Perovskite and Mullite-like Structure Catalysts for Diesel Oxidation and Method of Making Same

• US 20140336045A1
• Filed: 05/10/2013
• Published: 11/13/2014
• Est. Priority Date: 05/10/2013
• Status: Abandoned Application

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: CDTI
• Inventors: Nazarpoor, Zahra, Golden, Stephen J.
• Application Number:
  US13/891,668
• Publication Number:
  US 20140336045A1
• Time in Patent Office: Days
• US Class Current: 502/303
• CPC Class Codes: B01D 2255/104 Silver
• CPC Class Codes: B01D 2255/2061 Yttrium
• 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 2255/9022 Two layers
• 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 2523/36 Yttrium
• CPC Class Codes: B01J 2523/3706 Lanthanum
• CPC Class Codes: B01J 2523/72 Manganese
• CPC Class Codes: B01J 35/30 characterised by their physical properties
• CPC Class Codes: B01J 37/0215 Coating
• CPC Class Codes: B01J 37/0244 Coatings comprising several layers
• CPC Class Codes: B01J 37/031 Precipitation

Abstract

Disclosed here are material formulations of use in the conversion of exhaust gases. A catalyst is formed by using a perovskite structure having the general formula ABO3 or a mullite structure having the general formula of AB2O5 where components “A” and “B” may be any suitable non-platinum group metals. Suitable materials may include Yttrium, Lanthanum, Silver, Manganese and formulations thereof.

Claims

1. A zero platinum group metal (ZPGM) 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 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;

wherein at least one of the ZPGM catalysts comprises at least one perovskite structured compound having a formula ABO₃, wherein A is selected from the group consisting of at least one of yttrium, lanthanum, silver, magnesium, and mixtures thereof.

2. The catalyst system of claim 1, wherein the carrier material oxide is selected from the group consisting of ZrO2, doped ZrO2 with lanthanid group metals, alumina, doped alumina, TiO₂ doped TiO₂, Nb₂O₅, Nb₂O₅-ZrO₂, and combinations thereof.

3. The catalyst system of claim 1, wherein at least one of the ZPGM catalysts is deposited by co-precipitation at a temperature of about 600°

C. to about 800°

C.

4. The catalyst system of claim 1, wherein at least one of the ZPGM catalysts is deposited by co-precipitation at a temperature of about 500°

C. to about 800°

C. .

5. The catalyst system of claim 1, wherein the T50 conversion temperature for carbon monoxide is less than 250°

Celsius.

6. The catalyst system of claim 1, wherein the T50 conversion temperature for NO is less than 300°

Celsius.

7. A zero platinum group metal (ZPGM) catalyst system, comprising:

a substrate;

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

an overcoat suitable for deposition on the substrate;

wherein the ZPGM catalyst comprises at least one structured compound having the formula A_1-xM_xBO₃, wherein x is 0 to 1. and wherein each of A, B and M is selected from the group consisting at least one of yttrium, lanthanum, silver, manganese, and combinations thereof.

8. The catalyst of claim 7, wherein the overcoat further comprises at least one overcoat oxide solid selected from the group consisting at least one of a carrier metal oxide, and a ZPGM catalyst.

9. The catalyst system of claim 7, wherein the T50 conversion temperature for carbon monoxide is less than 250°

Celsius.

10. The catalyst system of claim 7, wherein the T50 conversion temperature for NO is less than 300°

Celsius.

11. A zero platinum group metal (ZPGM) catalyst system, comprising:

a substrate;

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

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 carrier metal oxide, and a ZPGM catalyst;

wherein at least one of the ZPGM catalysts comprises at least one mullite structured compound having the formula AB₂O₅, wherein each of A and B is selected from the group consisting at least one of yttrium, lanthanum, silver, manganese, and combinations thereof.

12. The catalyst system of claim 11, wherein at least one of the ZPGM catalysts oxidizes carbon monoxide, hydrocarbons or nitrogen oxides.

13. The catalyst system of claim 11, wherein the T50 conversion temperature for carbon monoxide is less than 250°

Celsius.

14. The catalyst system of claim 11, wherein the T50 conversion temperature for NO is less than 300°

Celsius.

15. A zero platinum group metal (ZPGM) catalyst system, comprising:

a substrate;

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

an overcoat suitable for deposition on the substrate;

wherein the ZPGM catalyst comprises at least one structured compound having the formula A_1-xM_xB₂O₅, wherein x is 0 to 1 and wherein each of A and B is selected from the group consisting at least one of yttrium, lanthanum, silver, manganese, and combinations thereof.

16. The catalyst system of claim 15, wherein the ZPGM catalyst oxidizes carbon monoxide, hydrocarbons or nitrogen oxides.

17. The catalyst system of claim 15, wherein the T50 conversion temperature for carbon monoxide is less than 250°

Celsius.

18. The catalyst system of claim 15, wherein the T50 conversion temperature for NO is less than 300°

Celsius.