Synergized PGM Catalyst Systems for Diesel Oxidation Catalyst Applications

• US 20150290630A1
• Filed: 04/11/2014
• Published: 10/15/2015
• Est. Priority Date: 11/26/2013
• Status: Abandoned Application

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: Clean Diesel Technologies, Inc.
• Inventors: Nazarpoor, Zahra, Golden, Stephen J.
• Application Number:
  US14/251,169
• Publication Number:
  US 20150290630A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B01D 2255/1021 Platinum
• CPC Class Codes: B01D 2255/1023 Palladium
• CPC Class Codes: B01D 2255/1025 Rhodium
• CPC Class Codes: B01D 2255/20715 Zirconium
• CPC Class Codes: B01D 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20761 Copper
• CPC Class Codes: B01D 2255/405 Spinels
• 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 2258/012 Diesel engines and lean burn gasoline engines
• CPC Class Codes: B01D 53/945 characterised by a specific catalyst
• CPC Class Codes: B01J 23/005 Spinels
• CPC Class Codes: B01J 23/8892 Manganese
• CPC Class Codes: B01J 23/8986 with manganese, technetium or rhenium
• CPC Class Codes: B01J 2523/00 Constitutive chemical elements of heterogeneous catalysts
• CPC Class Codes: B01J 2523/17 Copper
• CPC Class Codes: B01J 2523/31 Aluminium
• CPC Class Codes: B01J 2523/48 Zirconium
• CPC Class Codes: B01J 2523/56 Niobium
• CPC Class Codes: B01J 2523/72 Manganese
• CPC Class Codes: B01J 2523/824 : Palladium
• CPC Class Codes: B01J 37/0244 : Coatings comprising several layers
• CPC Class Codes: B01J 37/035 : Precipitation on carriers
• CPC Class Codes: B01J 37/038 : to form slurries or suspensions, e.g. a washcoat
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

Synergized platinum group metals (SPGM) oxidation catalyst systems are disclosed. Disclosed SPGM oxidation catalyst systems may include a washcoat with a Cu—Mn spinel structure and an overcoat including PGM, such as palladium (Pd), platinum (Pt), rhodium (Rh), or combinations thereof, supported on carrier material oxides. SPGM systems show significant improvement in abatement of unburned hydrocarbons (HC) and carbon monoxide (CO), and the oxidation of NO to NO₂, which allows reduction of fuel consumption. Disclosed SPGM oxidation catalyst systems exhibit enhanced catalytic activity compared to PGM oxidation systems, showing that there is a synergistic effect between PGM and Cu—Mn spinel composition within the disclosed SPGM oxidation catalyst systems. Disclosed SPGM oxidation catalyst systems may be available for a plurality of DOC applications.

Claims

1. A synergized platinum group metal (SPGM) catalyst system, comprising:

at least one substrate comprising at least one metal;

at least one washcoat comprising at least one oxygen storage material further comprising Cu—

Mn having a niobium-zirconia support oxide; and

at least one overcoat comprising at least one platinum group metal catalyst;

wherein the at least one platinum group metal catalyst comprises at least one selected from the group consisting of palladium, a bimetallic composite of platinum and rhodium, and combinations thereof;

wherein the at least one overcoat is supported on at least one carrier material oxide comprising alumina.

2. The catalyst system of claim 1, wherein the Cu—

Mn spinel comprises CuMn₂O₄.

3. The catalyst system of claim 1, wherein the at least one platinum group metal catalyst is present at about 0.5 g/ft³ to about 25.0 g/ft³.

4. The catalyst system of claim 1, wherein the at least one platinum group metal catalyst is present at about 1.0 g/ft³.

5. The catalyst system of claim 1, wherein the T₅₀ for CO is between about 235°

C. to about 325°

C.

6. The catalyst system of claim 1, wherein the T₅₀ for HC is between about 235°

C. to about 325°

C.

7. The catalyst system of claim 1, wherein the conversion of NO is about 34% at 390°

C.

8. The catalyst system of claim 1, wherein the conversion of NO is about 18% at 465°

C.

9. The catalyst system of claim 1, wherein the conversion of NO_x is about 19% at 460°

C.

10. The catalyst system of claim 1, wherein the Cu—

Mn is in spinel form.

11. The catalyst system of claim 1, wherein the niobium-zirconia support oxide comprises Nb₂O₅—

ZrO₂.

12. The catalyst system of claim 1, further comprising at least one impregnation layer.

13. The catalyst of claim 1, wherein the at least one substrate comprises a ceramic.

14. The catalyst of claim 1, wherein the at least one platinum group metal catalyst is prepared by co-milling.

15. The catalyst of claim 1, wherein the at least one platinum group metal catalyst is prepared by co-precipitation.