Method for improving lean performance of PGM catalyst systems: synergized PGM

• US 8,845,987 B1
• Filed: 11/26/2013
• Issued: 09/30/2014
• Est. Priority Date: 11/26/2013
• Status: Active Grant

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: Clean Diesel Technologies, Inc.
• Inventors: Golden, Stephen J., Nazarpoor, Zahra
• Primary Examiner(s): Vanoy, Timothy
• Application Number:
  US14/090,915
• Time in Patent Office: 308 Days
• Field of Search: 423/213.2, 423/213.5, 423/239.1, 423/245.3, 423/247, 602/74, 602/99, 603/01
• US Class Current: 423/213.2
• CPC Class Codes: B01D 2255/1021 Platinum
• 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 2255/908 O2-storage component incorporated in the catalyst
• CPC Class Codes: B01D 53/565 by treating the gases with solids
• CPC Class Codes: B01D 53/62 Carbon oxides
• CPC Class Codes: B01D 53/72 Organic compounds not provided for in groups B01D53/48 - B01D53/70, e.g. hydrocarbons
• CPC Class Codes: B01D 53/865 characterised by a specific catalyst
• CPC Class Codes: B01D 53/945 characterised by a specific catalyst
• CPC Class Codes: B01D 53/9463 with catalysts positioned on one brick
• CPC Class Codes: B01J 23/005 Spinels
• CPC Class Codes: B01J 23/34 Manganese
• CPC Class Codes: B01J 23/72 Copper
• CPC Class Codes: B01J 23/898 with vanadium, tantalum, niobium or polonium
• CPC Class Codes: B01J 2523/00 Constitutive chemical elements of heterogeneous catalysts
• CPC Class Codes: B01J 2523/17 Copper
• 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 37/0244 : Coatings comprising several layers
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

Synergized Platinum Group Metals (SPGM) catalyst system for TWC application is disclosed. Disclosed SPGM catalyst system may include a washcoat with a Cu—Mn spinel structure and an overcoat that includes PGM supported on carrier material oxides, such as alumina. SPGM catalyst system shows significant improvement in nitrogen oxide reduction performance under stoichiometric operating conditions and especially under lean operating conditions, which allows a reduced consumption of fuel. Additionally, disclosed SPGM catalyst system also enhances the reduction of carbon monoxide and hydrocarbon within catalytic converters. Furthermore, disclosed SPGM catalyst systems are found to have enhanced catalyst activity compared to commercial PGM catalyst system, showing that there is a synergistic effect among PGM catalyst and Cu—Mn spinel within the disclosed SPGM catalyst system.

Claims

1. A method for optimizing a catalytic system, comprising:

providing a catalyst system into at least one stream of lean combustion exhaust, comprising;

a substrate;

a washcoat suitable for deposition on the substrate, comprising at least one oxygen storage material further comprising Cu—

Mn spinel having a niobium-zirconia support oxide; and

an overcoat suitable for deposition on the substrate, comprising at least one platinum group metal catalyst and at least one carrier support oxide; and

converting at least one of NO, CO and HC through oxidation or reduction.

2. The method of claim 1, wherein the at least one carrier support oxide is Al₂O₃.

3. The method of claim 1, wherein the converting of NO is less than about 90%.

4. The method of claim 3, wherein the exhaust has an R value of about 0.88.

5. The method of claim 1, wherein the catalyst system is aged.

6. The method of claim 5, wherein the converting of NO is greater than about 80% and less than about 90%.

7. The method of claim 6, wherein the exhaust has an R value of about 0.88.

8. The method of claim 1, wherein the converting of NO is greater than about 95%.

9. The method of claim 8, wherein the exhaust has an R value of about 0.95.

10. A method for optimizing a catalytic system, comprising:

providing a catalyst system into at least one stream of lean combustion exhaust produced by an engine, comprising;

a substrate;

a washcoat suitable for deposition on the substrate, comprising at least one oxygen storage material further comprising Cu—

Mn spinel having a niobium-zirconia support oxide; and

an overcoat suitable for deposition on the substrate, comprising at least one platinum group metal catalyst and at least one carrier support oxide; and

converting at least one of NO, CO and HC through oxidation or reduction;

wherein the Cu—

Mn spinel is stoichiometric.

11. The method of claim 10, wherein the converting of NO is greater than about 98%.

12. The method of claim 10, wherein the converting of CO is greater than about 98%.

13. The method of claim 10, wherein the converting of HC is greater than about 98%.

14. The method of claim 10, wherein the stability of the catalyst system is improved by the addition of Cu—

Mn spinel.

15. The method of claim 10, wherein fuel consumption of the engine is reduced.