ZPGM Catalytic Converters (TWC application)
First Claim
1. A zero platinum group metal (ZPGM) catalyst system, comprising:
- a substrate;
an overcoat suitable for deposition on the substrate, comprising at least one overcoat oxide solid selected from the group consisting of at least one first carrier material oxide, and at least one first ZPGM catalyst; and
a washcoat suitable for deposition on the substrate, comprising at least one oxide solid selected from the group consisting of at least one second carrier material oxide, and at least one second ZPGM catalyst;
wherein at least the first ZPGM catalyst is selected from the group consisting of copper, cerium, manganese, and combinations thereof, and wherein the substrate at least partially comprises one selected from the group consisting of a refractive material, ceramic material, metallic alloy, foam, microporous material, zeolite, cordierite, or a combination thereof; and
wherein the at least one first carrier material oxide is selected form the group consisting of aluminum oxide (Al2O3) or doped aluminum oxide.
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Abstract
Compositions and methods for the preparation of ZPGM catalytic converters are disclosed. Addition of Mn to ZPGM catalytic converters from prior ZPGM catalytic may create a new ZPGM catalytic converter with greater improvement TWC conditions compared to previous types. Suitable known in the art chemical techniques, deposition methods and treatment systems may be employed in order to form the disclosed ZPGM catalyst systems. Disclosed ZPGM TWC systems in catalytic converters may be employed to decrease the pollution caused by exhaust from various sources, such as automobiles, utility plants, processing and manufacturing plants, airplanes, trains, all-terrain vehicles, boats, mining equipment, and other engine-equipped machines.
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Citations
25 Claims
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1. A zero platinum group metal (ZPGM) catalyst system, comprising:
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a substrate; an overcoat suitable for deposition on the substrate, comprising at least one overcoat oxide solid selected from the group consisting of at least one first carrier material oxide, and at least one first ZPGM catalyst; and a washcoat suitable for deposition on the substrate, comprising at least one oxide solid selected from the group consisting of at least one second carrier material oxide, and at least one second ZPGM catalyst; wherein at least the first ZPGM catalyst is selected from the group consisting of copper, cerium, manganese, and combinations thereof, and wherein the substrate at least partially comprises one selected from the group consisting of a refractive material, ceramic material, metallic alloy, foam, microporous material, zeolite, cordierite, or a combination thereof; and wherein the at least one first carrier material oxide is selected form the group consisting of aluminum oxide (Al2O3) or doped aluminum oxide. - View Dependent Claims (2, 3, 4, 5, 6, 7, 9, 10, 11, 12, 13, 14, 15)
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8. The ZPGM catalyst of claim 8, wherein the doped aluminum oxide is selected from the group consisting of lanthanum, yttrium, lanthanide, and mixtures thereof.
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16. A zero platinum group metal (ZPGM) catalyst system, comprising:
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a substrate; an overcoat suitable for deposition on the substrate, comprising at least one overcoat oxide solid selected from the group consisting at least one of a first carrier material oxide, and at least one first ZPGM catalyst; and a washcoat suitable for deposition on the substrate, comprising at least one oxide solid selected from the group consisting of at least one second carrier material oxide, and at least one second ZPGM catalyst comprising manganese; wherein the at least one first ZPGM catalyst is selected from the group consisting of copper, cerium, and combinations thereof, and wherein the at least one first ZPGM catalyst is hydrothermally aged. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23, 24, 25)
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Specification