Platinum Transition Metal Catalysts for Exhaust Gas Treatment
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Solution Overview
Problem
Current three-way catalysts (TWCs) for gasoline engines face challenges in cold start and hot transient performance, and are economically and environmentally unsustainable due to heavy dependency on palladium (Pd) and platinum group metals (PGM), which are expensive and scarce.
Innovation Solution
Incorporating a transition metal component such as iron (Fe) or copper (Cu) into platinum-based TWC catalysts, with a molar ratio of Pt to transition metal ranging from 0.2 to 10.0, to enhance catalytic activity and reduce PGM usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heavy dependency on Pd and PGM is used in TWC, then catalytic performance is maintained, but cost and resource sustainability deteriorate
Solution Approach 1:
The patent replaces expensive and scarce PGM (particularly Pd) with cheaper transition metals (Fe, Cu, Mn, Co, Ni, Zn) as the primary active catalytic component. This substitution dramatically reduces dependency on PGM resources while maintaining catalytic functionality for exhaust treatment, directly addressing the contradiction between performance reliability and resource sustainability.
Solution Approach 2:
The patent changes the chemical composition parameters of the catalyst by incorporating transition metals in specific molar ratios (0.1-10.0 relative to Pt) and combining them with oxygen storage materials. This parameter optimization enables the catalyst to achieve acceptable performance with reduced PGM content, resolving the contradiction between maintaining performance and reducing PGM usage.
2Reliability
If Pt is used instead of Pd in TWC, then PGM price fluctuation risk is mitigated, but catalytic activity deteriorates
Solution Approach 1:
The patent creates a composite catalyst system combining Pt with transition metals (Fe, Cu, Mn, Co, Ni, Zn) and oxygen storage materials. This composite structure leverages the price stability of Pt while the transition metal components compensate for Pt's lower catalytic activity, achieving both performance stability and maintained productivity through synergistic material combinations.
Solution Approach 2:
The transition metals act as intermediary components that enhance the overall catalytic system performance. They work in conjunction with Pt and oxygen storage materials to improve catalytic activity, effectively mediating between Pt's price stability advantage and its activity limitation, thereby resolving the contradiction.
3Loss of substance
If transition metal is incorporated into Pt-based TWC, then PGM usage is reduced and cost is lowered, but catalytic performance may deteriorate
Solution Approach 1:
The patent systematically optimizes the molar ratio of transition metal to Pt (0.1-10.0) and combines it with oxygen storage materials to achieve the desired balance. By carefully controlling these compositional parameters, the catalyst maintains acceptable performance while significantly reducing PGM usage, thus resolving the contradiction between cost reduction and performance maintenance.
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
This approach improves catalytic performance for NOx, CO, and HC conversion, particularly during cold start and A/F window tests, while conserving PGM resources and reducing costs.
Implementation Method 1
a catalyst composition comprising a platinum group metal (PGM) component and a transition metal component, wherein the PGM component comprises platinum (Pt), and the transition metal component is Fe or Cu
Implementation Method 2
TWCs perform three main functions: (1) oxidation of CO
Implementation Method 3
(2) oxidation of unburnt HCs
Implementation Method 4
(3) reduction of NOR
Data Source
AI summary
A three-way catalyst article, and its use in an exhaust system for internal combustion engines, is disclosed. The catalyst article for treating exhaust gas comprising: a substrate comprising an inlet end and an outlet end with an axial length L; a first catalytic region comprising a first platinum group metal (PGM) component and a first transition metal component, wherein the first PGM component comprises platinum (Pt), and the first transition metal component is Fe or Cu, and wherein the molar ratio of Pt and the first transition metal is from 0.2 to 10.0.