Optimization of Zero-PGM Catalyst Systems on Metallic Substrates

• US 20150005157A1
• Filed: 06/26/2013
• Published: 01/01/2015
• Est. Priority Date: 06/26/2013
• Status: Abandoned Application

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: CDTI
• Inventors: Nazarpoor, Zahra, Ngo, Johnny T., Kitazumi, Sen
• Application Number:
  US13/927,872
• Publication Number:
  US 20150005157A1
• Time in Patent Office: Days
• US Class Current: 502/303
• CPC Class Codes: B01D 2255/206 Rare earth metals
• CPC Class Codes: B01D 2255/2061 Yttrium
• CPC Class Codes: B01D 2255/2063 Lanthanum
• CPC Class Codes: B01D 2255/207 Transition metals
• CPC Class Codes: B01D 2255/20707 Titanium
• CPC Class Codes: B01D 2255/20715 Zirconium
• CPC Class Codes: B01D 2255/2094 Tin
• CPC Class Codes: B01D 2255/402 Perovskites
• CPC Class Codes: B01D 2255/70 Non-metallic catalysts, additives or dopants
• CPC Class Codes: B01D 2255/908 O2-storage component incorporated in the catalyst
• 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 23/74 Iron group metals
• CPC Class Codes: B01J 23/83 with rare earths or actinides
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B01J 37/0225 of metal substrates
• CPC Class Codes: B01J 37/03 Precipitation; Co-precipitation
• CPC Class Codes: B01J 37/038 to form slurries or suspensions, e.g. a washcoat

Abstract

Present disclosure provides a novel process for optimization of Zero-PGM catalyst systems using metallic substrate. Deposition of a homogeneous and well-adhered layer of catalyst on the metallic substrate may be enabled by the selection of a washcoat loading resulting from variation of metal loadings. Characterization of catalysts may be performed using a plurality of catalytic tests, including but not limited to washcoating adherence test, back pressure test, inspection of textural characteristics, and catalyst activity. Optimization may be applied to a plurality of metallic substrates of different geometries and cell densities.

Claims

1. A method for improving performance of catalytic systems, comprising:

providing at least one substrate;

depositing a washcoat suitable for deposition on the substrate, the washcoat comprising at least one oxide solid further comprising at least one carrier metal oxide;

depositing an overcoat suitable for deposition on the substrate, the overcoat comprising at least one ZPGM catalyst;

wherein the washcoat is deposited at about 60 g/L to about 100 g/L; and

wherein the substrate exhibits a back pressure of about 0.300 kPa to about 0.400 kPa when receiving an air flow of about 1.0 m³/min.

2. The method according to claim 1, wherein the washcoat is heated for about 2 to about 6 hours.

3. The method according to claim 1, wherein the washcoat is heated for about 4 hours.

4. The method according to claim 1, wherein the washcoat is heated between about 300°

C. and about 700°

C.

5. The method according to claim 1, wherein the washcoat is heated about 550°

C.

6. The method according to claim 1, wherein the substrate is about 100 cells per square inch.

7. The method according to claim 1, wherein the substrate comprises metal.

8. The method according to claim 1, wherein the at least one carrier material oxide comprises one selected from the group consisting of aluminum oxide, doped aluminum oxide, spinel, delafossite, lyonsite, garnet, perovksite, pyrochlore, doped ceria, fluorite, zirconium oxide, doped zirconia, titanium oxide, tin oxide, silicon dioxide, zeolite, and mixtures thereof.

9. The method according to claim 1, wherein the washcoat further comprises at least one oxygen storage material.

10. The method according to claim 9, wherein the at least one oxygen storage material is selected from the group consisting of cerium, zirconium, lanthanum, yttrium, lanthanides, actinides, and mixtures thereof.

11. The method according to claim 9, wherein the ratio of the at least one oxygen storage material to the at least one carrier metal oxide is 2:

3.

12. The method according to claim 1, wherein loss of the deposited washcoat is less than about 5%.

13. The method according to claim 1, wherein the T50 for hydrocarbon conversion is about 339°

C.

14. The method according to claim 1, wherein the T50 for hydrocarbon conversion is about 336°

C.

15. The method according to claim 1, wherein the T50 for hydrocarbon conversion is about 357°

C.

16. The method according to claim 1, wherein the T50 for carbon monoxide conversion is about 200°

C.

17. The method according to claim 1, wherein the T50 for carbon monoxide conversion is about 250°

C.

18. The method according to claim 1, wherein the exhibited back pressure is indicative of uniform washcoat deposition.

19. The method according to claim 1, wherein the at least one ZPGM catalyst comprises one selected from the group consisting of copper, cerium, and combinations thereof.