Mixed oxides were synthesized by co-precipitation of a Cu source in combination with Al, Fe or Mn corresponding salts as precursors. The materials were calcined at 600 and 1000 °C in order to crystallize the phases and to mimic the reaction conditions of the catalytic application. At 600 °C a mixed spinel structure was only formed for the combination of Cu and Mn, while at 1000 °C all the materials showed mixed spinel formation. The catalysts were applied in three-way catalysis using a reactor with a gas mixture containing CO, NO and O₂. All the materials calcined at 600 °C displayed the remarkable ability to oxidize CO with O₂ but also to reduce NO with CO, while the pure oxides such as CuO and MnO₂ were not able to. The high catalytic activity at 600 °C was attributed to small supported CuO particles present and imperfections in the spinel structure. Calcination at 1000 °C crystallized the structure further which led to a dramatic loss in catalytic activity, although CuAl₂O₄ and CuFe₂O₄ still converted some NO. The materials were characterized by X-ray diffraction (XRD), Raman spectroscopy, H₂-Temperatrue Programmed Reduction (H₂-TPR), N₂-sorption and scanning electron microscopy with energy dispersive X-ray spectroscopy (SEM-EDX).

To meet current economic demands enforcing the replacement of platinum-group metals, extensively used in three-way-catalytic converters (TWC), research is driven towards low-cost and widely available base metals. However, to cope with their lower activity, high metal loadings must be coupled with increased dispersion. Herein, a series of CuO/Al₂O₃ samples is produced and the effect of different alumina supports’ properties on CuO dispersion, speciation and eventually on the TWC performance is studied. The alumina samples are synthesized via different methods, including soft-templating routes and flame spray pyrolysis, and compared with a commercial one, while CuO used as the catalytic active phase is added through ammonia-driven deposition–precipitation. As found, the large surface area and low crystallinity of the aluminas produced by soft-templating routes favor strong metal–support interaction, generating highly dispersed and strongly bonded CuO species at low loading and copper-aluminate phases at high loading. Notably, the use of amorphous mesoporous alumina completely prevents the formation of crystalline CuO even at 15 wt% Cu. Such high metal loading and dispersion capacity without the application of elevated calcination temperatures is one of the best reported for nonreducible supports. Catalytic evaluation of this material reveals a pronounced enhancement of oxidation activity with metal loading increase.