Zero platinum group metal catalysts

• US 20090324469A1
• Filed: 08/26/2008
• Published: 12/31/2009
• Est. Priority Date: 06/27/2008
• Status: Active Grant

• Current Assignee: Catalyst Health Solutions Incorporated (UnitedHealth Group Incorporated)
• Original Assignee: Catalyst Health Solutions Incorporated (UnitedHealth Group Incorporated)
• Inventors: Golden, Stephen J., Hatfield, Randal, Pless, Jason, Ngo, Johnny
• Granted Patent: US 8,496,896 B2
• Time in Patent Office: Days
• US Class Current: 423/212
• CPC Class Codes: B01D 2251/11 Air
• CPC Class Codes: B01D 2255/20 Metals or compounds thereof
• CPC Class Codes: B01D 2255/40 Mixed oxides
• CPC Class Codes: B01D 2255/50 Zeolites
• CPC Class Codes: B01D 2255/65 Catalysts not containing noble metals
• CPC Class Codes: B01D 2258/01 Engine exhaust gases
• CPC Class Codes: B01D 53/945 characterised by a specific catalyst
• CPC Class Codes: B01D 53/9454 characterised by a specific device
• CPC Class Codes: B01D 53/9477 with catalysts positioned on separate bricks, e.g. exhaust systems
• CPC Class Codes: F01N 13/009 having two or more separate purifying devices arranged in series
• CPC Class Codes: F01N 2270/00 Mixing air with exhaust gases
• CPC Class Codes: F01N 2370/02 used in catalytic reactors
• CPC Class Codes: F01N 2410/00 By-passing, at least partially, exhaust from inlet to outlet of apparatus, to atmosphere or to other device
• CPC Class Codes: F01N 2570/14 Nitrogen oxides
• CPC Class Codes: F01N 3/10 by thermal or catalytic conversion of noxious components of exhaust by using other chemical processes, chemical aspects of catalytic conversion, e.g. using specified catalysts, B01D53/34
• CPC Class Codes: Y02A 50/20 Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

The present invention relates improving the performance of nitrogen oxide reduction by exposing rich exhaust to catalysts systems comprising a catalyst, wherein the catalyst systems are free of platinum group metals. The present invention also relates to improving reduction of carbon monoxide and hydrocarbon in exhaust by introducing air into a portion of the exhaust between a first catalyst system and a second catalyst system. The present invention also relates to improving nitrogen oxide, carbon monoxide and hydrocarbon reduction by (1) exposing rich exhaust to a first catalysts system, wherein the exhaust has an R value of greater than 1.0 and the first catalyst system comprises a catalyst and is free of platinum group metals and (2) introducing air into a portion of the exhaust in between the first catalyst system and a second catalyst system, wherein the second catalyst system is free of platinum group metals.

Claims

1-146. -146. (canceled)

147. A method for reducing nitrogen oxide emission, comprising:

exposing an exhaust to a catalyst,

wherein the exhaust has an R value of greater than 1.0, and

wherein the catalyst is substantially free of platinum group metals.

148. The method of claim 147, wherein the catalyst is one or more selected from the group consisting of a ZPGM transition metal catalyst, a zeolite catalyst, and a mixed metal oxide catalyst.

149. The method of claim 147, wherein the catalyst is completely free of platinum group metals.

150. The method of claim 147, wherein the exhaust is one or more selected from the group consisting of an engine, a boiler, a utility plant, a processing plant, and a manufacturing plant.

151. A method for improving carbon monoxide and hydrocarbon reduction in an exhaust comprising:

exposing the exhaust to a first catalyst system,

exposing a portion of the exhaust to a second catalyst system,

wherein the first catalyst system and the second catalyst system are in series; and

introducing air into the portion of the exhaust before the exposing to the second catalyst system,

wherein the first catalyst system comprises a first catalyst and is substantially free of platinum group metals,

wherein the air comprises oxygen,

wherein the second catalyst system comprises a second catalyst and is substantially free of platinum group metals; and

wherein the portion of the exhaust results in an air to fuel ratio above about 14.7.

152. The method of claim 151, wherein the portion of the exhaust is 100% of the exhaust.

153. The method of claim 151, wherein the introducing comprises injecting.

154. The method of claim 151, wherein the first catalyst is one or more selected from the group consisting of a ZPGM transition metal catalyst, a zeolite catalyst, and a mixed metal oxide catalyst.

155. The method of claim 151, wherein the second catalyst is one or more selected from the group consisting of a ZPGM transition metal catalyst, a zeolite catalyst, and a mixed metal oxide catalyst.

156. The method of claim 151, wherein the first catalyst system is completely free of platinum group metals.

157. The method of claim 151, wherein the second catalyst system is completely free of platinum group metals.

158. The method of claim 151, wherein the second catalyst system comprises at least one platinum group metal.

159. The method of claim 151, wherein the air consists of oxygen.

160. The method of claim 151, wherein the exhaust is one or more selected from the group consisting of an engine, boiler, utility plant, processing plant, and manufacturing plant.

161. The method of claims 151, further comprising:

adding a second exhaust to the portion after the first catalyst system and before the introducing.

162. The method of claim 151, further comprising:

adding a second exhaust to the portion after the first catalyst system and after the introducing.

163. The method of claim 151, wherein the exhaust comprises a portion and a bypass.

164. The method of claim 151, further comprising:

diverting the bypass from the exposing to the second catalyst system.

165. A method for improving the reduction of hydrocarbon, carbon monoxide, and nitrogen oxide in an exhaust comprising:

exposing the exhaust to a first catalyst system,

wherein the exhaust has an R value of greater than 1.0, and

wherein the first catalyst system comprises a first catalyst and is substantially free of platinum group metals; and

exposing a portion of the exhaust to a second catalyst system,

wherein the second catalyst system comprises a second catalyst and is substantially free of platinum group metals,

wherein the first catalyst system and the second catalyst system are in series; and

introducing air into the portion of the exhaust after the first catalyst system,

wherein the air comprises oxygen, and

wherein the portion of the exhaust has an air to fuel ratio above about 14.7 before the exposing to the second catalyst system.

166. The method of claim 165, wherein the first catalyst is selected from the group consisting of a ZPGM transition metal catalyst, a zeolite catalyst, and a mixed metal oxide catalyst.

167. The method of claim 165, wherein second catalyst is selected from the group consisting of a ZPGM transition metal catalyst, a zeolite catalyst, and a mixed metal oxide catalyst.

168. The method of claim 165, wherein the first catalyst is completely free of platinum group metals.

169. The method of claim 165, wherein the second catalyst is completely free of platinum group metals.

170. The method of claim 165, wherein the air consists of oxygen.