Patent application number | Description | Published |
20140271384 | System and Methods for using Copper- Manganese- Iron Spinel as Zero PGM Catalyst for TWC Applications - A Cu—Mn—Fe spinel on a plurality of support oxides is disclosed as ZPGM catalyst. The active phase for ZPGM samples may be Cu—Mn—Fe spinel on ZrO | 09-18-2014 |
20140271387 | Optimal Composition of Copper-Manganese Spinel in ZPGM Catalyst for TWC Applications - It is an object of the present disclosure, to provide an optimized catalyst composition with variations of Cu and Mn molar ratio, which may include a formulation Cu | 09-18-2014 |
20140271388 | Formation and Stability of Cu-Mn Spinel Phase for ZPGM Catalyst Systems - Optimized Cu—Mn spinel compositions, with optimal spinel phase formation and phase stability properties, for a plurality of ZPGM catalysts in underfloor and closed-loop coupled catalyst applications are disclosed. Plurality of Cu—Mn spinel compositions are prepared with variations of molar ratios. Effect of calcination temperature is analyzed to determine spinel phase formation and phase stability, as well as the effect of calcination temperature on lattice parameter of spinel, as correlated to spinel phase formation and phase stability of optimal Cu—Mn spinel compositions disclosed. Disclosed Cu—Mn spinels with enhanced spinel phase formation and phase stability may be suitable for ZPGM catalyst systems used in a vast number of TWC applications. | 09-18-2014 |
20140271390 | ZPGM Catalyst Systems and Methods of Making Same - Described are ZPGM catalyst systems which are free of any platinum group metals for reducing emissions of carbon monoxide, nitrogen oxides, and hydrocarbons in exhaust streams. ZPGM catalyst systems may include a substrate, a washcoat, and an overcoat. Both manganese and copper may be provided as catalysts, with copper in the overcoat and manganese preferably in the washcoat. The manganese can also be provided in the overcoat, but when in the overcoat should be stabilized for greatest effectiveness. A carrier material oxide may be included in both washcoat and overcoat. It has been discovered that the ZPGM catalyst systems are effective even without OSM in washcoat and the ZPGM catalysts within washcoat and overcoat may be best prepared by co-milling an aqueous slurry that includes manganese with alumina for the washcoat and copper and cerium salts with alumina and an OSM, for overcoat prior to overcoating and heat treating. Disclosed ZPGM TWC systems in catalytic converters may be employed to decrease the pollution caused by exhaust from various sources, such as automobiles, utility plants, processing and manufacturing plants, airplanes, trains, all-terrain vehicles, boats, mining equipment, and other engine-equipped machines. | 09-18-2014 |
20140271391 | ZPGM TWC Systems Compositions and Methods Thereof - Compositions and methods for the preparation of ZPGM TWC systems are disclosed. ZPGM TWC systems may be employed within catalytic converters to oxidize toxic gases, such as carbon monoxide and other hydrocarbons, as well as to reduce nitrogen oxides. ZPGM TWC systems are completely free of PGM catalyst and may include: a substrate, a washcoat, and an overcoat. Washcoat may include manganese as ZPGM catalyst, and carrier material oxides. Similarly, overcoat may include at least one ZPGM catalyst, carrier material oxides and OSMs. Suitable known in the art chemical techniques, deposition methods and treatment systems may be employed in order to form the disclosed ZPGM TWC systems. ZPGM TWC systems may include high surface area, low conversion temperature catalysts that may exhibit high efficiency in the conversion of exhaust gases. | 09-18-2014 |
20140271392 | System and Method for Two and Three Way ZPGM Catalyst - Disclosed here are material formulations of use in the conversion of exhaust gases, where the formulations may include Copper (Cu), Cerium (Ce), Tin (Sn), Niobium (Nb), Zirconium (Zr), Calcium (Ca) and combinations thereof. | 09-18-2014 |
20140271393 | Methods for Variation of Support Oxide Materials for ZPGM Oxidation Catalysts and Systems Using Same - 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 ZrO | 09-18-2014 |
20140271425 | Methods for Oxidation and Two-way and Three-way ZPGM Catalyst Systems and Apparatus Comprising Same - Oxidation ZPGM catalyst systems and three way ZPGM catalyst systems are disclosed. ZPGM catalyst systems may oxidize toxic gases, such as carbon monoxide and hydrocarbons, optionally some ZPGM catalyst systems may as well reduce nitrogen oxides that may be included in exhaust gases. ZPGM catalyst systems may include: a substrate, a washcoat, and an overcoat. The washcoat may include at least one ZPGM catalyst and carrier material oxides. Similarly, overcoat may include at least one ZPGM catalyst, carrier material oxides and OSMs. Suitable known in the art chemical techniques, deposition methods and treatment systems may be employed in order to form the disclosed ZPGM catalyst systems. | 09-18-2014 |
20140274662 | Systems and Methods for Variations of ZPGM Oxidation Catalysts Compositions - The present disclosure refers to variation of compositions for catalytic converters free of platinum group metals, which may be employed to manufacture ZPGM oxidation catalyst systems, to remove main pollutants from exhaust of diesel engines, by oxidizing toxic gases. Suitable support oxides material may include ZrO | 09-18-2014 |
20140274663 | Firing (Calcination) Process and Method Related to Metallic Substrates Coated with ZPGM Catalyst - The effect of firing (calcination) cycle on metallic substrates in ZPGM catalyst systems is disclosed. ZPGM catalyst samples with washcoat and overcoat are separately fired in a normal, slow and fast firing cycles to determine the optimal firing cycling that may provide an enhanced catalyst performance, as well as the minimal loss of washcoat adhesion from the samples. | 09-18-2014 |
20140274674 | Influence of Support Oxide Materials on Coating Processes of ZPGM Catalyst Materials for TWC Applications - The influence of a plurality of support oxides on coating process for ZPGM catalysts is disclosed. ZPGM catalyst samples with washcoat on suitable ceramic substrate and overcoat including a plurality of support oxides are prepared including an impregnation layer of Cu—Mn spinel or overcoat may be prepared from powder of Cu—Mn spinel with support oxide. Testing of fresh and aged ZPGM catalyst samples is developed under isothermal steady state sweep test condition. Catalyst testing allows to determine effect of a plurality of support oxides on coating processes, TWC performance, and stability of ZPGM catalysts for a plurality of TWC applications. Stability of ZPGM-TWC systems may be improved by promotion of the activity of ZPGM materials incorporating support oxides. Improvements that may be provided by the combination of support oxides with ZPGM materials in the catalyst may lead to a most effective utilization of ZPGM materials in TWC converters. | 09-18-2014 |
20140274675 | Oxidation Catalyst Systems Compositions and Methods Thereof - Compositions and methods for the preparation of ZPGM oxidation catalyst systems are disclosed. ZPGM catalyst systems may be employed within catalytic converters under lean hydrocarbon, air to fuel ratio condition to oxidize toxic gases, such as carbon monoxide and other hydrocarbons that may be included in exhaust gas. ZPGM oxidation catalyst systems are completely free of PGM catalyst and may include: a substrate, a washcoat, and an overcoat. Washcoat may include silver as ZPGM catalyst, and carrier material oxides. Similarly, overcoat may include at least one ZPGM catalyst, carrier material oxides and OSMs. Overcoat of the disclosed ZPGM catalyst system may include copper and cerium as ZPGM catalysts. Suitable known in the art chemical techniques, deposition methods and treatment systems may be employed in order to form the disclosed ZPGM catalyst systems. ZPGM catalyst systems may include high surface area, low conversion temperature catalysts that may exhibit high efficiency in the conversion of exhaust gases. | 09-18-2014 |
20140274677 | System and Method for Optimized Oxygen Storage Capacity and Stability of OSM Without Rare Metals - It is an object of the present disclosure, to provide an oxygen storage material which may include optimum composition and structure of Cu—Mn spinel as OSM, with a suitable doped zirconia, including Niobium-Zirconia support oxide for OSM applications, which may include a chemical composition substantially free from rare metals. The OSC properties of Cu—Mn spinel with a suitable doped zirconia, including Niobium-Zirconia support oxide as OSM may be determined by comparing variations of Cu—Mn composition for determination of the optimum structure of spinel to achieve optimal OSC properties and thermal stability, which may be particularly useful for treating exhaust gases produced by internal combustion engines, where lean/rich fluctuations in operating conditions may produce high variation in exhaust contaminants that may be removed, achieving optimal OSC property of spinel at different temperatures, as well as thermal stability behavior of OSM. | 09-18-2014 |
20140274678 | Coating Process of Zero-PGM Catalysts and Methods Thereof - Variations of coating processes of ZPGM catalyst materials for TWC applications are disclosed. The disclosed coating processes for ZPGM materials are enabled in the preparation of ZPGM catalyst samples according to a plurality of catalyst configurations, which may include washcoat and an overcoat layer with or without an impregnation layer, including Cu—Mn spinel and doped Zirconia support oxide, prepared according to variations of disclosed coating processes. Activity measurements under isothermal steady state sweep test condition are considered under lean condition and rich condition close to stoichiometric condition to analyze the influence of disclosed coating processes on TWC performance of ZPGM catalysts. Different coating processes may substantially increase TWC activity, providing improved levels of NO, CO, and HC conversions and cost effective manufacturing solutions. | 09-18-2014 |
20140301909 | System and Method for ZPGM Catalytic Converters - Compositions and methods for the preparation of ZPGM oxidation catalytic converters are disclosed. ZPGM catalyst systems may be employed within catalytic converters under lean hydrocarbon, air to fuel ratio condition to oxidize toxic gases, such as carbon monoxide and other hydrocarbons that may be included in exhaust gas. ZPGM oxidation catalyst systems are completely free of PGM catalyst and may include: a substrate, a washcoat, and an overcoat. Washcoat may include silver as ZPGM catalyst, and carrier material oxides. Similarly, overcoat may include at least one ZPGM catalyst, carrier material oxides and OSMs. Overcoat of the disclosed ZPGM catalyst system may include copper and cerium as ZPGM catalysts. Suitable known in the art chemical techniques, deposition methods and treatment systems may be employed in order to form the disclosed ZPGM catalyst systems. ZPGM catalyst systems may include high surface area, low conversion temperature catalysts that may exhibit high efficiency in the conversion of exhaust gases | 10-09-2014 |
20140301931 | System and Method for Two and Three Way Mixed Metal Oxide ZPGM Catalyst - Disclosed here are material formulations of use in the conversion of exhaust gases, where the formulations may include Iron (Fe), Cobalt (Co), Manganese (Mn), Cerium (Ce), Lanthanum and combinations thereof. | 10-09-2014 |
20140302983 | System and Method for Two and Three Way NB-ZR Catalyst - Disclosed here are material formulations of use in the conversion of exhaust gases, where the formulations may include Niobium (Nb), Zirconium (Zr) and combinations thereof. | 10-09-2014 |
20140334989 | ZPGM Diesel Oxidation Catalysts and Methods of Making and Using Same - Diesel oxidation ZPGM catalyst systems are disclosed. ZPGM catalyst systems may oxidize toxic gases, such as carbon monoxide, hydrocarbons and nitrogen oxides that may be included in exhaust gases. ZPGM catalyst systems may include: a substrate, a washcoat, and an impregnation layer. The washcoat may include at least one carrier material oxides. The impregnation layer may include at least one ZPGM catalyst, carrier material oxides and OSMs. Suitable known in the art chemical techniques, deposition methods and treatment systems may be employed in order to form the disclosed ZPGM catalyst systems. | 11-13-2014 |
20140334990 | ZPGM Diesel Oxidation Catalyst Systems and Methods Thereof - The present disclosure refers to a plurality of methods employed for production of ZPGM diesel oxidation catalyst systems substantially free of PGM, which may include a substrate, a washcoat, and an impregnation layer. Washcoat may include at least one carrier material oxides. An optional impregnation layer component, which may include at least one ZPGM catalyst. This catalyst system may be free of any oxygen storage material (OSM). Suitable deposition methods and firing systems may be employed in order to form disclosed ZPGM oxidation catalyst systems, which may be able to remove main pollutants from exhaust of diesel engines, by oxidizing toxic gases. | 11-13-2014 |
20140336038 | ZPGM Catalytic Converters (TWC application) - Compositions and methods for the preparation of ZPGM catalytic converters are disclosed. Addition of Mn to ZPGM catalytic converters from prior ZPGM catalytic may create a new ZPGM catalytic converter with greater improvement TWC conditions compared to previous types. Suitable known in the art chemical techniques, deposition methods and treatment systems may be employed in order to form the disclosed ZPGM catalyst systems. Disclosed ZPGM TWC systems in catalytic converters may be employed to decrease the pollution caused by exhaust from various sources, such as automobiles, utility plants, processing and manufacturing plants, airplanes, trains, all-terrain vehicles, boats, mining equipment, and other engine-equipped machines. | 11-13-2014 |
20140336044 | Copper-Manganese Spinel Catalysts and Methods of Making Same - Disclosed here are material formulations of use in the conversion of exhaust gases, where the formulations may include Copper (Cu), Manganese (Mn) and combinations thereof. Combinations of use may include Cu—Mn Spinels. Catalysts including these materials may be synthesized by methods including co-precipitation, co-milling, templating, and the sol-gel method, using any suitable carrier material oxide and any suitable oxygen storage material. The properties of the catalysts disclosed may vary according to the calcining temperature, where stoichiometric and non-stoichiometric Cu—Mn Spinels may form when calcining suitable formulations at suitable temperatures. | 11-13-2014 |
20140336045 | Perovskite and Mullite-like Structure Catalysts for Diesel Oxidation and Method of Making Same - Disclosed here are material formulations of use in the conversion of exhaust gases. A catalyst is formed by using a perovskite structure having the general formula ABO3 or a mullite structure having the general formula of AB2O5 where components “A” and “B” may be any suitable non-platinum group metals. Suitable materials may include Yttrium, Lanthanum, Silver, Manganese and formulations thereof. | 11-13-2014 |
20140356243 | Systems and Methods for Providing ZPGM Perovskite Catalyst for Diesel Oxidation Applications - Diesel oxidation ZPGM catalyst systems using Y | 12-04-2014 |
20140357475 | Systems and Methods Using Cu-Mn Spinel Catalyst on Varying Carrier Material Oxides for TWC Applications - Disclosed here are variations of carrier material oxide formulations to create Cu—Mn spinel, where the formulations may include Ti | 12-04-2014 |
20140357479 | Variations for Synthesizing Zero Platinum Group Metal Catalyst Systems - Variations of synthesis methods for Zero Platinum Group Metal (ZPGM) catalyst systems are disclosed herein. The methodologies of influence of synthesis methods on Cu—Mn catalyst systems which may include a variation of carrier metal oxides are disclosed. The XRD characterization and activity measurements of a series of stoichiometric and non-stoichiometric Cu—Mn spinels with different support oxide are discussed. | 12-04-2014 |
20150017082 | PROCESS FOR ELIMINATION OF HEXAVALENT CHROMIUM COMPOUNDS ON METALLIC SUBSTRATES WITHIN ZERO-PGM CATALYST SYSTEMS - Systems and Methods for manufacturing ZPGM catalysts systems that may allow the prevention of formation or the conversion of corrosion causing compounds, such as hexavalent chromium compounds, within ZPGM catalyst systems are disclosed. ZPGM catalysts systems, may include metallic substrate, which may include alloys of iron and chromium, a washcoat and an overcoat. Disclosed manufacturing processes may include a thermal decomposition of hexavalent chromium compounds which may allow the decomposition of such compounds into trivalent chromium compounds, and may also produce metallic catalyst, such as silver. | 01-15-2015 |
20150018202 | Variations of Loading of Zero-PGM Oxidation Catalyst on Metallic Substrate - The present disclosure refers to processes and formulations employed for optimization of variations of Zero-PGM catalyst coated on metallic substrates. Deposition of a uniform and well-adhered layer of catalyst on the metallic substrate may be enabled by the selection of a washcoat loading resulting from variation of metal loadings. Characterization of catalysts may be performed using a plurality of catalytic tests, including but not limited to washcoating adherence test, back pressure test, inspection of textural characteristics, and catalyst activity. Optimized variations may be applied to a plurality of metallic substrates for achieving coating uniformity, desired level of WCA loss, and optimized performance of catalyst activity. | 01-15-2015 |
20150018203 | Optimization of Zero-PGM Washcoat and Overcoat Loadings on Metallic Substrate - The present disclosure refers to a plurality of process employed for optimization of Zero-PGM washcoat and overcoat loadings on metallic substrates. According to an embodiment a substantial increase in conversion of HC and CO may be achieved by optimizing the total washcoat and overcoat loadings of the catalyst. According to another embodiment, the present disclosure may provide solutions to determine the optimum total washcoat and overcoat loadings for minimizing washcoat adhesion loss. As a result, may increase the conversion of HC and CO from discharge of exhaust gases from internal combustion engines, optimizing performance of Zero-PGM catalyst systems. | 01-15-2015 |
20150018204 | Minimizing Washcoat Adhesion Loss of Zero-PGM Catalyst Coated on Metallic Substrate - Solutions to the problem of washcoat and/or overcoat adhesion loss of ZPGM catalyst on metallic substrates are disclosed. Present disclosure provides an enhanced process for improving WCA to metallic substrates of ZPGM catalyst systems. Reduction of WCA loss and improved catalyst activity may be enabled by the selection of processing parameters determined from variation of rheological properties by the solid content of the overcoat slurry and variation of the overcoat slurry particle size distribution to produce desirable homogeneity, specific loading, and adherence of the coating on metallic substrates. Processing parameters may be applied to a plurality of metallic substrates of different geometries and cell densities. | 01-15-2015 |
20150018205 | Optimum Loading of Copper-Manganese Spinel on TWC Performance and Stability of ZPGM Catalyst Systems - Influence of a plurality of base metal loadings on TWC performance and thermal stability of ZPGM catalysts for TWC applications is disclosed. ZPGM catalyst samples are prepared and configured with washcoat on ceramic substrate, overcoat including doped Zirconia support oxide, and impregnation layer of Cu—Mn spinel with different base metal loadings. Testing of ZPGM catalyst samples including variations of base metal loadings is developed under isothermal steady state sweep test condition for fresh and aged ZPGM catalysts to evaluate the influence of variations of base metal loadings on TWC performance specially NO | 01-15-2015 |
20150050742 | Analysis of Occurrence of Corrosion Products with ZPGM and PGM Catalysts Coated on Metallic Substrates - The present disclosure provides identification techniques on platinum group metal (PGM) and zero platinum group metal (ZPGM) catalyst systems, in order to identify responsible materials for the formation of corrosion products, such as hexavalent chromium compounds. Identification analyses, such as X-ray diffraction analysis (XRD) and X-ray fluorescence (XRF) may be performed on various thermally treated PGM and ZPGM catalyst systems. Results of identification analyses may show that for both PGM and ZPGM catalysts, hexavalent chromium (Cr | 02-19-2015 |
20150051067 | Oxygen storage material without rare earth metals - The present disclosure relates to an enhanced oxygen storage material (OSM) that may be converted into powder form and used as a raw material for a vast number of applications, and more particularly in catalyst systems. The disclosed OSM, substantially free from PGM and rare earth (RE) metals, has significantly higher oxygen storage capacity (OSC) than conventional OSM including PGM and RE metals. The disclosed OSM may be converted into powder, including a formulation of Cu—Mn spinel structure deposited on Nb—Zr oxide support. The disclosed OSM may also be coated onto a ceramic substrate as washcoat layer for characterization under OSC isothermal oscillating condition. The disclosed OSM may have an optimal OSC property that increases with the temperature, showing acceptable level of O | 02-19-2015 |