Combination of Pseudobrookite Oxide and Low Loading of PGM as High Sulfur-Resistant Catalyst for Diesel Oxidation Applications

• US 20160346765A1
• Filed: 06/01/2015
• Published: 12/01/2016
• Est. Priority Date: 06/01/2015
• Status: Abandoned Application

• Current Assignee: CDTi Advanced Materials, Inc.
• Original Assignee: Clean Diesel Technologies, Inc.
• Inventors: Nazarpoor, Zahra, Golden, Stephen J.
• Application Number:
  US14/726,807
• Publication Number:
  US 20160346765A1
• 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 2255/1026 Ruthenium
• CPC Class Codes: B01D 2255/1028 Iridium
• 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 2255/2065 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 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20738 Iron
• CPC Class Codes: B01D 2255/20761 Copper
• CPC Class Codes: B01D 2255/2092 Aluminium
• CPC Class Codes: B01D 2255/40 Mixed oxides
• 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: B01D 53/9468 : in different layers
• CPC Class Codes: B01J 21/066 : Zirconium or hafnium; Oxides or hydroxides thereof
• CPC Class Codes: B01J 23/002 : Mixed oxides other than spinels, e.g. perovskite
• CPC Class Codes: B01J 23/34 : Manganese
• CPC Class Codes: B01J 23/40 : of the platinum group metals
• CPC Class Codes: B01J 23/6562 : Manganese
• CPC Class Codes: B01J 2523/00 : Constitutive chemical elements of heterogeneous catalysts
• CPC Class Codes: B01J 2523/31 : Aluminium
• CPC Class Codes: B01J 2523/36 : Yttrium
• CPC Class Codes: B01J 2523/48 : Zirconium
• CPC Class Codes: B01J 2523/72 : Manganese
• CPC Class Codes: B01J 2523/824 : Palladium
• CPC Class Codes: B01J 2523/828 : Platinum
• CPC Class Codes: B01J 35/19 : Catalysts containing parts with different compositions
• CPC Class Codes: B01J 37/0036 : Grinding
• CPC Class Codes: B01J 37/0201 : Impregnation
• CPC Class Codes: B01J 37/0244 : Coatings comprising several layers
• CPC Class Codes: B01J 37/0248 : Coatings comprising impregnated particles
• CPC Class Codes: B01J 37/088 : Decomposition of a metal salt

Abstract

Sulfur-resistant synergized platinum group metals (SPGM) catalysts with significant oxidation capabilities are disclosed. Catalytic layers of SPGM catalyst samples are prepared using conventional synthesis techniques to build a washcoat layer completely or substantially free of PGM material. The SPGM catalyst includes a washcoat layer comprising YMn₂O₅ (pseudobrookite) and an overcoat layer including a Pt/Pd composition with total PGM loading of at or below 5.0 g/ft³. Resistance to sulfur poisoning and catalytic stability is observed under 5.2 gS/L condition to assess significant improvements in NO oxidation, and HC and CO conversions.

Claims

1. A catalytic composition comprising:

a platinum group metal and YMn₂O₅.

2. The composition of claim 1, wherein the YMn₂O₅ has a pseudobrookite structure.

3. A catalytic composition suitable for diesel oxidation catalysts applications, comprising:

a platinum group metal and at least one pseudobrookite structured compound.

4. The composition of claim 3, wherein the pseudobrookite structured compound has a general formula of AB₂O₅.

5. The composition of claim 3, wherein the pseudobrookite structured compound is selected from the group consisting of silver, manganese, yttrium, lanthanum, cerium, iron, praseodymium, neodymium, strontium, cadmium, cobalt, scandium, copper, and niobium.

6. The composition of claim 3, wherein the platinum group metal is selected from the group consisting of platinum, palladium, ruthenium, iridium, rhodium, and combinations thereof.

7. A catalyst system, comprising:

at least one substrate;

at least one washcoat comprising a pseudobrookite structured compound; and

at least one overcoat comprising a platinum group metal.

8. The catalyst system of claim 7, wherein the pseudobrookite structured compound has a general formula of AB₂O₅.

9. The catalyst system of claim 7, wherein the pseudobrookite structured compound is selected from the group consisting of silver, manganese, yttrium, lanthanum, cerium, iron, praseodymium, neodymium, strontium, cadmium, cobalt, scandium, copper, and niobium.

10. The catalyst system of claim 7, wherein the platinum group metal is selected from the group consisting of platinum, palladium, ruthenium, iridium, rhodium, and combinations thereof.

11. The catalyst system of claim 7, wherein the pseudobrookite structured compound is on a ZrO₂ support oxide.

12. The catalyst system of claim 7, wherein the platinum group metal is applied on the washcoat at 5.0 g/ft³.

13. The catalyst system of claim 7, wherein the conversion of CO is about 100% under sulfation of 5.2 g/L.

14. The catalyst system of claim 7, wherein the conversion of NO is about 50% under sulfation of 5.2 g/L.

15. The catalyst system of claim 7, wherein the conversion of HC is about 88% under sulfation of 5.2 g/L.

16. The catalyst system of claim 7, wherein the conversion of NO is about 60% at about 340°

C.