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Compositions of lean NOX trap (LNT) systems and methods of making and using same

a technology of nox traps and compounds, applied in the field of catalysts, can solve the problems of high oxygen content, high loading of expensive pgms, and inhibition of the catalytic reduction of nosub>x

Inactive Publication Date: 2017-06-01
SDC MATERIALS
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The solution achieves comparable or improved performance to traditional LNTs with reduced PGM loading, lowering costs and maintaining effectiveness over the lifespan of the catalytic converter, with lower light-off temperatures and reduced emissions.

Problems solved by technology

These engines, however, have high amounts of oxygen present in the exhaust gas, which leads to inhibition of the catalytic reduction of NOx.
Although these traps are effective at removing NOx from the exhaust of lean-burn vehicles, high loadings of expensive PGMs are required.
As such, there is a significant cost associated with the use of these LNTs.

Method used

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  • Compositions of lean NOX trap (LNT) systems and methods of making and using same
  • Compositions of lean NOX trap (LNT) systems and methods of making and using same
  • Compositions of lean NOX trap (LNT) systems and methods of making and using same

Examples

Experimental program
Comparison scheme
Effect test

example 1

Two-Layer Washcoat Configuration-Separate Oxidation and Reduction Washcoat Layers, Combined Reduction and NOx Storage Layer

[1096](a) First Washcoat Composition: Approx. 85 g / L as follows:[1097]3% Boehmite;[1098]47% Porous alumina (MI-386 or the like), impregnated with 15% BaO;[1099]50% NNm powder (nano-on-nano-on-micro particle), the powder that contains Pt, Pd, or a mixture of Pt / Pd.[1100](b) Second Washcoat Composition: Approx. 326 g / L as follows:[1101]2% Boehmite;[1102]83% Cerium oxide (HSAS or the like), impregnated with 8% BaO and 0.6% Pt, Pd, or a mixture of Pt / Pd;[1103]15% NNm powder (nano-on-nano-on-micro particle), the powder that contains Rh.

[1104]Mix the washcoat ingredients from (a) with water and acetic acid and adjust the pH to about 4. After adjusting the viscosity to the proper levels, the washcoat is coated onto the substrate with an approximate layer thickness of 85 g / L. Excess washcoat is blown off and recycled. This first washcoat layer is then dried and calcined...

example 2

Three-layer Washcoat Configuration-Separate Oxidation and Reduction Washcoat Layers, Separate Reduction and NOx Storage Layer

[1105](a) First Washcoat Composition: Approx. 85 g / L as follows:[1106]3% Boehmite;[1107]47% Porous alumina (MI-386 or the like), impregnated with 15% BaO;[1108]50% NNm powder (nano-on-nano-on-micro particle), the powder that contains Pt, Pd, or a mixture of Pt / Pd.[1109](b) Second Washcoat Composition: Approx. 75 g / L as follows:[1110]3% Boehmite;[1111]17% Porous alumina (MI-386 or the like);[1112]80% NNm powder (nano-on-nano-on-micro particle), the powder that contains Rh.[1113](c) Third Washcoat Composition: Approx. 275 g / L as follows:[1114]4% Boehmite;[1115]73% Cerium oxide (HSAS or the like), impregnated with 8% BaO;[1116]23% NNm powder (nano-on-nano-on-micro particle), the powder that contains Pt, Pd, or Pt / Pd.

[1117]Mix the washcoat ingredients from (a) with water and acetic acid and adjust the pH to about 4. After adjusting the viscosity to the proper leve...

example 3

Comparison of Catalytic Converter Performance Described Herein to Commercially Available Catalytic Converters

[1118]FIG. 4 illustrates the performance of a coated substrate with reduced PGM in the NOx storage layer component of a catalytic converter (indicated as “PGM-reduced LNT”), and a coated substrate with no PGM in the NOx storage layer component of a catalytic converter (indicated as “PGM-free LNT”), where the coated substrates are prepared according to embodiments of the present invention, compared to a commercially available catalytic converter (indicated as “reference”). The catalysts were artificially aged at 750° C. for 25 hours to simulate operation after 125,000 miles in a car.

[1119]The commercially available coated substrate displays a CO light-off temperature of 113° C. The coated substrate with the reduced PGM loading in the NOx storage layer washcoat displays a CO light-off temperature of 107° C., or about 6° C. lower than the commercially available coated substrate....

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PUM

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Abstract

The present disclosure relates to a substrate comprising nanoparticle catalysts and NOx storage materials for treatment of gases, and washcoats for use in preparing such a substrate. Also provided are methods of preparation of the nanoparticle catalysts and NOx storage materials, as well as methods of preparation of the substrate comprising the nanoparticle catalysts and NOx storage materials. More specifically, the present disclosure relates to a coated substrate comprising nanoparticle catalysts and NOx storage materials for lean NOx trap (LNT) systems, useful in the treatment of exhaust gases.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application claims priority benefit of U.S. Provisional Patent Application No. 61 / 894,346, filed Oct. 22, 2013. The entire contents of that application are hereby incorporated by reference herein.FIELD OF THE INVENTION[0002]The present disclosure relates to the field of catalysts. More specifically, the present invention relates to nanoparticle catalysts and storage materials for nitrogen oxides as part of a lean NOx trap (LNT) system.BACKGROUND OF THE INVENTION[0003]Car exhaust primarily contains harmful gases such as carbon monoxide (CO), nitrogen oxides (NOx), and hydrocarbons. Environmental concerns and government regulations have led efforts to remove these noxious combustion products from vehicle exhaust by conversion to more benign gases such as carbon dioxide (CO2), nitrogen (N2), and water (H2O). In order to accomplish this conversion, the exhaust gases must pass through a treatment system that contains materials that can ox...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B01J23/46B01J23/10B01J23/02F01N3/10B01J35/04B01J37/04B01J37/02B01D53/94B01J23/44B01J35/00
CPCB01J23/464F01N2370/02B01J23/10B01J23/02B01J35/0006B01J35/04B01J37/04B01J37/0244B01J37/0248B01J37/0236B01D53/9431B01D53/9422F01N3/10B01D2255/91B01D2255/1021B01D2255/1023B01D2255/1025B01D2255/908B01D2255/9202F01N2570/14B01J23/44B01J23/63B01D2255/104B01D2255/2061B01D2255/2063B01D2255/2065B01D2255/20715B01D2255/20738B01D2255/20776B01D2255/20792B01D2255/407B01D2255/40B01J37/349B01J35/45B01J35/733B01J35/393B01J35/23B01J35/19B01J35/56
Inventor KEARL, BRYANTYIN, QINGHUAQI, XIWANGLEAMON, DAVIDBIBERGER, MAXIMILIAN A.
Owner SDC MATERIALS
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