Zero PGM Catalysts Using Doped Oxide Supports

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Solution Overview

Problem

Current diesel oxidation catalysts face challenges in meeting stringent emission standards due to the high demand and increasing prices of Platinum Group Metals (PGM), necessitating the development of cost-effective alternatives that can efficiently oxidize hydrocarbons, carbon monoxide, and nitrogen oxides in exhaust gases.

Innovation Solution

The development of Zero Platinum Group Metal (ZPGM) catalyst systems, comprising a substrate, washcoat, and impregnation layer with materials like cordierite, metallic alloys, and perovskite structures containing Lanthanum, Silver, and Manganese, which promote the oxidation of toxic gases without using PGMs, employing suitable deposition methods and support oxide materials like ZrO2 and doped alumina.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If Platinum Group Metals (PGM) are used in catalyst fabrication, then catalytic activity and emission conversion efficiency are improved, but cost increases due to high demand and increasing prices

Engineering Contradiction:

Improveemission conversion efficiencyVSAvoidcost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive Platinum Group Metals with cheaper alternative materials including base metals (Fe, Co, Ni, Cu, Zn, Mn, Cd, Hg, Mo, W, V), alkaline earth metals (Mg, Ca, Sr, Ba), and their oxides, sulfides, and composite structures. This substitution directly addresses the cost issue while maintaining catalytic functionality through carefully designed alternative compositions that can achieve comparable emission conversion efficiency without relying on scarce and expensive PGMs

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent employs composite material structures including metal oxides (Al2O3, SiO2, TiO2, ZrO2, CeO2), sulfides, and combinations thereof as catalyst supports and active phases. These composite materials provide the necessary catalytic activity, thermal stability, and structural integrity previously associated with PGM-based catalysts, while significantly reducing cost through the use of abundant, inexpensive materials that work synergistically in composite formulations

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If alternative metal combinations are used to replace PGMs, then cost is reduced, but catalytic activity and conversion rates may be compromised

Engineering Contradiction:

ImprovecostVSAvoidcatalytic activity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent systematically varies compositional parameters (metal ratios, oxide concentrations, doping levels) and structural parameters (particle size, surface area, porosity) of alternative metal combinations to optimize catalytic activity. By carefully controlling these parameters, the patent achieves conversion rates comparable to PGM catalysts while maintaining cost advantages through the use of abundant materials configured in optimized formulations

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If emission standards become more stringent, then environmental protection is improved, but the complexity and requirements for catalyst systems increase

Engineering Contradiction:

Improveemission standards complianceVSAvoidcatalyst system requirements

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent designs catalyst systems with multi-functional capabilities that can simultaneously address multiple emission components (hydrocarbons, carbon monoxide, nitrogen oxides, particulate matter) through a single catalyst formulation or integrated system. This universality allows the catalyst to meet stringent multi-component emission standards without requiring separate catalyst systems for each pollutant type, thereby reducing overall system complexity while achieving comprehensive emission control

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 ZPGM catalyst systems effectively oxidize carbon monoxide, hydrocarbons, and nitrogen oxides, achieving significant conversion rates at lower costs by utilizing alternative metal combinations, thereby meeting emission standards while reducing reliance on expensive PGMs.

Implementation Method 1

ZPGM catalyst systems may oxidize toxic gases, such as carbon monoxide, hydrocarbons and nitrogen oxides that may be included in exhaust gases

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

ZPGM catalyst systems may oxidize NO to NO2 which may be used for the oxidation of carbon soot

Methodology Applied

Scientific EffectOxidation: Oxidation

Data Source

PatentUS9216382B2Methods for variation of support oxide materials for ZPGM oxidation catalysts and systems using same

Publication Date: 2015.12.22 CDTI ADVANCED MATERIALS INC

AI summary

Disclosed here are methods of preparing zero platinum group metal catalysts systems with different support oxide material. A ZPGM catalyst system may include a substrate and a washcoat and an impregnation layer, wherein said impregnation layer may include the ZPGM pervoskite catalyst and the washcoat layer may include the support oxides material. Suitable support oxides material may include ZrO2, ZrO2 doped with lanthanide group metals, Nb2O5, Nb2O5—ZrO2, Al2O3 and Al2O3 doped with lanthanide group metals, TiO2 and doped TiO2 or mixtures thereof.