Nanostellar, Inc.

Shubin, Inc.

Jifei Jia

Kyle L Fujdala

Xianghong Hao

Timothy J Truex

Jonathan W Woo

Jian Wang

Mats Larsson

Juan Cai

Cetin Kilic

Jangsuk Hyun

Ligen Wang

A monomer is added to a solvent containing metal salt and porous support materials and the solvent is stirred for a period of time to distribute and fix the metal in the pores of the support materials. The solids that are dispersed in the solvent are then separated from the liquid, dried and calcined to form heterogeneous catalysts. The monomer that is added is of a type that can be polymerized in the solvent to form oligomers or polymers, or both. When forming heterogeneous catalysts containing platinum, acrylic acid is selected as the preferred monomer.

Method for producing heterogeneous catalysts containing metal nanoparticles

An emission control catalyst that exhibits improved CO and HC reduction performance includes a supported platinum-based catalyst, and a supported palladium-gold catalyst. The two catalysts are coated onto different layers, zones, or monoliths of the substrate for the emission control catalyst such that the platinum-based catalyst encounters the exhaust stream before the palladium-gold catalyst. Zeolite may be added to the emission control catalyst as a hydrocarbon absorbing component to boost the oxidation activity of the palladium-gold catalyst.

Engine exhaust catalysts containing palladium-gold

An engine exhaust catalyst exhibits improved CO oxidation performance relative to conventional engine exhaust catalysts and includes a first supported catalyst comprising platinum and a second supported catalyst comprising palladium and gold species in close contact. The first supported catalyst may be a platinum catalyst, a platinum&#x2014;palladium catalyst, or a platinum catalyst promoted with bismuth, and the second supported catalyst preferably has a palladium to gold weight ratio of about 0.85:1.0. To improve aged catalyst performance, the first and second supported catalysts are coated onto different layers, zones, or monoliths of the substrate for the engine exhaust catalyst.

An engine exhaust catalyst containing precious metal nanoparticles is promoted with bismuth. The bismuth promotion improves the catalyst's CO oxidation performance. Also, by varying the amount of bismuth that is added, the NO conversion rate that can be realized with the catalyst can be controlled. The control over the NO conversion rate is important because the passive regenerative performance of a particulate filter used in engine exhaust systems is based on the amount NOthat is present in the exhaust stream that reaches the particulate filter. The amount of NObeing produced needs to be optimized (not necessarily maximized) so that adequate particulate filter regeneration performance can be maintained while avoiding unused, toxic NOfrom being exhausted into the atmosphere.

Platinum-bismuth catalysts for treating engine exhaust

A sample preparation method for characterization of nanoparticles embedded in the supports of heterogeneous catalysts, with improved particle dispersion, is introduced. The supported catalyst is first ground or milled into fine powder. Then, the powder is mixed into an organic solvent, and an etchant is added to the solvent to digest the supports and release metallic nanoparticles. The resulting solution is then placed in an ultrasonic bath where ultrasonic waves are generated and applied to the solution. The ultrasonic waves suppress agglomeration of the particles and also break up those particle clusters resulting from agglomeration during the prior steps. Subsequently, a sample is extracted from the solution and prepared for analysis.

Dissolving metal particles from supported catalyst using ultrasonic energy, solvent and etchant

The catalytic efficiency of supported catalysts containing metal nanoparticles is strongly related to the chemical softness at the surfaces of such nanoparticles. Supported catalysts containing platinum nanoparticles having average surface softness values (expressed in scaled units ranging from 0 to 1) between 0.07198 and 0.09247 exhibit high catalytic efficiency. The catalytic efficiency of such platinum nanoparticles for CO oxidation, expressed as the turn-over frequency (TOF), was observed to be on or above 0.03062 s. The supported catalysts containing platinum nanoparticles with tighter average surface softness ranges exhibit even higher catalytic efficiencies. The TOF for CO oxidation of platinum nanoparticles having average surface softness values between 0.08031 and 0.08679 was observed to be on or above 0.06554 s.

Supported catalysts having platinum particles

The catalytic efficiency of supported catalysts containing metal nanoparticles is strongly related to the chemical softness at the surfaces of such nanoparticles. The chemical softness of a nanoparticle is obtained using results from Density Functional Theory modeling, an extended version of Embedded Atom Method modeling, and continuum modeling based on size and shape of the nanoparticle. A metal nanoparticle of a certain size and shape is first modeled using the extended EAM and EAM parameters that have been validated with results from DFT modeling, to obtain atomic energy densities at each atom location. The chemical softness value at each atom location is then calculated from the atomic energy densities and various parameters that are derived based on results from DFT modeling. The surface chemical softness value is derived from the local chemical softness values based on the geometry and atomistic structure of the metal nanoparticle.

Method of estimating chemical reactivity of nanoparticles

A method for producing highly dispersed catalysts is disclosed. The method includes contacting a support material with a solvent for a period of time, adding a metal salt to the solvent and support mixture, and then adding a reducing agent to the solution to reduce the metal salt to nanometer sized metal particles on the surface of the support. Excess solvent is used in the process, the volume of solvent being greater than two times the pore volume of the support.

Supported catalysts are produced with nanometer sized particles comprised of different metals dispersed throughout the catalyst support material. The supported catalysts reduce substantially or completely the amount of platinum that is required without sacrificing catalytic performance. In place of platinum, the supported catalysts employ palladium, silver, or copper, all of which costs significantly less than platinum.

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El Cerrito, CA, United States of America

Jifei Jia