Ford Global Technolgoies, LLC

Alexei Dubkov

Brendan Patrick Carberry

Albert Nazipovich Chigapov

Robert Walter McCabe

George Wade Graham

Steven Maertens

Clifford Norman Montreuil

Woosang Chun

Elmar Riesmeier

Yasser Mohammed Sayed Yacoub

Albert Chigapov

Christoph Boerensen

Matthew Schneider

Jan Harmsen

Mario Balenovic

A catalyst composition for facilitating the oxidation of soot from diesel engine exhaust is provided. The catalyst composition includes a catalytic metal selected from Pt, Pd, Pt&#x2014;Pd, Ag, or combinations thereof, an active metal oxide component containing Cu and La, and a support selected from alumina, silica, zirconia, or combinations thereof. The platinum group metal loading of the composition is less than about 20 g/ft. The catalyst composition may be provided on a diesel particulate filter by impregnating the filter with an alumina, silica or zirconia sol solution modified with glycerol and/or saccharose, impregnating the filter with a stabilizing solution, and impregnating the filter with a solution containing the active metal oxide precursor(s) and the catalytic metal precursor(s). The resulting catalyst coated diesel particulate filter provides effective soot oxidation, exhibits good thermal stability, has a high BET surface area, and exhibits minimal backpressure.

Diesel exhaust gas treatment system

Soot oxidation catalyst and method of making

A catalyst composition is provided for use on a diesel particulate filter which facilitates the oxidation of soot from diesel engine exhaust and which generates low NOemissions during regeneration of the filter. The catalyst composition includes a catalytic metal comprising a platinum group metal selected from Pt, Pd, Pt&#x2014;Pd, or combinations thereof, an active metal oxide component containing Cu and La; and an oxide component selected from oxides of Co, Fe, or combinations thereof. The catalyst composition includes a support selected from alumina, silica, zirconia, or combinations thereof. The catalyst composition may be provided on a diesel particulate filter by impregnating the filter with an alumina, silica or zirconia sol solution modified with glycerol and/or saccharose, impregnating the filter with a stabilizing solution, and impregnating the filter with a solution containing the catalyst metal precursor(s), the active metal oxide precursor(s) and the Co or Fe oxide(s). The resulting catalyst coated diesel particulate filter provides effective soot oxidation, exhibits good thermal stability, has a high BET surface area, exhibits minimal backpressure, and produces low NOemissions during filter regeneration.

Catalyst composition for diesel particulate filter

The present invention provides a regenerable catalyst composition suitable for entrapping SO. The composition of the invention comprises a copper oxide having the formula (Cu/(A oxide) where A oxide is SiO, Zr&#x2014;SiO, AlO, TiO&#x2014;AlO, ZrOand InOor mixtures thereof. Copper loading may vary from about 10 to 60 mol % and is preferably about 25 mol %. The catalyst composition adsorbs SOas metal sulfate under lean conditions and desorbs accumulated SOas SOunder rich conditions. Such reversible SOtrap are able to operate under conventional NOtrap operating conditions to prevent sulfur poisoning of the NOtrap. Furthermore, these traps may be regenerated under rich conditions at 300-450&#xb0; C. In another embodiment of the present invention, an irreversible SOtrap capable of collecting SOunder lean conditions is provided. The traps of this embodiment include praseodymia, zirconia-praseodymia and mixed manganese-yttria and mixtures thereof.

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The present invention provides new platinum group metal ('PGM') free catalytic compositions that comprise silver and/or cobalt stabilized ceria. These compositions facilitate soot oxidation during the regeneration of diesel particulate filters (DPF) thereby replacing PGM formulations. The compositions of the invention are particularly useful as washcoat compositions for DPFs as part of an automotive after-treatment system. Among the formulations tested, the silver-stabilized ceria and cobalt-stabilized ceria formulations e.g. can oxidize soot at 250&#x2013;300&#xb0; C. in the presence of NOand oxygen, while silver-stabilized ceria can oxidize diesel soot even in the presence of oxygen as the sole oxidizing agent at these temperatures. A perovshite composition containing Ag&#x2014;La&#x2014;Mn was very active at temperatures above 300&#xb0; C.

PGM-free washcoats for catalyzed diesel particulate filter applications

Growing community of inventors

Aachen, Germany

Alexei Dubkov