Firing (calcination) process and method related to metallic substrates coated with ZPGM catalyst

• US 9,511,353 B2
• Filed: 06/06/2013
• Issued: 12/06/2016
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Clean Diesel Technologies, Inc.
• Original Assignee: Clean Diesel Technologies, Inc.
• Inventors: Nazarpoor, Zahra
• Primary Examiner(s): Hailey, Patricia L
• Application Number:
  US13/912,011
• Publication Number:
  US 20140274663A1
• Time in Patent Office: 1,279 Days
• Field of Search: 502/244, 502/246, 502/304, 502/345, 502/346, 502/351, 502/353, 502/439, 502/524
• US Class Current: 1/1
• CPC Class Codes: B01D 2255/104 Silver
• CPC Class Codes: B01D 2255/2065 Cerium
• 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 2255/65 Catalysts not containing noble metals
• 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 53/944 Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts three-way-catalysts [TWC] B01D53/9445
• CPC Class Codes: B01D 53/945 characterised by a specific catalyst
• CPC Class Codes: B01J 23/002 Mixed oxides other than spinels, e.g. perovskite
• CPC Class Codes: B01J 23/688 with manganese, technetium or rhenium
• CPC Class Codes: B01J 23/83 with rare earths or actinides
• CPC Class Codes: B01J 2523/00 Constitutive chemical elements of heterogeneous catalysts
• CPC Class Codes: B01J 2523/18 Silver
• CPC Class Codes: B01J 2523/31 Aluminium
• CPC Class Codes: B01J 2523/36 Yttrium
• CPC Class Codes: B01J 2523/3706 Lanthanum
• CPC Class Codes: B01J 2523/48 Zirconium
• CPC Class Codes: B01J 2523/72 Manganese
• CPC Class Codes: B01J 29/06 : Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
• CPC Class Codes: B01J 37/0244 : Coatings comprising several layers
• CPC Class Codes: B01J 37/03 : Precipitation; Co-precipitation
• CPC Class Codes: Y02A 50/20 : Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

The effect of firing (calcination) cycle on metallic substrates in ZPGM catalyst systems is disclosed. ZPGM catalyst samples with washcoat and overcoat are separately fired in a normal, slow and fast firing cycles to determine the optimal firing cycling that may provide an enhanced catalyst performance, as well as the minimal loss of washcoat adhesion from the samples.

Claims

1. A method of controlling a firing cycle for use with catalytics, comprising:

providing at least one substrate;

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

calcinating the washcoat through at least one first heating and at least one second heating;

depositing an overcoat suitable for deposition on the substrate, the overcoat comprising at least one oxygen storage material and at least one ZPGM catalyst;

wherein the at least one ZPGM catalyst comprises at least one compound having the formula AB₂O₄, wherein each of A and B is selected from the group consisting of at least one of copper and cerium; and

wherein one of the at least one carrier metal oxide is a mixed metal oxide.

2. The method of claim 1, wherein the mixed metal oxide is selected from the group consisting of TiO₂, doped TiO₂, Ti_1-xNb_xO₂, SiO₂, alumina, doped alumina, ZrO₂, doped ZrO₂ , Nb₂O₅-ZrO₂ , Nb₂O₅-ZrO₂-CeO₂, and combinations thereof.

3. The method of claim 1, wherein the at least one ZPGM catalyst comprises about 12.0g/L of copper and about 14.4 g/L of cerium.

4. The method of claim 1, wherein the mixed metal oxide has a concentration of about 120 g/L.

5. The method of claim 1, wherein the at least one first heating is from about room temperature to about 150°

C.

6. The method of claim 5, wherein the rate of the at least one first heating is about 120°

C/hr.

7. The method of claim 5, wherein the temperature of about 150°

C. is held for about 2 hours.

8. The method of claim 1, wherein the at least one second heating is to about 550°

C.

9. The method of claim 5, wherein the rate of the at least one second heating is about 180°

C/hr.

10. The method of claim 5, wherein the temperature of about 550°

C. is held for about 4 hours.

11. The method of claim 1, wherein the at least one second heating is to about 300°

C.

12. The method of claim 11, wherein the rate of the at least one second heating is about 120°

C/hr.

13. The method of claim 11, wherein the temperature of about 300°

C. is held for about 2 hours.

14. The method of claim 1, further comprising at least one third heating, wherein the at least one third heating is to about 550°

C.

15. The method of claim 14, wherein the rate of the at least one third heating is about 120°

C/hr.

16. The method of claim 14, wherein the temperature of about 550°

C. is held for about 4 hours.

17. The method of claim 1, wherein the at least one substrate may be selected from the group consisting of cordierite, zeolite, and combinations thereof.

18. The method of claim 1, further comprising calcinating the overcoat through at least one first heating and at least one second heating.

19. A method of controlling a firing cycle for use with catalytics, comprising:

providing at least one substrate;

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

calcinating the washcoat through at least one heating, wherein the at least one heating is from about room temperature to about 550°

C. and wherein the temperature of about 550°

C. is held for about 4 hours;

depositing an overcoat suitable for deposition on the substrate, the overcoat comprising at least one oxygen storage material and at least one ZPGM catalyst;

wherein the at least one ZPGM catalyst comprises at least one compound having the formula AB₂O₄, wherein each of A and B is selected from the group consisting of at least one of copper and cerium; and

wherein one of the at least one carrier metal oxide is a mixed metal oxide.

20. The method of claim 19, further comprising calcinating the overcoat through at least one heating, wherein the at least one heating is from about room temperature to about 550°

C. and wherein the temperature of about 550°

C. is held for about 4 hours.