ZPGM TWC Systems Compositions and Methods Thereof

• US 20140271391A1
• Filed: 03/22/2013
• Published: 09/18/2014
• Est. Priority Date: 03/15/2013
• Status: Abandoned Application

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: CDTI
• Inventors: Nazarpoor, Zahra
• Application Number:
  US13/849,191
• Publication Number:
  US 20140271391A1
• Time in Patent Office: Days
• US Class Current: 422/177
• 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 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20761 Copper
• CPC Class Codes: B01D 2255/2092 Aluminium
• CPC Class Codes: B01D 2255/40 Mixed oxides
• CPC Class Codes: B01D 2255/407 Zr-Ce mixed oxides
• CPC Class Codes: B01D 2255/9022 Two layers
• CPC Class Codes: B01D 2255/908 O2-storage component incorporated in the catalyst
• CPC Class Codes: B01D 53/945 characterised by a specific catalyst
• CPC Class Codes: B01J 23/002 Mixed oxides other than spinels, e.g. perovskite
• CPC Class Codes: B01J 23/83 with rare earths or actinides
• CPC Class Codes: B01J 23/8892 Manganese
• CPC Class Codes: B01J 2523/00 Constitutive chemical elements of heterogeneous catalysts
• CPC Class Codes: B01J 2523/17 Copper
• CPC Class Codes: B01J 2523/31 Aluminium
• CPC Class Codes: B01J 2523/3706 Lanthanum
• CPC Class Codes: B01J 2523/3712 Cerium
• CPC Class Codes: B01J 2523/3718 : Praseodymium
• CPC Class Codes: B01J 2523/3725 : Neodymium
• CPC Class Codes: B01J 2523/48 : Zirconium
• CPC Class Codes: B01J 2523/72 : Manganese
• CPC Class Codes: B01J 37/0036 : Grinding
• CPC Class Codes: B01J 37/0219 : the coating containing organic compounds
• CPC Class Codes: B01J 37/0244 : Coatings comprising several layers
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

Compositions and methods for the preparation of ZPGM TWC systems are disclosed. ZPGM TWC systems may be employed within catalytic converters to oxidize toxic gases, such as carbon monoxide and other hydrocarbons, as well as to reduce nitrogen oxides. ZPGM TWC systems are completely free of PGM catalyst and may include: a substrate, a washcoat, and an overcoat. Washcoat may include manganese as ZPGM catalyst, and carrier material oxides. Similarly, overcoat may include at least one ZPGM catalyst, carrier material oxides and OSMs. Suitable known in the art chemical techniques, deposition methods and treatment systems may be employed in order to form the disclosed ZPGM TWC systems. ZPGM TWC systems may include high surface area, low conversion temperature catalysts that may exhibit high efficiency in the conversion of exhaust gases.

Claims

1. An apparatus for reducing emissions from an engine having associated therewith an exhaust system, the apparatus leading to a reaction effective for selective catalytic reduction, comprising:

a catalyst system, comprising;

a substrate;

a washcoat suitable for deposition on the substrate, comprising at least one oxide solid selected from the group consisting of at least one of a carrier material oxide, and a zero platinum group metal (ZPGM) catalyst; and

an overcoat suitable for deposition on the substrate, comprising at least one overcoat oxide solid selected from the group consisting of at least one of a carrier material oxide, and a ZPGM catalyst.

2. The apparatus of claim 1, wherein the washcoat ZPGM catalyst comprises one or more elements selected from the group consisting of copper, cerium, and manganese, and wherein the washcoat carrier metal oxide comprises lanthanum doped alumina.

3. The apparatus of claim 2, wherein the washcoat further comprises an oxygen storage material comprising one or more elements selected from the group consisting of at least cerium, zirconium, neodymium, praseodymium, samarium, lanthanum, and yttrium.

4. The apparatus of claim 2, wherein the washcoat ZPGM catalyst comprises about 4% to about 20% by weight manganese.

5. The apparatus of claim 1, wherein the overcoat ZPGM catalyst comprises one or more elements selected from the group consisting of copper, cerium, and manganese, and wherein, when the overcoat is the carrier material oxide, it comprises lanthanum doped alumina.

6. The apparatus of claim 5, wherein the overcoat further comprises an oxygen storage material comprising one or more elements selected from the group consisting of at least cerium, zirconium, neodymium, praseodymium, samarium, lanthanum, and yttrium.

7. The apparatus of claim 5, wherein the overcoat ZPGM catalyst comprises about 10% to about 16% copper and about 10% to about 20% cerium.

8. The apparatus of claim 1, wherein the washcoat ZPGM catalyst comprises cerium, and wherein the overcoat is the ZPGM catalyst which comprises at least one element selected from the group consisting of at least copper and manganese.

9. The apparatus of claim 8, wherein the washcoat ZPGM catalyst comprises about 10% to about 20% by weight cerium.

10. The apparatus of claim 1, wherein the overcoat ZPGM catalyst comprises one or more elements selected from the group consisting of copper, and manganese, and wherein the overcoat carrier material oxide comprises lanthanum doped alumina.

11. The apparatus of claim 10, wherein the overcoat further comprises an oxygen storage material comprising one or more elements selected from the group consisting of cerium, zirconium, neodymium, praseodymium, samarium, lanthanum, and yttrium.

12. The apparatus of claim 10, wherein the overcoat ZPGM catalyst comprises about 4% to about 20% manganese and about 10% to about 16% copper.

13. The apparatus of claim 1, wherein the washcoat ZPGM catalyst comprises at least one element selected from the group consisting of cerium, and manganese, and the overcoat comprises copper.

14. The apparatus of claim 13, wherein the washcoat ZPGM catalyst comprises about 4% to about 20% by weight manganese.

15. The apparatus of claim 1, wherein the overcoat ZPGM catalyst comprises one or more elements selected from the group consisting of copper, and cerium, and wherein the overcoat carrier material oxide comprises lanthanum doped alumina.

16. The apparatus of claim 15, wherein the overcoat further comprises an oxygen storage material comprising one or more elements selected from the group consisting of cerium, zirconium, neodymium, praseodymium, samarium, lanthanum, and yttrium.

17. The apparatus of claim 15, wherein the overcoat ZPGM catalyst comprises about 10% to about 16% copper and about 10% to about 20% cerium.

18. The apparatus of claim 1, wherein the T50 conversion temperature for carbon monoxide is less than 310 degrees Celsius

19. The apparatus of claim 1, wherein the T50 conversion temperature for carbon monoxide is less than 300 degrees Celsius.

20. The apparatus of claim 1, wherein the T50 conversion temperature for nitrogen oxide is less than 400 degrees Celsius.

21. The apparatus of claim 1, wherein the T50 conversion temperature for hydrocarbons is less than 350 degrees Celsius.

22. The apparatus of claim 1, wherein the T50 conversion temperature for hydrocarbons is less than 400 degrees Celsius.

23. The apparatus of claim 1, wherein the washcoat ZPGM catalyst comprises manganese, and the overcoat comprises at least one element selected from the group consisting of copper, and cerium.