium component in an amount from about 0.05 to about 5 wt.%.

7. The TWC catalytic article of any of claims 1-6, wherein the alkaline earth metal component is selected from barium oxide, magnesium oxide, calcium oxide, strontium oxide, and combinations thereof.

8. The TWC catalytic article of claim 7, wherein the alkaline earth metal component is barium oxide.

9. The TWC catalytic article of claim 8, wherein the second layer contains the barium oxide in an amount from about 1 to about 40 wt.%.

10. The TWC catalytic article of any of claims 1-9, wherein the metal oxide is alumina, zirconia, titania, ceria, or a combination thereof

11. The TWC catalytic article of claim 10, wherein the metal oxide is alumina.

12. The TWC catalytic article of any of claims 1-11, wherein the phosphorus trap material is a composite of barium oxide and alumina.

13. The TWC catalytic article of any of claims 1-12, further comprising a second rhodium component, wherein the second rhodium component is impregnated on a refractory metal oxide support selected from alumina, lanthana-alumina, ceria-alumina, zirconia-alumina, ceria-zirconia-alumina, lanthana-zirconia-alumina, lanthana-neodymia alumina, and combinations thereof.

14. The TWC catalytic article of claim 13, wherein the refractory metal oxide support is lanthana-alumina.

15. The TWC catalytic article of any of claims 1-14, further comprising a second rhodium component impregnated on ceria-zirconia, lanthana-ceria-zirconia, neodymia-cena-zirconia, praseodymia-ceria-zirconia, yttria-ceria-zirconia, mobia-ceria-zirconia, strontia-ceria-zirconia, or a combination thereof.

16. The TWC catalytic article of any of claims 1-15, wherein the first layer comprises a platinum group metal (PGM) component impregnated on a first support material.

17. The TWC catalytic article of claim 16, wherein at least a portion of the first support material is an oxygen storage component selected from ceria, zirconia, lanthana, yttria, neodymia, praseodymia, niobia, and combinations thereof.

18. The TWC catalytic article of claim 17, wherein the oxygen storage component is ceria-zirconia comprising ceria in an amount from about 5 to about 75 wt.%.

19. The TWC catalytic article of claim 16, wherein at least a portion of the first support material is a refractory metal oxide support selected from alumina, lanthana-alumina, ceria-alumina, zirconia-alumina, ceria-zirconia-alumina, lanthana-zirconia-alumina, lanthana-neodymia-alumina, and combinations thereof.

20. The TWC catalytic article of claim 16, wherein the PGM component is palladium.

21. The TWC catalytic article of claim 16, wherein the first layer further comprises barium oxide, magnesium oxide, calcium oxide, strontium oxide, lanthanum oxide, cerium oxide, zirconium oxide, manganese oxide, copper oxide, iron oxide, praseodymium oxide, yttrium oxide, neodymium oxide, or any combination thereof.

22. The TWC catalytic article of any of claims 1-21, wherein the second layer is a physical mixture of the phosphorus trap material and the rhodium component impregnated on the phosphorus-resistant support material.

23. The TWC catalytic article of any of claims 1-22, wherein the alkaline earth metal component is present in an amount of about 1 to about 20 wt.% of the second layer.

24. The TWC catalytic article of any of claims 1-23, wherein the phosphorus-resistant support material is lanthana-zirconia, and the alkaline earth metal component is barium oxide, wherein the barium oxide is supported on alumina or is in the form of a barium oxide-alumina composite.

25. The TWC catalytic article of claim 24, wherein the first layer comprises palladium impregnated on ceria-zirconia and lanthana-alumina, and wherein the first layer further comprises barium oxide.

26. The TWC catalytic article of any of claims 1-25, wherein the second layer is zoned into an upstream zone and a downstream zone, and wherein the upstream zone comprises the phosphorus trap material.

27. The TWC catalytic article of claim 26, wherein the upstream zone has a length of about 20 to about 60% that of the substrate.

28. The TWC catalytic article of any of claims 1-27, wherein the substrate is a metal or ceramic monolithic honeycomb substrate.

29. The TWC catalytic article of claim 28, wherein the metal or ceramic monolithic honeycomb substrate is a wall flow filter substrate or a flow through substrate.

30. The TWC catalytic article of claim 29, wherein the catalytic material is coated on one or more walls or contained within one or more walls of the metal or ceramic monolithic honeycomb substrate.

31. A method for reducing CO, HC, and NOx levels in a gas stream, comprising contacting the gas stream with the TWC catalytic article of any one of claims 1-30 for a time and at a temperature sufficient to reduce the levels of CO, HC, and NOx in the gas stream.

32. The method of claim 31, wherein the CO, HC, and NOx levels in the gas stream are reduced by at least 50% compared to the CO, HC, and NOx levels in the gas stream prior to contact with the TWC catalytic article.

33. An emission treatment system for treatment of an exhaust gas stream, the emission treatment system comprising:

an engine producing an exhaust gas stream; and

the TWC catalytic article of any one of claims 1-30 positioned downstream from the engine in fluid communication with the exhaust gas stream and adapted for the abatement of CO and HC and conversion of NOsto N2.

34. The emission treatment system of claim 33, wherein the engine is a gasoline engine or Compressed Natural Gas (CNG) engine.

35. The emission treatment system of claim 33, wherein the engine is a mobile source.

36. The emission treatment system of claim 35, wherein the mobile source is selected from a gasoline car, a gasoline motorcycle, a CNG car, or a CNG motorcycle.

37. The emission treatment system of claim 33, wherein the engine is a stationary source.

38. The emission treatment system of claim 37, wherein the stationary source is an electricity generator or a pumping station.