Clean Diesel Technologies, Inc.

Clean Diesel Technologies Inc. (cdti)

Clean Diesel Technology Inc

Other

Cdti Advanced Materials, Inc.

Cdt Advanced Materials, Inc.

Zahra Nazarpoor

Stephen J Golden

Johnny T Ngo

Maxime Launois

Sen Kitazumi

Randal L Hatfield

Anke Abken

Edward J Lee

Oguzhan Selim Yaglidere

Synergized platinum group metals (SPGM) with ultra-low PGM loadings employed as close-coupled (CC) three-way catalysts (TWC) systems with varied material compositions and configurations are disclosed. SPGM CC catalysts in which ZPGM compositions of binary or ternary spinel structures supported onto support oxides are coupled with commercialized PGM UF catalysts and tested under Federal Test Procedure FTP-75 within TGDI and PI engines. The performance of the TWC systems including SPGM CC (with ultra-low PGM loadings) catalyst and commercialized PGM UF catalyst is compared to the performance of commercialized PGM CC and PGM UF catalysts. The disclosed TWC systems indicate that SPGM CC TWC catalytic performance is comparable or even exceeds high PGM-based conventional TWC catalysts, with reduced tailpipe emissions.

Application of synergized-PGM with ultra-low PGM loadings as close-coupled three-way catalysts for internal combustion engines

Synergized platinum group metals (SPGM) with ultra-low PGM loadings employed as underfloor (UF) three-way catalyst (TWC) systems with varied material compositions and configurations are disclosed. SPGM UF catalysts in which ZPGM compositions of binary and ternary spinel structures supported onto support oxides are coupled with commercialized PGM close-coupled (CC) catalysts and tested under Federal Test Procedure FTP-75 within TGDI and PI engines. The performance of the TWC systems including commercialized PGM CC and SPGM UF (with ultra-low PGM loadings) catalysts is compared to the performance of commercialized PGM CC and PGM UF catalysts. The disclosed TWC systems indicate that SPGM UF TWC catalytic performance is comparable or even exceeds high PGM-based conventional TWC catalysts, with reduced tailpipe emissions.

Application of synergized-PGM with ultra-low PGM loadings as underfloor three-way catalysts for internal combustion engines

Modified calibration strategies for controlling an internal combustion engine and monitoring catalyst performance are disclosed. The modified calibration strategies are implemented using an engine and test cell/catalyst chamber setup wherein the engine is a Euro V 1.2 L turbo gasoline direct injection engine and test cells/catalyst chamber are implemented as substantially free of platinum group metals (PGM) catalysts, herein referred as ZPGM catalysts, and synergized PGM (SPGM) catalysts including a stoichiometric spinel structure within the catalyst configuration. The utilization of an open ECU enables the modified calibration of the engine out targeted AFR. The conventional ECU AFR control strategies are not modified to have the ECU AFR control strategies to continue running normally and only the final engine out targeted AFR values are modified by applying offset AFR values. The modified calibration strategies improve engine operation and catalyst conversion efficiency of the ZPGM and SPGM catalysts including the spinel structures.

Calibration strategies to improve spinel mixed metal oxides catalytic converters

The present disclosure relates to zero-PGM (ZPGM) catalysts including variations of Nickel-doped Copper-Manganese spinel for improved catalyst performance at the stoichiometric condition for use within three-way catalyst (TWC) applications. The ZPGM catalyst material compositions within the aforementioned ZPGM catalysts are expressed with general formulas of CuNiMnO(A-site substitution) and CuMnNiO(B-site substitution). The ZPGM catalysts are subjected to a TWC isothermal steady-state sweep test to assess the catalytic performance (e.g., NO conversion). Test results indicate the ZPGM catalysts exhibit higher NO conversions, at stoichiometric condition and lean conditions, when Ni substituted the B-site cation of the Cu&#x2014;Mn spinel as compared to Ni substituted the A-site cation of the Cu&#x2014;Mn spinel. Additionally, NO conversions of the ZPGM catalysts are significantly affected, at the stoichiometric condition, by the molar ratio of the Ni dopant within the A or B-site cation of the Cu&#x2014;Mn spinel.

Enhanced catalytic activity at the stoichiometric condition of zero-PGM catalysts for TWC applications

Effect of the type of ZPGM material composition to improve thermal stability of ZPGM catalyst systems for TWC application is disclosed. ZPGM catalyst system samples are prepared and configured with washcoat on ceramic substrate, overcoat including doped Zirconia support oxide, and impregnation layer including either CuMnOspinel or CuCoMnOspinel. Testing of ZPGM catalyst samples including variations of aging temperatures and different impregnation layer materials are developed under isothermal steady state sweep test condition for ZPGM catalyst systems to evaluate performance especially NOconversions and level of thermal stability. As a result disclosed ZPGM catalyst systems with most suitable spinel that includes CuCoMnOin impregnation layer exhibit high NOx conversion and significant improved thermal stability compare to CuMnOspinel, which is suitable for under floor and close coupled TWC application. The effect of adding Co to Cu&#x2014;Mn spinel composition to improve thermal stability confirmed by TPR measurement.

Thermal stability of copper-manganese spinel as Zero PGM catalyst for TWC  application

Variations of coating processes of Cu&#x2014;Mn&#x2014;Fe ZPGM catalyst materials for TWC applications are disclosed. The disclosed coating processes for Cu&#x2014;Mn&#x2014;Fe spinel materials are enabled in the preparation ZPGM catalyst samples according to a plurality of catalyst configurations, which may include an alumina only washcoat layer coated on a suitable ceramic substrate, and an overcoat layer with or without an impregnation layer, including Cu&#x2014;Mn&#x2014;Fe spinel and doped Zirconia support oxide, prepared according to variations of disclosed coating processes. Activity measurements are considered under variety of lean condition to rich condition to analyze the influence of disclosed coating processes on TWC performance of ZPGM catalysts for a plurality of TWC applications. Different coating processes may substantially increase thermal stability and TWC activity, providing improved levels of NOconversion that may lead to cost effective manufacturing solutions for ZPGM-TWC systems.

Methods and processes of coating zero-PGM catalysts including with Cu, Mn, Fe for TWC applications

The present disclosure describes zoned three way catalyst (TWC) systems including Rhodium-iron overcoat layers and Nb&#x2014;Zr&#x2014;Al Oxide overcoat layers. Disclosed herein are TWC sample systems that are configured to include a substrate and one or more of a washcoat layer, an impregnation layer, and/or an overcoat layer. In catalyst systems disclosed herein, closed-coupled catalysts include a first catalyst zone with an overcoat layer formed using a slurry that includes an oxide mixture and an Oxygen Storage Material (OSM). In catalyst systems disclosed herein, oxide mixtures include niobium oxide (NbO), zirconia, and alumina. Further, catalyst systems disclosed herein include a second catalyst zone with an overcoat layer formed to include a rhodium-iron catalyst. Yet further, catalyst systems disclosed herein include impregnation layers that include one or more of Palladium, Barium, Cerium, Neodymium, and Rhodium.

Three-way catalyst systems including Nb&#x2014;Zr&#x2014;Al-mixed oxide supports, Ba&#x2014;Pd, and Rh&#x2014;Fe material compositions

Synergized Platinum Group Metals (SPGM) catalyst system for TWC application is disclosed. Disclosed SPGM catalyst system may include a washcoat that includes stoichiometric Cu&#x2014;Mn spinel structure, supported on doped ZrO, and an overcoat that includes PGM, such as platinum (Pt) supported on carrier material oxides, such as alumina. SPGM catalyst system shows significant improvement in nitrogen oxide reduction performance under lean and also rich operating conditions. Additionally, disclosed SPGM catalyst system exhibits enhanced catalytic activity for carbon monoxide conversion. Furthermore, disclosed SPGM catalyst systems are found to have enhanced catalytic activity compared to PGM catalyst system, showing that there is a synergistic effect between PGM catalyst, such as Pt, and Cu&#x2014;Mn spinel within disclosed SPGM catalyst system, which help in activity and thermal stability of disclosed SPGM catalyst.

Synergized PGM catalyst systems including platinum for TWC application

The present disclosure refers to a plurality of process employed for optimization of Zero-PGM washcoat and overcoat loadings on metallic substrates. According to an embodiment a substantial increase in conversion of HC and CO may be achieved by optimizing the total washcoat and overcoat loadings of the catalyst. According to another embodiment, the present disclosure may provide solutions to determine the optimum total washcoat and overcoat loadings for minimizing washcoat adhesion loss. As a result, may increase the conversion of HC and CO from discharge of exhaust gases from internal combustion engines, optimizing performance of Zero-PGM catalyst systems.

Optimization of Zero-PGM washcoat and overcoat loadings on metallic substrate

Solutions to the problem of washcoat and/or overcoat adhesion loss of ZPGM catalyst on metallic substrates are disclosed. Present disclosure provides a novel process for improving WCA to metallic substrates of ZPGM catalyst systems. Reduction of WCA loss and improved catalyst activity may be enabled by the selection of processing parameters determined from variations of pH and addition of binder to overcoat slurry, and particle size of washcoat. Processing parameters may be applied to a plurality of metallic substrates of different geometries and cell densities.

Optimization of washcoat adhesion of zero-PGM catalyst on metallic substrates

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.

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

Spinels having a general formula of ABO, where A and B are a transition metal but not the same transition metal are disclosed. Spinel and spinel compositions of the application are useful in various applications and methods as further described.

Spinel compositions and applications thereof

Synergies resulting from combinations of catalyst systems including Copper-Manganese material compositions and PGM catalysts are disclosed. Variations of catalyst system configurations are tested to determine most effective material composition, formulation, and configuration for an optimal synergized PGM (SPGM) catalyst system. The synergistic effect of the selected SPGM catalyst system is determined under steady state and oscillating test conditions, from which the optimal NO/CO cross over R-value indicates enhanced catalytic behavior of the selected SPGM catalyst system as compared with current PGM catalysts for TWC applications. According to principles in the present disclosure, application of Pd on alumina-based support as overcoat and Cu&#x2014;Mn spinel structure supported on NbO&#x2014;ZrOas washcoat on suitable ceramic substrate, produce higher catalytic activity, efficiency, and better performance in TWC condition, especially under lean condition, than commercial PGM catalysts.

System and methods for using synergized PGM as a three-way catalyst

Diesel oxidation ZPGM catalyst systems are disclosed. ZPGM catalyst systems may oxidize toxic gases, such as carbon monoxide, hydrocarbons and nitrogen oxides that may be included in exhaust gases. ZPGM catalyst systems may include: a substrate, a washcoat, and an impregnation layer. The washcoat may include at least one carrier material oxides. The impregnation layer may include at least one ZPGM catalyst, carrier material oxides and OSMs. Suitable known in the art chemical techniques, deposition methods and treatment systems may be employed in order to form the disclosed ZPGM catalyst systems.

ZPGM Diesel Oxidation Catalysts and methods of making and using same

Diesel oxidation ZPGM catalyst systems using YAgMnOperovskite are disclosed. The ZPGM catalyst system compositions may include YAgMnOperovskite in impregnation component and at least one carrier material oxide in washcoat. The ZPGM catalyst system compositions may also include YAgMnOperovskite co-precipitated in a carrier material oxide as washcoat. The catalyst activity is measured with an inlet gas mixture containing diesel exhaust composition and characterized according to performance in NO oxidation, NOproduction, NO storage capability and diesel oxidation applications.

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Camarillo, CA, United States of America

Zahra Nazarpoor