Particulate filter containing a nickel-copper catalyst

Patent metadata

Field	Value
Publication number	US-9630146-B2
Application number	US-201313908475-A
Country	US
Kind code	B2
Filing date	Jun 3, 2013
Priority date	Jun 3, 2013
Publication date	Apr 25, 2017
Grant date	Apr 25, 2017

Abstract

A particulate filter for use in a vehicle engine exhaust is provided which includes a catalyst containing a mixture of nickel and copper. The catalyst is impregnated into the filter substrate, which is non-reactive with nickel and copper. When used in a vehicle exhaust gas treatment system, the catalyst on the filter improves soot burn-off at low temperatures, provides improved efficiency in reducing CO and NO x emissions over the use of conventional three-way-catalyst washcoats, and provides enhanced oxygen storage capacity (OSC) and water-gas-shift (WGS) functions.

First claim

What is claimed is:

1. A particulate filter comprising:
a filter substrate; and
a catalyst comprising a mixture of nickel and copper impregnated in said substrate; wherein said filter substrate is non-reactive with nickel and copper; wherein said catalyst is substantially uniformly distributed through the substrate; and
wherein said catalyst is directly loaded without a metal oxide washcoat.

2. An exhaust treatment system comprising:
a particulate filter positioned in an exhaust stream; said particulate filter including an inlet, an outlet, and a plurality of porous walls; said particulate filter comprising a substrate including a catalyst impregnated therein comprising a mixture of nickel and copper; wherein said catalyst is substantially uniformly distributed through the substrate; and wherein said particulate filter substrate is non-reactive with copper and nickel; and
wherein said catalyst is directly loaded without a metal oxide washcoat.

3. The exhaust treatment system of claim 2 having a CO conversion efficiency of at least 90% at a temperature between about 200° C. to about 1000° C.

4. The exhaust treatment system of claim 2 wherein said particulate filter includes a plurality of channels separated by the plurality of porous walls; wherein said channels are open at one end and plugged at an opposite end to trap particulates therein.

5. The exhaust treatment system of claim 2 wherein said catalyst provides a supplemental oxygen storage capacity of about 0.3 mole O to about 350.0 mole O per cubic feet.

6. The exhaust treatment system of claim 2 wherein said catalyst provides a water-gas-shift activity of 50 to 100% equilibrium conversion of CO at about 200° C. to 800° C.

7. The exhaust treatment system of claim 2 wherein said catalyst provides regeneration of said particulate filter at a temperature of between about 200° C. to 1000° C. and burns off from about 90% to 100% of soot deposited on said particulate filter.

8. The exhaust treatment system of claim 2 wherein said catalyst provides substantially complete oxidation of soot to CO 2 .

9. The exhaust treatment system of claim 2 wherein said catalyst provides sufficient oxygen storage capacity for soot and CO oxidation under oxygen-deficient conditions at a temperature between about 200° C. and 1000° C.

10. The exhaust treatment system of claim 2 wherein said catalyst provides sufficient oxygen storage capacity for NO x removal at a temperature between about 250° C. to 1000° C.

11. The exhaust treatment system of claim 2 wherein said substrate consists of a material selected from the group consisting of cordierite, aluminum titanate, silicon carbide, and mullites.

12. The exhaust treatment system of claim 2 wherein the catalyst is impregnated directly into the particulate filter, the catalyst permeates particulate filter walls and directly contacts deposited particulates.

13. The exhaust treatment system of claim 2 wherein said catalyst is substantially free of precious metals.

14. The exhaust treatment system of claim 2 wherein said mixture of nickel and copper is impregnated in said substrate at a loading of between about 1.0 and 50 wt. %.

15. The exhaust treatment system of claim 2 wherein said nickel is impregnated in said substrate at a loading of between about 0.1 to about 99 wt. %.

16. The exhaust treatment system of claim 15 wherein said nickel is impregnated in said substrate at a loading of about 10 wt. %.

17. The exhaust treatment system of claim 2 wherein said copper is contained on said substrate at a loading of between about 0.1 to about 99 wt. %.

18. The exhaust treatment system of claim 17 wherein said copper is impregnated in said substrate at a loading of about 10 wt. %.

19. The exhaust treatment system of claim 2 wherein a weight ratio of nickel to copper is from about 99:1 to 50:50.

20. The exhaust treatment system of claim 2 wherein said catalyst is directly impregnated in a material selected from the group consisting of cordierite, aluminum titanate, silicon carbide, and mullites.

Assignees

• Ford Global Tech Llc

Inventors

• Warner James Robert
• Dobson Douglas Allen
• Jen Hungwen
• Cavataio Giovanni

Classifications

• Y02T10/22

  Cross-Sectional Technologies · mapped topic

• B01J23/755

  Nickel · CPC title

• B01D2258/012

  Diesel engines and lean burn gasoline engines · CPC title

• B01D53/945 Primary

  characterised by a specific catalyst · CPC title

• B01D2255/20753

  Nickel · CPC title