NiO catalyst configurations, methods for making NOx adsorbers, and methods for reducing emissions
View Patent ↗In one embodiment, a catalyst configuration, comprises: a substrate, a NiO layer disposed on the substrate, wherein the NiO layer comprises greater than or equal to about 75 wt % of the NiO in the catalyst configuration; and a catalyst layer comprising a NOx adsorbing catalyst. In another embodiment, a catalyst configuration, comprises: a substrate, a catalyst layer disposed on the substrate, wherein the catalyst layer comprises a NOx adsorbing catalyst and thermally treated NiO. In one embodiment, the method for making a NOx adsorber comprises: thermally treating NiO to a temperature of about a maximum catalyst application temperature minus 100° C. and the maximum catalyst application temperature, disposing a catalyst configuration on the substrate, wherein the catalyst configuration comprises the thermally treated NiO and a NOx adsorption catalyst, and disposing the substrate in a housing.
1. A catalyst configuration, comprising:
a substrate;
a NiO layer disposed on the substrate, wherein the NiO layer comprises greater than or equal to about 75 wt % of the NiO in the catalyst configuration; and
a catalyst layer comprising a NOx adsorbing catalyst;
wherein no platinum group metal was added to the NiO layer.
2. The catalyst configuration of claim 1 , further comprising a trapping material selected from the group consisting of barium carbonate, potassium carbonate, and combination thereof.
3. The catalyst configuration of claim 2 , wherein the trapping material comprises barium carbonate and wherein the trapping material is disposed in the catalyst layer.
4. A catalyst configuration of claim 1 ,
wherein the NiO comprises NiO that has been thermally treated to between about a maximum catalyst application temperature minus 100° C. and the maximum catalyst application temperature.
5. The catalyst configuration of claim 4 , wherein the catalyst layer further comprises metal selected from the group consisting of platinum, palladium, rhodium, alloys thereof, and combinations thereof.
6. The catalyst configuration of claim 4 , wherein the catalyst layer further comprises underlayer disposed between the NiO layer and an overlayer.
7. The catalyst configuration of claim 6 , wherein the overlayer further comprises greater an or equal to about 75 wt % of palladium in the catalyst configuration.
8. The catalyst configuration of claim 6 , the underlayer comprises platinum and greater than or equal to 75 wt % of the rhodium and is free of the palladium in the catalyst configuration.
9. The catalyst configuration of claim 1 , wherein the catalyst layer further comprises metal selected from the group consisting of platinum, palladium, rhodium, alloys thereof, and combinations thereof.
10. A catalyst configuration, comprising:
a substrate;
a NiO layer disposed on the substrate, wherein the NiO layer comprises greater than or equal to about 75 wt % of the NiO in the catalyst configuration; and
a catalyst layer comprising a NOx adsorbing catalyst;
wherein the catalyst layer further comprises an underlayer disposed between the NiO layer and an overlayer.
11. The catalyst configuration of claim 10 , wherein the catalyst configuration further comprises palladium, and wherein the overlayer further comprises greater than or equal to about 75 wt % of the palladium.
12. The catalyst configuration of claim 11 , wherein the overlayer is free of rhodium.
13. The catalyst configuration of claim 10 , the underlayer comprises platinum and greater than or equal to 75 wt % of the rhodium in the catalyst layer.
14. The catalyst configuration of claim 13 , wherein the underlayer is free of palladium.
15. A catalyst configuration, comprising:
a substrate
a NiO layer disposed on the substrate, wherein the NiO layer comprises greater than or equal to about 75 wt % of the NiO in the catalyst configuration; and
a catalyst layer comprising a NOx adsorbing catalyst;
wherein the NOx adsorbing catalyst has been post-impregnated into the catalyst layer on a side of the catalyst layer opposite the NiO layer.
16. A catalyst configuration, comprising:
a substrate;
a catalyst layer disposed on the substrate, wherein the catalyst layer comprises a NOx adsorbing catalyst and thermally treated NiO that has been thermally treated to between about a maximum catalyst application temperature minus 100° C. and the maximum catalyst application temperature;
wherein the NOx adsorbing catalyst has been post-impregnated into the catalyst layer on a side of the catalyst layer opposite the NiO layer.