Platinum group metal-free catalysts for reducing the ignition temperature of particulates on a diesel particulate filter

• US 8,318,629 B2
• Filed: 10/14/2005
• Issued: 11/27/2012
• Est. Priority Date: 10/14/2004
• Status: Active Grant

• Current Assignee: Catalyst Health Solutions Incorporated (UnitedHealth Group Incorporated)
• Original Assignee: ECS Holdings Limited, Catalyst Health Solutions Incorporated (UnitedHealth Group Incorporated)
• Inventors: Alive, Keshavaraja, Baudoux, Anne-Laure, Golden, Stephen J., Iretskaya, Svetlana
• Primary Examiner(s): Nguyen, Cam N.
• Application Number:
  US11/251,372
• Publication Number:
  US 20060120936A1
• Time in Patent Office: 2,601 Days
• Field of Search: 502/302, 502/303, 502/304, 502/324, 502325-328, 502/332, 502/340, 502/341, 502/345, 502/346, 502/355, 502/415, 502/439, 502/527.12, 502/527.13
• US Class Current: 502/304
• CPC Class Codes: B01D 2255/204 Alkaline earth metals
• CPC Class Codes: B01D 2255/206 Rare earth metals
• CPC Class Codes: B01D 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20746 Cobalt
• CPC Class Codes: B01D 2255/20761 Copper
• 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 23/34 Manganese
• CPC Class Codes: B01J 23/83 with rare earths or actinides
• CPC Class Codes: B01J 37/0205 in several steps
• CPC Class Codes: B01J 37/0242 Coating followed by impregnation
• CPC Class Codes: F01N 2370/02 used in catalytic reactors
• CPC Class Codes: F01N 2510/065 for reducing soot ignition temperature
• CPC Class Codes: F01N 3/0231 using special exhaust apparatus upstream of the filter for producing nitrogen dioxide, e.g. for continuous filter regeneration systems [CRT]
• CPC Class Codes: F01N 3/035 with catalytic reactors , e.g. catalysed diesel particulate filters

Abstract

A catalyzed diesel particulate filter (CDPF) and a method for filtering particulates from diesel engine exhaust are provided, where the catalyzed diesel particulate filter includes a substrate and a catalyst composition, where the catalyst composition contains at least one first component, at least one second component, and at least one third component, where the first component is at least one first component selected from the group consisting of cerium and a lanthanide and mixtures thereof, the at least one second component is selected from the group consisting of cobalt, copper, manganese and mixtures thereof; and the third component comprises strontium, where the first component, the second component, and the third component are in an oxide form after calcination. The catalyst on the catalyzed diesel particulate filter lowers the temperature at which particulates are removed from the CDPF by oxidizing the particulates on the filter. The catalyzed diesel particulate filter may also include a washcoat. Washcoats prepared from colloidal aluminum oxide may have higher surface areas and pore volumes loadings than washcoats containing aluminum oxide prepared from aluminum nitrate.

Claims

1. A catalyzed diesel particulate filter consisting essentially of:

a) a substrate for filtering particulates from diesel engine exhaust; and

b) a catalyst composition, wherein said catalyst composition comprises;

i) at least one first component selected from the group consisting of cerium, a lanthanide and mixtures thereof; and

ii) at least one second component selected from the group consisting of copper, manganese and mixtures thereof,

wherein said first component and said second component are in an oxide form after a calcination;

wherein the catalyst composition does not comprise metal sulfates and platinum group metals, and further wherein the catalyst composition does not comprise a perovskite and the second component does not comprise cobalt.

2. The catalyzed diesel particulate filter of claim 1, wherein said substrate is selected from the group consisting of a woven fabric, a wire mesh, a disk filter, a ceramic honeycomb monolith, a ceramic foam, a metallic foam, and a wall flow filter.

3. The catalyzed diesel particulate filter of claim 1, wherein said substrate is made from a material selected from the group consisting of a metal, alumina, silica alumina, cordierite, silicon nitride, silicon carbide, sodium zirconium phosphate, and mullite.

4. The catalyzed diesel particulate filter of claim 1, wherein when said second component comprises manganese, a molar ratio of the first component to the second component is in a range of 15-60:

30-70.

5. The catalyzed diesel particulate filter of claim 1, wherein said first component, said second component, and said third component are initially in the form of water-soluble salts.

6. The catalyzed diesel particulate filter of claim 5, wherein said water-soluble salts are dissolved in water to form an aqueous solution, and said aqueous solution is impregnated into said substrate.

7. The catalyzed diesel particulate filter of claim 6, wherein said substrate is calcined after said aqueous solution is impregnated into said substrate, thereby forming said catalyst composition.

8. The catalyzed diesel particulate filter of claim 1, wherein a loading of said catalyst composition on said catalyzed diesel particulate filter is in a range of approximately 5 g/L to approximately 90 g/L, wherein the loading is on the basis of the oxides.

9. A catalyzed diesel particulate filter, consisting essentially of:

a) a substrate for filtering particulates from diesel engine exhaust, wherein the substrate has a washcoat thereon; and

b) a catalyst composition, wherein said catalyst composition comprises;

i) at least one first component selected from the group consisting of cerium, a lanthanide and mixtures thereof; and

ii) at least one second component selected from the group consisting of copper, manganese and mixtures thereof,

wherein said first component and said second component are in an oxide form after a calcination;

wherein the catalyst composition does not comprise metal sulfates and platinum group metals, and further wherein the catalyst composition does not comprise a perovskite and the second component does not comprise cobalt.

10. The catalyzed diesel particulate filter of claim 9, wherein said catalyst composition is supported on said washcoat.

11. The catalyzed diesel particulate filter of claim 9, wherein said washcoat comprises aluminum oxide.

12. The catalyzed diesel particulate filter of claim 11, wherein said aluminum oxide is applied to said substrate in a form of colloidal alumina.

13. The catalyzed diesel particulate filter of claim 12, wherein said colloidal alumina is prepared with nano particle technology.

14. The catalyzed diesel particulate filter of claim 11, wherein said aluminum oxide is produced from aluminum nitrate.

15. The catalyzed diesel particulate filter of claim 11, wherein said washcoat further comprises at least one oxide selected from the group consisting of silica alumina, a zeolite, silica, cerium oxide, lanthanide oxide, zirconium oxide, and mixtures thereof.

16. The catalyzed diesel particulate filter of claim 9, wherein a loading of said washcoat is in a range of approximately 5 g/L to approximately 100 g/L.

17. A catalyzed diesel particulate filter consisting essentially of:

a) a substrate for filtering particulates from diesel engine exhaust; and

b) a catalyst composition, wherein said catalyst composition comprises;

i) at least one first component selected from the group consisting of cerium, a lanthanide and mixtures thereof; and

ii) at least one second component selected from the group consisting of copper, manganese and mixtures thereof, and

c) at least one third component comprising strontium, wherein said first component, said second component, and said third component are in an oxide foam after a calcination;

wherein the catalyst composition does not comprise metal sulfates and platinum group metals, and further wherein the catalyst composition does not comprise a perovskite and the second component does not comprise cobalt.

18. The catalyzed diesel particulate filter of claim 17, wherein when said second component comprises manganese, a molar ratio of the first component to the second component is in a range of 15-60:

30-70.