ZPGM Diesel Oxidation Catalysts and methods of making and using same

• US 9,511,350 B2
• Filed: 05/10/2013
• Issued: 12/06/2016
• Est. Priority Date: 05/10/2013
• Status: Active Grant

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: Clean Diesel Technologies, Inc.
• Inventors: Nazarpoor, Zahra, Golden, Stephen J.
• Primary Examiner(s): Griffin, Walter D
• Assistant Examiner(s): PEREZ, JELITZA M
• Application Number:
  US13/891,647
• Publication Number:
  US 20140334989A1
• Time in Patent Office: 1,306 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B01D 2255/104 Silver
• CPC Class Codes: B01D 2255/2061 Yttrium
• CPC Class Codes: B01D 2255/2073 Manganese
• CPC Class Codes: B01D 2255/91 NOx-storage component incorporated in the catalyst
• CPC Class Codes: B01D 2258/012 Diesel engines and lean burn gasoline engines
• 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 23/002 Mixed oxides other than spinels, e.g. perovskite
• CPC Class Codes: B01J 23/6562 Manganese
• CPC Class Codes: B01J 2523/00 Constitutive chemical elements of heterogeneous catalysts
• CPC Class Codes: B01J 2523/18 Silver
• CPC Class Codes: B01J 2523/36 Yttrium
• CPC Class Codes: B01J 2523/72 Manganese
• CPC Class Codes: Y02A 50/20 Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters

Abstract

Diesel oxidation ZPGM catalyst systems are disclosed. ZPGM catalyst systems may oxidize toxic gases, such as carbon monoxide, hydrocarbons and nitrogen oxides that may be included in exhaust gases. ZPGM catalyst systems may include: a substrate, a washcoat, and an impregnation layer. The washcoat may include at least one carrier material oxides. The impregnation layer may include at least one ZPGM catalyst, carrier material oxides and OSMs. Suitable known in the art chemical techniques, deposition methods and treatment systems may be employed in order to form the disclosed ZPGM catalyst systems.

Claims

1. A zero platinum group metal (ZPGM) catalyst system, comprising:

a substrate; and

a washcoat suitable for deposition on the substrate, comprising at least one carrier metal oxide, and at least one ZPGM catalyst; and

wherein at least one of the ZPGM catalyst comprises at least one perovskite structured compound having the formula ABO₃, wherein each of A and B is selected from the group consisting of at least one of yttrium, silver, manganese, and combinations thereof;

wherein yttrium is present in about 1% to about 5% by weight of the at least one ZPGM catalyst, silver is present in about 1% to about 5% by weight of the at least one ZPGM catalyst, and wherein manganese is present in about 1% to about 5% by weight of the at least one ZPGM catalyst.

2. The ZPGM catalyst system of claim 1, further comprising at least one impregnation layer, wherein the impregnation layer includes at least one ZPGM catalyst.

3. The ZPGM catalyst system of claim 2, wherein yttrium is present in about 1% to about 10% by weight of the at least one ZPGM catalyst in the at least one impregnation layer.

4. The ZPGM catalyst system of claim 2, wherein silver is present in about 1% to about 10% by weight of the at least one ZPGM catalyst in the at least one impregnation layer.

5. The ZPGM catalyst system of claim 2, wherein manganese manganese is present in about 1% to about 10% by weight of the at least one ZPGM catalyst in the at least one impregnation layer.

6. The ZPGM catalyst system of claim 1, wherein the substrate is selected from the group consisting of cordierite, metallic alloys, foams, microporous materials, zeolites, and combinations thereof.

7. The ZPGM catalyst system of claim 1, wherein the ZPGM catalyst comprises at least one perovskite structured compound having the formula Y_1-xAg_xMnO₃ or YMnO₃, wherein x is from 0 to 1.

8. The ZPGM catalyst system of claim 1, wherein the at least one perovskite structured compound comprises about 1% to about 30% of the at least one of the ZPGM catalyst by weight.

9. The ZPGM catalyst system of claim 1, wherein the at least one oxide solid is selected from the group consisting of ZrO₂, doped ZrO₂ with lanthanide group metals, Nb₂O₅, Nb₂O₅—

ZrO₂, alumina and doped alumina, TiO₂ and doped TiO₂.

10. The ZPGM catalyst system of claim 1, wherein the at least one catalyst oxidizes one selected from the group consisting of CO, hydrocarbons, nitrogen oxides, and combinations thereof.

11. An apparatus for reducing emissions from an engine having associated therewith an exhaust system, comprising:

a substrate;

a washcoat suitable for deposition on the substrate, comprising at least one oxide solid further comprising at least one carrier metal oxide; and

at least one impregnation layer, wherein the impregnation layer includes at least one ZPGM catalyst;

wherein the at least one ZPGM catalyst comprises at least one perovskite structured compound having the formula ABO₃, wherein each of A and B is selected from the group consisting at least one of yttrium, silver, manganese, and combinations thereof;

wherein yttrium is present in about 1% to about 5% by weight of the at least one ZPGM catalyst, silver is present in about 1% to about 5% by weight of the at least one ZPGM catalyst, and wherein manganese is present in about 1% to about 5% by weight of the at least one ZPGM catalyst.

12. The apparatus of claim 11, wherein the washcoat and at least one impregnation layer are applied in two different application steps.

13. The apparatus of claim 12, further comprising at least one continuously regenerating trap associated with the exhaust system wherein NO or NO₂ is oxidized and at least partially removes carbon soot from the exhaust system.

14. The apparatus of claim 13, wherein the at least one continuously regenerating trap comprises zeolite.

15. The apparatus of claim 12, further comprising at least one lean NOx trap associated with the exhaust system.

16. A zero platinum group metal (ZPGM) catalyst system, comprising:

a substrate;

an overcoat suitable for deposition on the substrate, comprising at least one overcoat oxide solid selected from the group consisting at least one of a carrier metal oxide, and a ZPGM catalyst; and

a washcoat suitable for deposition on the substrate, comprising at least one oxide solid selected from the group consisting of at least one carrier metal oxide, and at least one ZPGM catalyst; and

wherein at least one of the ZPGM catalyst comprises at least one perovskite structured compound having the formula ABO₃, wherein each of A and B is selected from the group consisting at least one of yttrium, silver, manganese, and combinations thereof;

wherein at least one of the washcoat and overcoat comprises a carrier metal oxide and the at least one ZPGM catalyst, and wherein the yttrium is present in about 1% to about 5% by weight of the at least one ZPGM catalyst, silver is present in about 1% to about 5% by weight of the at least one ZPGM catalyst, and wherein manganese is present in about 1% to about 5% by weight of the at least one ZPGM catalyst.