Catalyst composition comprising magnetic material adapted for inductive heating

Abstract

The invention provides a catalyst composition, including a mixture of catalytically active particles and a magnetic material, such as superparamagnetic iron oxide nanoparticles, capable of inductive heating in response to an applied alternating electromagnetic field. The catalytically active particles will typically include a base metal, platinum group metal, oxide of base metal or platinum groupmetal, or combination thereof, and will be adapted for use in various catalytic systems, such as diesel oxidation catalysts, catalyzed soot filters, lean NOx traps, selective catalytic reduction catalysts, ammonia oxidation catalysts, or three- way catalysts. The invention also includes a system and method for heating a catalyst material, which includes a catalyst article that includes the catalyst composition and a conductor for receiving current and generating an alternating electromagnetic field in response thereto, the conductor positioned such that the generated alternating electromagnetic field is applied to at least a portion of the magnetic material.

Description

field of invention [0001] The present invention relates to catalyst compositions for treating engine emissions, methods of making such catalyst compositions and their use, and catalyst articles and systems using such catalyst compositions. Background of the invention [0002] Diesel engine emissions include particulate matter (PM), nitrogen oxides (NO x ), unburned hydrocarbons (HC) and carbon monoxide (CO). NO x is the term used to describe various chemicals of nitrogen oxides, including nitric oxide (NO) and nitrogen dioxide (NO 2 ). The two main components of emitted particulate matter are the soluble organic fraction (SOF) and the soot fraction. SOF condenses on soot in layers and is usually derived from unburned diesel fuel and lubricating oil. SOF can be present in diesel emissions as a vapor or as an aerosol (ie, fine droplets of liquid condensate), depending on the temperature of the exhaust. Soot is mainly composed of carbon particles. The HC content of the e...

AI Technical Summary

Problems solved by technology

Several challenges exist for the successful commercialization of such systems, including the need for high energy consumption and inefficient heating due to the need to first heat the catalyst substrate

Additionally, most electrical heating designs in the art use metal substrates and are not compatible with the more widely used ceramic substrates used as catalyst supports in many systems

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