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Zero platinum group metal catalysts

a platinum group metal and catalyst technology, applied in the field of catalysts, can solve the problems of driving up the cost of platinum group metals, catalysts and catalytic converters, and achieve the effect of reducing pollutants and reducing pollutants in the exhaus

Inactive Publication Date: 2009-12-31
CATALYTIC SOLUTIONS INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

"The present invention is about a catalyst system that is free of platinum group metals and includes a substrate, a washcoat, and an overcoat. The washcoat includes at least one oxide solid selected from the group consisting of a carrier material oxide, a catalyst, and mixtures thereof. The overcoat includes at least one oxide solid selected from the group consisting of a carrier material oxide, a catalyst, and mixtures thereof. The catalyst system can be used to reduce pollutants in exhaust emissions. The technical effects of the invention include improved catalyst performance, reduced cost, and improved environmental impact."

Problems solved by technology

However, this demand along with other demands for platinum group metals places a strain on the supply of platinum group metals, which in turn drives up the cost of platinum group metals and therefore catalysts and catalytic converters.

Method used

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Examples

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example 1

Pore Volume and Surface Area Measurements for Zero Platinum Group Metal Catalysts

[0123]FIG. 4 shows the measured pore volume for the fresh catalyst systems ZPGM-1 through ZPGM-5 and FIG. 5 shows the measured pore volume for the aged catalyst systems ZPGM-1 through ZPGM-5. The aged catalyst systems were aged at 950° C. for 16 hours with 10% H2O and air. The y-axis on the right side of FIG. 4 is for the pore volume (cm3 / g) of ZPGM-1 only.

[0124]The pore volumes were measured using a Micromeritics® (Norcross, Ga.) TriStar 3000 gas adsorption analyzer at 77K. The pore volumes were obtained from the nitrogen adsorption isotherms using the Barrett-Joiner-Halenda (BJH) method (E. P. Barrett, L. G. Joyner, P. P. Halenda, “The determination of pore volume and area distributions in porous substances. I. Computations from nitrogen isotherms,” J. Am. Chem. Soc. (1951), 73, 373-380).

[0125]The results in FIGS. 4 and 5 show that the pore volume decreases for all the catalyst systems (ZPGM-1 through...

example 2

Surface Area Analysis for Fresh and Aged Catalyst Systems ZPGM-1 through ZPGM-5

[0126]The surface areas for the fresh and aged ZPGM catalyst systems are presented in FIG. 6. The aged catalyst systems were aged at 950° C. for 16 hours with 10% H2O and air.

[0127]The surface areas were measured using a Micromeritics® (Norcross, Ga.) TriStar 3000 gas adsorption analyzer at 77K. The surface areas were calculated using the BET (Brunauer, Emmitt and Teller) method (S. Brunauer, P. H. Emmett and E. Teller, J. Am. Chem. Soc., 1938, 60, 309).

[0128]The results in FIG. 6 show that the surface area decreases for all catalyst systems (ZPGM-1 through ZPGM-5) upon aging. The surface area decreases from 18.72 m2 / g for the fresh ZPGM-1 to 2.76 m2 / g for the aged catalyst. Similarly, the surface area decreases from 38.60 m2 / g for the fresh ZPGM-2 to 15.48 m2 / g for the aged catalyst. The surface area decreases from 30.78 m2 / g for the fresh ZPGM-3 to 16.71 m2 / g for the aged catalyst. The surface area decr...

example 3

X-Ray Diffraction Analysis for ZPGM Transition Metal Catalysts

[0129]FIGS. 7-12 show the X-ray diffraction (XRD) patterns of fresh and aged catalyst systems ZPGM-1 through ZPGM-6; the aged catalyst systems were aged at 950° C. for 16 hrs with 10% H2O and air.

[0130]The XRD analysis was conducted to determine the crystalline phases present for each catalyst system. The XRD patterns were measured on a Rigaku® powder diffractometer (MiniFlex™) using Cu Ka radiation in the 2-theta range of 20-70° with a step size of 0.05° and a dwell time of 2 s. The tube voltage and current were set at 40 kV and 30 mA, respectively. The resulting diffraction patterns were analyzed using the International Centre for Diffraction Data (ICDD) database.

[0131]FIG. 7 shows the XRD spectra of the fresh and aged ZPGM-1 catalyst system, Ce0.6La0.4Mn0.6Cu0.4O3, shows the presence of the perovskite (open circles) and fluorite (filled squares) structures. The fluorite and the perovskite structures are larger in the a...

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Abstract

The present invention pertains to catalyst systems for nitrogen oxide, carbon monoxide, hydrocarbon, and sulfur reactions that are free or substantially free of platinum group metals. The catalyst system of the present invention comprise a substrate and a washcoat, wherein the washcoat comprises at least one oxide solid, wherein the oxide solid comprises one or more selected from the group consisting of a carrier material oxide, a catalyst, and mixtures thereof. The catalyst system may optionally have an overcoat, wherein the overcoat comprises at least one oxide solid, wherein the oxide solid comprises one or more selected from the group consisting of a carrier material oxide, a catalyst, and mixtures thereof. The catalyst comprises one or more selected from the group consisting of a ZPGM transition metal catalyst, a mixed metal oxide catalyst, a zeolite catalysts, or mixtures thereof.

Description

TECHNICAL FIELD OF THE INVENTION[0001]The present invention relates to catalysts which are free of any platinum group metals for reducing emissions of nitrous oxide, carbon monoxide, hydrocarbons, and sulfur in exhaust streams.BACKGROUND OF THE INVENTION[0002]Catalysts in catalytic converters have been used to decrease the pollution caused by exhaust from various sources, such as automobiles, utility plants, processing and manufacturing plants, airplanes, trains, all terrain vehicles, boats, mining equipment, and other engine-equipped machines. A common catalyst used in this way is the three-way catalyst (“TWC”). The TWC works by converting carbon monoxide, hydrocarbons, and nitrogen oxides into less harmful compounds or pollutants. Specifically, a TWC works by simultaneously reducing the nitrogen oxides to nitrogen and oxygen, oxidizing carbon monoxide to less harmful carbon dioxide, and oxidizing unburnt hydrocarbons to carbon dioxide and water. The prior art TWC is made using at ...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B01D53/86B01J23/10B01J23/16B01J23/20B01J23/26B01J23/28B01J23/30B01J23/34B01J23/50B01J23/755B01J23/75B01J23/745B01J21/08B01J21/10B01J21/12B01J27/12
CPCB01D53/945Y02T10/22B01D2255/20715B01D2255/20753B01D2255/20761B01D2255/2092B01D2255/405B01D2255/50B01D2255/908B01D2257/30B01J21/005B01J23/002B01J23/08B01J23/10B01J23/72B01J23/75B01J23/755B01J23/83B01J35/0006B01J35/002B01J35/04B01J35/1014B01J35/1038B01J35/1042B01J37/0219B01J37/0244B01J2523/00Y02C20/10B01D2255/20707B01J2523/3706B01J2523/3712B01J2523/48B01J2523/17B01J2523/72B01J2523/3718B01J2523/3725Y02T10/12B01J35/19B01J35/30B01J35/56B01J35/613B01J35/635B01J35/633
Inventor GOLDEN, STEPHEN J.HATFIELD, RANDALPLESS, JASONNGO, JOHNNYSAKBODIN, MANN
Owner CATALYTIC SOLUTIONS INC
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