Methods for Variation of Support Oxide Materials for ZPGM Oxidation Catalysts and Systems Using Same

• US 20140271393A1
• Filed: 06/06/2013
• Published: 09/18/2014
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: CDTI
• Inventors: Nazarpoor, Zahra
• Granted Patent: US 9,216,382 B2
• Time in Patent Office: Days
• US Class Current: 422/177
• CPC Class Codes: B01D 2255/104 Silver
• CPC Class Codes: B01D 2255/2063 Lanthanum
• CPC Class Codes: B01D 2255/2073 Manganese
• CPC Class Codes: B01D 2255/402 Perovskites
• CPC Class Codes: B01D 2255/65 Catalysts not containing noble metals
• CPC Class Codes: B01D 2258/01 Engine exhaust gases
• CPC Class Codes: B01D 53/944 Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts three-way-catalysts [TWC] B01D53/9445
• CPC Class Codes: B01J 23/002 Mixed oxides other than spinels, e.g. perovskite
• CPC Class Codes: B01J 23/688 with manganese, technetium or rhenium
• CPC Class Codes: B01J 2523/00 Constitutive chemical elements of heterogeneous catalysts
• CPC Class Codes: B01J 2523/18 Silver
• CPC Class Codes: B01J 2523/3706 Lanthanum
• CPC Class Codes: B01J 2523/72 Manganese
• CPC Class Codes: B01J 37/0242 Coating followed by impregnation

Abstract

Disclosed here are methods of preparing zero platinum group metal catalysts systems with different support oxide material. A ZPGM catalyst system may include a substrate and a washcoat and an impregnation layer, wherein said impregnation layer may include the ZPGM pervoskite catalyst and the washcoat layer may include the support oxides material. Suitable support oxides material may include ZrO₂, ZrO₂ doped with lanthanide group metals, Nb₂O₅, Nb₂O₅—ZrO₂, Al₂O₃ and Al₂O₃ doped with lanthanide group metals, TiO₂ and doped TiO₂ or mixtures thereof.

Claims

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

at least one source of exhaust comprising NO and NO₂; and

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 a carrier material oxide, at least one first catalyst, and a mixture thereof; and

an impregnation layer, comprising at least one second catalyst;

wherein the catalyst system oxidizes the NO, NO₂ and carbon soot.

2. The apparatus of claim 1, wherein the at least one first catalyst comprises at least one selected from the group consisting lanthanum, silver, manganese, and combinations thereof.

3. The apparatus of claim 1, wherein the at least one second catalyst comprises at least one selected from the group consisting lanthanum, silver, manganese, and combinations thereof.

4. The apparatus of claim 1, wherein the at least one first catalyst comprises at least one perovskite structured compound having the formula ABO₃, wherein each of A and B is selected from the group consisting of lanthanum, silver, manganese, and combinations thereof.

5. The apparatus of claim 1, wherein the at least one second catalyst comprises at least one perovskite structured compound having the formula ABO₃, wherein each of A and B is selected from the group consisting of lanthanum, silver, manganese, and combinations thereof.

6. The apparatus of claim 1, wherein the substrate is selected from the group consisting of a metallic alloy, a foam, microporous materials, and combinations thereof.

7. The apparatus of claim 1, wherein the substrate comprises zeolite.

8. The apparatus of claim 1, wherein the at least one perovskite structured compound is of the general formula La_1-xAg_xMnO₃, wherein x is from 0 to 1.

9. The apparatus of claim 1, wherein the at least one carrier material oxide further comprises at least one selected from the group consisting of TiO₂, doped TiO₂, alumina, doped alumina, doped ZrO₂, Nb₂O₅—

ZrO₂, and combinations thereof.

10. The apparatus of claim 1, wherein a T50 conversion temperature for carbon monoxide is less than about 273 degrees Celsius.

11. The apparatus of claim 1, wherein a T50 conversion temperature for hydrocarbons is less than about 318 degrees Celsius.

12. The apparatus of claim 1, wherein a T50 conversion temperature for NO is less than about 398 degrees Celsius.

13. The apparatus of claim 1, wherein the impregnation layer is heated treated for 4 hours.

14. The apparatus of claim 1, wherein the impregnation layer is heated at about 750°

C.