Nanoscale Metal Oxide Catalyst for Low-Temperature Exhaust Purification

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Solution Overview

Problem

Existing catalysts for exhaust gas purification from diesel engines lack sufficient thermal durability and are ineffective at low temperatures for purifying carbon monoxide (CO) and hydrocarbon (HC).

Innovation Solution

A catalyst comprising a carrier with aluminum oxide (Al2O3) and specific metal oxides such as zirconium oxide (ZrO2), cerium oxide (CeO2), yttrium oxide (Y2O3), neodymium oxide (Nd2O3), silicon oxide (SiO2), and titanium oxide (TiO2) supporting precious metals like gold (Au), silver (Ag), platinum (Pt), palladium (Pd), rhodium (Rh), iridium (Ir), ruthenium (Ru), and osmium (Os), with metal oxide particle diameters less than 10 nm, is developed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional catalysts are used for exhaust gas purification, then they can operate at high temperatures, but they lack sufficient thermal durability and are ineffective at low temperatures

Engineering Contradiction:
Improveoperating temperature rangeVSAvoidthermal durability
Core Design Contradiction:
TemperatureVSReliability

Solution Approach 1:

The patent employs a composite carrier structure consisting of Al2O3 combined with specific metal oxides (ZrO2, CeO2, Y2O3, Nd2O3, SiO2, or TiO2) in a nanoscale mixture. This composite material approach enables the catalyst to simultaneously achieve high thermal durability through the stable Al2O3 framework and effective low-temperature activity through the synergistic metal oxide components, thereby resolving the contradiction between temperature range and reliability.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent changes the physical parameter of metal oxide particle size to less than 10 nm, creating a nanoscale mixture that fundamentally alters the catalyst's performance characteristics. This parameter change enables the material to exhibit both high thermal stability and enhanced low-temperature reactivity, effectively bridging the performance gap between high-temperature durability and low-temperature effectiveness.

Inventive Principle:
Principle #35Parameter changes

2Productivity

If metal oxide particle size is reduced to enhance low-temperature activity, then catalytic effectiveness at low temperatures improves, but maintaining thermal durability becomes more difficult

Engineering Contradiction:
Improvelow-temperature purification efficiencyVSAvoidthermal stability
Core Design Contradiction:
ProductivityVSTemperature

Solution Approach 1:

The patent applies parameter change by precisely controlling metal oxide particle size to less than 10 nm, which enhances low-temperature catalytic activity through increased surface area and quantum effects. Simultaneously, the nanoscale mixture with Al2O3 provides a stable framework that maintains thermal durability, thus resolving the contradiction between productivity at low temperatures and thermal stability.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The composite structure of Al2O3 with nanoscale metal oxides creates a synergistic effect where the Al2O3 matrix provides thermal stability while the fine metal oxide particles contribute low-temperature activity. This composite approach allows the system to achieve both high productivity at low temperatures and maintained thermal stability.

Inventive Principle:
Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The catalyst effectively purifies CO and HC at low temperatures and maintains thermal durability, making it suitable for diesel engine exhaust gas purification even under high-temperature conditions.

Implementation Method 1

having a carrier that includes aluminum oxide (Al2O3) and one or more metal oxides selected from the group consisting of zirconium oxide (ZrO2), cerium oxide (CeO2), yttrium oxide (Y2O3), neodymium oxide (Nd2O3), silicon oxide (SiO2) and titanium oxide (TiO2) support one or more catalyst components

Methodology Applied
Scientific EffectAdsorption: Adsorption

Implementation Method 2

oxidation catalysts which oxidize carbon monoxide (hereinafter also referred to as 'CO') and hydrocarbon (hereinafter also referred to as 'HC') into CO2 and H2O

Methodology Applied
Scientific EffectOxidation: Oxidation

Data Source

PatentUS9561494B2Catalyst for exhaust gas purification, method for producing the same, and exhaust gas purification method using the same
Publication Date: 2017.02.07 UMICORE SHOKUBAI JAPAN CO LTD
  • US9561494B2 patent drawing
  • US9561494B2 patent drawing
  • US9561494B2 patent drawing

AI summary

The purpose of the present invention is to provide a catalyst for exhaust gas purification, which is capable of effectively processing an exhaust gas, particularly carbon monoxide (CO) and hydrocarbon (HC) in the exhaust gas at a low temperature, and a method for producing the catalyst for exhaust gas purification. The purpose is achieved by a catalyst for exhaust gas purification, which is obtained by having a carrier that contains Al2O3 and one or more metal oxides selected from the group consisting of zirconium oxide (ZrO2), cerium oxide (CeO2), yttrium oxide (Y2O3), neodymium oxide (Nd2O3), silicon oxide (SiO2) and titanium oxide (TiO2) support one or more catalyst components selected from the group consisting of gold (Au), silver (Ag), platinum (Pt), palladium (Pd), rhodium (Rh), iridium (Ir), ruthenium (Ru) and osmium (Os). The metal oxides have particle diameters of less than 10 nm.