Perovskite-based catalysts, catalyst combinations and methods of making and using the same

Patent metadata

Field	Value
Publication number	US-8943811-B2
Application number	US-97541910-A
Country	US
Kind code	B2
Filing date	Dec 22, 2010
Priority date	Dec 22, 2010
Publication date	Feb 3, 2015
Grant date	Feb 3, 2015

Abstract

One embodiment of the invention may include a method comprising providing a product comprising a substrate comprising a perovskite catalyst, NO x stored in or on the substrate and particulate matter in or on the substrate; releasing at least some of the stored NO x and oxidizing the released NOx to form NO 2 , and reacting the NO 2 with carbon in the particulate matter to form at least one of CO or CO 2 .

First claim

What is claimed is:

1. A product comprising:
a combustion engine and exhaust treatment system wherein the combustion engine produces exhaust comprising particulate matter and NO x , the system comprising an engine and a catalytic converter downstream of the engine; a combination particulate filter and NO x storage component; the particulate filter comprising a perovskite catalyst and a NO x storage material, and constructed and arranged so that particulate matter from the combustion engine exhaust is trapped in the particulate filter and NO x is stored in the NO x storage material wherein the particulate filter comprises a second non-perovskite catalyst comprising platinum and the perovskite catalyst comprises an alkaline earth metal.

2. A product as set forth in claim 1 wherein the perovskite catalyst and NO x storage material are in the same layer.

3. A product as set forth in claim 1 wherein the perovskite catalyst and NO x storage material are in different layers or sections of the substrate or product.

4. A product as set forth in claim 1 wherein the NO x storage material comprises an alkaline earth metal rare earth based oxide comprising CeO 2 —ZrO 2 , CeO 2 —ZrO 2 —Pr 6 O II , CeO 2 —ZrO 2 —Pd 2 O 3 or CeO 2 —ZrO 2 —La 2 O 3 .

5. A product comprising a combination of particulate filter and NO x storage component; the particulate filter comprising a perovskite catalyst and a NO x storage material, and constructed and arranged so that particulate matter from combustion engine exhaust is trapped particulate filter and NO x is stored in the NO x storage material wherein the particulate filter comprises a second non-perovskite catalyst comprising platinum and the perovskite catalyst comprises an alkaline earth metal.

6. A product as set forth in claim 5 wherein the perovskite catalyst and NO x storage material are in the same layer.

7. A product as set forth in claim 5 wherein the perovskite catalyst and NO x storage material are in different layers or sections of the substrate or product.

8. A method as set forth in claim 5 wherein the perovskite catalyst has the general formula ABO 3 , AA′BO 3 , ABB′O 3 , or AA′BB′O 3 , wherein A comprises an alkaline-earth metal and wherein B comprises a transition metal.

9. A method as set forth in claim 8 , wherein said perovskite catalyst has the general formula AA′BO 3 ;
wherein A comprises an alkaline-earth metal;
wherein B comprises a transition metal; and
wherein A′ comprises a substitution of a promoter material for a portion of A.

10. A method as set forth in claim 8 , wherein said perovskite catalyst has the general formula ABB′O 3 ,
wherein A comprises an alkaline-earth metal;
wherein B comprises a transition metal; and
wherein B′ comprises a substitution of a promoter material for a portion of B.

11. A method as set forth in claim 8 , wherein said perovskite catalyst has the general formula AA′BB′O 3 ,
wherein A comprises an alkaline-earth metal;
wherein B comprises a transition metal;
wherein A′ comprises a substitution of a promoter material for a portion of A; and
wherein B′ comprises a substitution of a promoter material for a portion of B.

12. A method as set forth in of claim 11 , wherein A′ comprises Strontium.

13. A product as set forth in claim 8 , wherein B is Cobalt or Manganese or Iron.

14. A product as set forth in claim 5 wherein the NO x storage material comprises a rare earth based oxide comprising CeO 2 —ZrO 2 ,CeO 2 —ZrO 2 —Pr 6 O II , CeO 2 —ZrO 2 —Pd 2 O 3 or CeO 2 —ZrO 2 —La 2 O 3 .

15. A method comprising providing a product comprising a particulate filter comprising a substrate comprising perovskite catalyst, NO x stored in or on the substrate and particulate matter in or on the substrate; releasing at least some of the stored NO x and oxidizing the released NOx to form NO 2 , and reacting the NO 2 with carbon in the particulate matter to form at least one of CO or CO 2 wherein the product comprises a second non-perovskite catalyst comprising platinum and the perovskite catalyst comprises an alkaline earth metal.

16. A method as set forth in claim 15 , wherein the substrate further comprises a noble metal catalyst.

17. A method as set forth in claim 15 , wherein the product may further comprise a NO x storage material.

18. A product as set forth in claim 15 wherein the substrate further comprises a nitrogen trap material comprises a rare earth based oxide comprising CeO 2 —ZrO 2 , CeO 2 —ZrO 2 —Pr 6 O II , CeO 2 —ZrO 2 —Pd 2 O 3 or CeO 2 —ZrO 2 —La 2 O 3 .

19. A method comprising providing a particulate filter comprising a substrate comprising a perovskite catalyst, NO x stored in or on the substrate and particulate matter in or on the substrate; releasing at least some of the stored NO x and oxidizing the released NO x to form NO 2 , and reacting the NO 2 with carbon in the particulate matter to form at least one of CO or CO 2 wherein the particulate filter comprises a second non-perovskite catalyst comprising platinum and the perovskite catalyst comprises an alkaline earth metal.

20. A product as set forth in claim 19 wherein the substrate further comprises a nitrogen trap material comprises a rare earth based oxide comprising CeO 2 —ZrO 2 , CeO 2 —ZrO 2 —Pr 6 O II , CeO 2 —ZrO 2 —Pd 2 O 3 or CeO 2 —ZrO 2 —La 2 O 3 .

21. A product comprising a particulate filter and NO x trap combination, wherein the particulate filter comprises a substrate constructed and arranged to trap particulate matter in a gas stream flowing in, through or over the substrate, and further comprising a trap material in, on or over the substrate and a perovskite catalyst in, on or over the substrate wherein the particulate filter and NO x trap combination comprises a second non-perovskite catalyst comprising platinum and the perovskite catalyst comprises an alkaline earth metal.

22. A product as set forth in claim 21 wherein the nitrogen trap material comprises a rare earth based oxide comprising CeO 2 —ZrO 2 , CeO 2 —ZrO 2 —Pr 6 O II , CeO 2 —ZrO 2 —Pd 2 O 3 or CeO 2 —ZrO 2 —La 2 O 3 .

Assignees

• Li Wei
• Brown David B
• Kim Chang H
• Qi Gongshin
• Schmieg Steven J
• Gm Global Tech Operations Inc

Inventors

• Li Wei
• Brown David B
• Kim Chang H
• Qi Gongshin
• Schmieg Steven J

Classifications

• B01J2523/24

  Strontium · CPC title

• B01D2255/1021

  Platinum · CPC title

• B01D2255/204

  Alkaline earth metals · CPC title

• B01J37/0228

  in several steps · CPC title

• B01J35/0006

  Operations & Transport · mapped topic