Zero platinum group metal catalysts
First Claim
1. A catalyst system, comprising:
- a substrate; and
a washcoat,wherein the washcoat comprises at least one oxide solid,wherein the oxide solid is selected from the group consisting of a carrier material oxide, a catalyst, and a mixture thereof,wherein the catalyst system is substantially free of platinum group metals.
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Accused Products
Abstract
The present invention pertains to catalyst systems for nitrogen oxide, carbon monoxide, hydrocarbon, and sulfur reactions that are free or substantially free of platinum group metals. The catalyst system of the present invention comprise a substrate and a washcoat, wherein the washcoat comprises at least one oxide solid, wherein the oxide solid comprises one or more selected from the group consisting of a carrier material oxide, a catalyst, and mixtures thereof. The catalyst system may optionally have an overcoat, wherein the overcoat comprises at least one oxide solid, wherein the oxide solid comprises one or more selected from the group consisting of a carrier material oxide, a catalyst, and mixtures thereof. The catalyst comprises one or more selected from the group consisting of a ZPGM transition metal catalyst, a mixed metal oxide catalyst, a zeolite catalysts, or mixtures thereof.
142 Citations
146 Claims
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1. A catalyst system, comprising:
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a substrate; and a washcoat, wherein the washcoat comprises at least one oxide solid, wherein the oxide solid is selected from the group consisting of a carrier material oxide, a catalyst, and a mixture thereof, wherein the catalyst system is substantially free of platinum group metals. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 18, 19, 20, 21, 22, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98)
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13. A catalyst system, comprising:
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a substrate; a washcoat, wherein the washcoat comprises one or more selected from the group consisting of a carrier material oxide, ceramic, and mixtures thereof; and an overcoat, wherein the overcoat comprises a catalyst, wherein the catalyst comprises one or more selected from the group consisting of a ZPGM transition metal catalyst, a mixed metal oxide catalyst, a zeolite catalyst, and a mixture thereof, and wherein the catalyst system is substantially free of platinum group metals. - View Dependent Claims (14, 15, 16, 17)
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23. A catalyst system, comprising:
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a substrate, wherein the substrate comprises cordierite; a washcoat, wherein the washcoat comprises copper, a spinel, and at least one oxygen storage material, wherein the spinel comprises magnesium aluminum oxide, wherein the oxygen storage material comprises one or more selected from the group consisting of cerium, zirconium, and lanthanum; and an overcoat, wherein the overcoat comprises copper, a spinel, and at least one oxygen storage material, wherein the spinel comprises magnesium aluminum oxide, wherein the oxygen storage material comprises one or more selected from the group consisting of cerium, zirconium, neodymium, and praseodymium, wherein the catalyst system is substantially free of platinum group metals. - View Dependent Claims (24, 25, 26, 27)
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28. A catalyst system, comprising:
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a substrate, wherein the substrate comprises cordierite; a washcoat, wherein the washcoat comprises lanthanum aluminum oxide and at least one oxygen storage material; and an overcoat, wherein the overcoat comprises copper oxide, lanthanum aluminum oxide, and at least one oxygen storage material, wherein the catalyst system is substantially free of platinum group metals. - View Dependent Claims (29, 30, 31, 32, 33, 34)
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35. A catalyst system, comprising:
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a substrate; a washcoat, wherein the washcoat comprises tin aluminum oxide, copper, cerium, zirconium, lanthanum, and at least one oxygen storage material, wherein the oxygen storage material comprises a mixture of cerium, zirconium, neodymium, and praseodymium; and an overcoat, wherein the overcoat comprises aluminum, copper, and at least one oxygen storage material, wherein the catalyst system is substantially free of platinum group metals. - View Dependent Claims (36, 37, 38, 39, 40, 41)
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42. A catalyst system, comprising:
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a substrate; and a washcoat, wherein the washcoat comprises copper, tin aluminum oxide, and at least one oxygen storage material, wherein the catalyst system is substantially free of platinum group metals. - View Dependent Claims (43, 44, 45, 46, 47, 48)
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49. A catalyst system, comprising:
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a substrate; and a washcoat, wherein the washcoat comprises aluminum oxide, copper, and at least one oxygen storage material, wherein the oxygen storage material comprises a mixture of cerium, zirconium, and lanthanum, wherein the catalyst system is substantially free of platinum group metals. - View Dependent Claims (50, 51, 52, 53)
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54. A catalyst system, comprising:
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a substrate; and a washcoat, wherein the washcoat comprises at least one carrier material oxide and a perovskite, wherein the perovskite comprises Ce0.6La0.4Mn0.6Cu0.4O3, wherein the catalyst system is substantially free of platinum group metals. - View Dependent Claims (55, 56)
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99. A method of making a catalyst system by impregnation, comprising:
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depositing a washcoat on a substrate, wherein the washcoat comprises at least one oxide solid, wherein the oxide solid comprises one or more selected from the group consisting of a carrier material oxide, a catalyst, and a mixture thereof; treating the washcoat and the substrate to convert metal salts into metal oxides; wherein the catalyst system is substantially free of platinum group metals. - View Dependent Claims (100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110)
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111. A method of making a catalyst system by precipitation, comprising:
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precipitating a transition metal salt on a washcoat, wherein, the transition metal salt comprises at least one transition metal and at least one carrier material oxide, wherein the washcoat comprises at least one carrier material oxide; treating the precipitated transition metal salt and the washcoat; depositing the precipitated transition metal salt and the washcoat on a substrate; and treating the precipitated transition metal salt and the washcoat on the substrate; wherein the catalyst system is substantially free of platinum group metals. - View Dependent Claims (112, 113, 114, 115, 116, 117, 118, 119, 120, 121)
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122. A method of making a catalyst system by co-milling, comprising:
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milling together a catalyst and at least one carrier material oxide, wherein the catalyst comprises one or more selected from the group consisting of a ZPGM transition metal catalyst, a mixed metal oxide catalyst, a zeolite catalyst, and mixtures thereof; depositing the milled catalyst in the form of a washcoat on to a substrate; and treating the substrate and the washcoat; wherein the catalyst system is substantially free of platinum group metals. - View Dependent Claims (123, 124, 125, 126, 127, 128)
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129. A method of reducing pollutants emitted in exhaust, comprising:
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flowing exhaust substantially through a catalyst system, wherein the catalyst system comprises, a substrate; and a washcoat, wherein the washcoat comprises at least one oxide solid,
wherein the oxide solid comprises one or more selected from the group consisting of a carrier material oxide, a catalyst, and a mixture thereof;wherein the catalyst system is substantially free of platinum group metals; wherein the exhaust comprises pollutants; and reducing the pollutants in the exhaust. - View Dependent Claims (130, 131, 132, 133, 134, 135, 136, 137, 138)
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139. A catalyst system, comprising:
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a first catalyst system, comprising a substrate; and a washcoat, wherein the washcoat comprises at least one oxide solid, wherein the oxide solid comprises one or more selected from the group consisting of a carrier material oxide, a catalyst, and a mixture thereof; wherein the first catalyst system is substantially free of platinum group metals; and a second catalyst system, wherein the second catalyst system comprises at least one platinum group metal; wherein the first catalyst and the second catalyst are in series in any order, and wherein a gas stream is capable of passing through the first catalyst system and the second catalyst system sequentially. - View Dependent Claims (140, 141, 142, 143, 144, 145, 146)
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Specification