Application of synergized-PGM with ultra-low PGM loadings as close-coupled three-way catalysts for internal combustion engines

• US 10,533,472 B2
• Filed: 05/04/2017
• Issued: 01/14/2020
• Est. Priority Date: 05/12/2016
• Status: Active Grant

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: CDTi Advanced Materials, Inc.
• Inventors: Nazarpoor, Zahra, Golden, Stephen J., Launois, Maxime
• Primary Examiner(s): Bradley, Audrey K
• Assistant Examiner(s): Delgado, Anthony Ayala
• Application Number:
  US15/586,847
• Publication Number:
  US 20170328250A1
• Time in Patent Office: 985 Days
• CPC Class Codes: B01D 2255/102 Platinum group metals
• CPC Class Codes: B01D 2255/1021 Platinum
• CPC Class Codes: B01D 2255/1023 Palladium
• CPC Class Codes: B01D 2255/1025 Rhodium
• CPC Class Codes: B01D 2255/1026 Ruthenium
• CPC Class Codes: B01D 2255/1028 Iridium
• CPC Class Codes: B01D 2255/2022 Potassium
• CPC Class Codes: B01D 2255/2027 Sodium
• CPC Class Codes: B01D 2255/2042 Barium
• CPC Class Codes: B01D 2255/2045 Calcium
• CPC Class Codes: B01D 2255/2047 Magnesium
• CPC Class Codes: B01D 2255/2063 Lanthanum
• CPC Class Codes: B01D 2255/2065 Cerium
• CPC Class Codes: B01D 2255/2066 Praseodymium
• CPC Class Codes: B01D 2255/2068 Neodymium
• CPC Class Codes: B01D 2255/20707 Titanium
• CPC Class Codes: B01D 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20738 Iron
• CPC Class Codes: B01D 2255/20746 Cobalt
• CPC Class Codes: B01D 2255/20753 Nickel
• CPC Class Codes: B01D 2255/20761 : Copper
• CPC Class Codes: B01D 2255/20784 : Chromium
• CPC Class Codes: B01D 2255/20792 : Zinc
• CPC Class Codes: B01D 2255/2092 : Aluminium
• CPC Class Codes: B01D 2255/405 : Spinels
• CPC Class Codes: B01D 2255/65 : Catalysts not containing noble metals
• CPC Class Codes: B01D 2255/9022 : Two layers
• CPC Class Codes: B01D 2255/9025 : Three layers
• CPC Class Codes: B01D 2255/904 : Multiple catalysts
• CPC Class Codes: B01D 2257/404 : Nitrogen oxides other than dinitrogen oxide
• CPC Class Codes: B01D 2257/502 : Carbon monoxide
• CPC Class Codes: B01D 2257/702 : Hydrocarbons
• CPC Class Codes: B01D 2258/01 : Engine exhaust gases
• CPC Class Codes: B01D 53/945 : characterised by a specific catalyst
• CPC Class Codes: B01D 53/9468 : in different layers
• CPC Class Codes: B01D 53/9477 : with catalysts positioned on separate bricks, e.g. exhaust systems
• CPC Class Codes: B01J 23/005 : Spinels
• CPC Class Codes: B01J 23/42 : Platinum
• CPC Class Codes: B01J 23/464 : Rhodium
• CPC Class Codes: B01J 23/755 : Nickel
• CPC Class Codes: F01N 13/0093 : the purifying devices are of the same type
• CPC Class Codes: F01N 2370/02 : used in catalytic reactors
• CPC Class Codes: F01N 2510/06 : for exhaust purification, e.g. catalytic reaction
• CPC Class Codes: F01N 3/0864 : Oxygen
• CPC Class Codes: F01N 3/101 : Three-way catalysts
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

Synergized platinum group metals (SPGM) with ultra-low PGM loadings employed as close-coupled (CC) three-way catalysts (TWC) systems with varied material compositions and configurations are disclosed. SPGM CC catalysts in which ZPGM compositions of binary or ternary spinel structures supported onto support oxides are coupled with commercialized PGM UF catalysts and tested under Federal Test Procedure FTP-75 within TGDI and PI engines. The performance of the TWC systems including SPGM CC (with ultra-low PGM loadings) catalyst and commercialized PGM UF catalyst is compared to the performance of commercialized PGM CC and PGM UF catalysts. The disclosed TWC systems indicate that SPGM CC TWC catalytic performance is comparable or even exceeds high PGM-based conventional TWC catalysts, with reduced tailpipe emissions.

Claims

1. A catalytic system for treating an exhaust stream of a combustion engine, comprising:

a close-coupled catalytic converter configured to accept at least one exhaust gas stream from said combustion engine, the close-coupled catalytic converter comprising a synergized platinum group metal catalyst comprising a spinel catalytic composition, wherein the synergized platinum group metal catalyst has a platinum group metal concentration of 1 g/ft³ to 10 g/ft³;

an underfloor catalytic converter downstream of, and, in fluid communication with said close-coupled catalytic converter, the underfloor catalytic converter comprising a platinum group metal catalyst; and

wherein the spinel catalyst composition comprises a binary spinel having a general formula A_xB_3-xO₄ wherein X is from 0.01 to 2.99, and A and B are selected from the group consisting of sodium, potassium, calcium, barium, zinc, cadmium, aluminum, magnesium, manganese, nickel, copper, cobalt, iron, chromium, titanium, cerium, strontium, lanthanum, praseodymium, neodymium, samarium, indium, and mixtures thereof.

2. The catalytic system of claim 1, wherein the binary spinel comprises a Ni—

Fe spinel.

3. The catalytic system of claim 2, wherein the Ni—

Fe spinel comprises Ni_0.5Fe_2.5O₄.

4. A catalytic system for treating an exhaust stream of a combustion engine, comprising:

a close-coupled catalytic converter configured to accept at least one exhaust gas stream from said combustion engine, the close-coupled catalytic converter comprising a synergized platinum group metal catalyst comprising a spinel catalytic composition, wherein the synergized platinum group metal catalyst has a platinum group metal concentration of 1 g/ft³ to 10 g/ft³;

an underfloor catalytic converter downstream of, and, in fluid communication with said close-coupled catalytic converter, the underfloor catalytic converter comprising a platinum group metal catalyst;

wherein the spinel catalyst composition comprises at least one substrate, and a catalyst composition comprising a spinel oxide having a formula A_xB_yM_3-X-Y where X is from about 0.01 to about 1.99 and Y is from about 0.01 to about 1.0; and

wherein A, B, and M are different from each other, and are selected from the group consisting of sodium, potassium, calcium, barium, zinc, cadmium, aluminum, magnesium, manganese, nickel, copper, cobalt, iron, chromium, titanium, cerium, strontium, lanthanum, praseodymium, neodymium, samarium, indium, and mixtures thereof.