Systems and Methods for Using Copper-Manganese Spinel as Active Phase for Diesel Oxidation Applications

• US 20150290627A1
• Filed: 04/11/2014
• Published: 10/15/2015
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: Clean Diesel Technologies, Inc.
• Inventors: Nazarpoor, Zahra, Golden, Stephen J.
• Granted Patent: US 9,486,783 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B01D 2255/104 Silver
• 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 2255/2065 Cerium
• CPC Class Codes: B01D 2255/2066 Praseodymium
• CPC Class Codes: B01D 2255/2068 Neodymium
• CPC Class Codes: B01D 2255/20715 Zirconium
• CPC Class Codes: B01D 2255/20761 Copper
• CPC Class Codes: B01D 2255/65 Catalysts not containing noble metals
• 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 53/944 Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts three-way-catalysts [TWC] B01D53/9445
• 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 23/005 Spinels
• CPC Class Codes: B01J 23/66 Silver or gold
• CPC Class Codes: B01J 23/688 with manganese, technetium or rhenium
• CPC Class Codes: B01J 23/83 with rare earths or actinides
• CPC Class Codes: B01J 23/8892 Manganese
• CPC Class Codes: B01J 37/0244 : Coatings comprising several layers
• CPC Class Codes: B01J 37/0246 : Coatings comprising a zeolite
• CPC Class Codes: Y02A 50/20 : Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies
• CPC Class Codes: Y10S 502/52712 : Plural layers on a support, each layer having a distinct function

Abstract

A diesel oxidation catalyst (DOC) system for the treatment of exhaust gas emissions, including oxidation of nitrogen oxides (NO), unburned hydrocarbons (HC), and carbon monoxide (CO) is disclosed. Fresh and hydrothermally aged Zero-PGM (ZPGM) DOC samples are prepared and configured with an alumina-based washcoat on ceramic substrate, overcoat including doped Zirconia support oxide, and impregnation layer of Cu—Mn spinel of selected base metal loadings. Testing of fresh and hydrothermally aged ZPGM DOC system samples including Cu—Mn spinel is developed to evaluate the performance of Cu—Mn spinel active phase in oxidation CO, HC, and NO, as well as production of NO₂. Key to improvement in light-off performance and NO oxidation is to have a diesel oxidation catalyst that is substantially PGM-free and available for a plurality of applications in lean burn engine operations.

Claims

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

providing at least one ceramic-based substrate;

depositing a washcoat suitable for deposition on the substrate;

depositing an overcoat suitable for deposition on the substrate, the overcoat comprising at least one support oxide material comprising ZrO₂; and

depositing at least one impregnation layer;

wherein one of the at least one impregnation layer comprises Cu—

Mn spinel.

2. The method of claim 1, wherein the washcoat may be doped with at least one selected from the group consisting of aluminum oxide, zirconium oxide, doped Zirconia, titanium oxide, tin oxide, silicon dioxide, zeolite, and mixtures thereof.

3. The method of claim 1, wherein the overcoat may comprise at least one material oxide selected from the group consisting of doped aluminum oxide, zirconium oxide, doped Zirconia, titanium oxide, tin oxide, silicon dioxide, zeolite, and mixtures thereof.

4. The method of claim 1, wherein at least a portion of the Cu—

Mn spinel has a general of Cu_1.0M_2.0O₄.

5. The method of claim 1, wherein the T₅₀ of CO is about 180°

C.

6. The method of claim 1, wherein the T₅₀ of HC is about 235°

C.

7. The method of claim 1, wherein the conversion of NO is greater than 55% at about 350°

C.

8. The method of claim 1, wherein the T₅₀ of CO increases less than 15°

C. after hydrothermal aging at 750°

C.

9. The method of claim 1, wherein the T₅₀ of NO increases less than 15°

C. after hydrothermal aging at 750°

C.

10. The method of claim 1, wherein the T₅₀ of HC increases less than 15°

C. after hydrothermal aging at 750°

C.

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

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

13. The method according to claim 1, wherein the washcoat is heated to greater than 300°

C.

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

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

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

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

C.

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

C.

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

C.

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

C.