Compositions of lean NO
The present disclosure relates to a substrate comprising nanoparticle catalysts and NO x storage materials for treatment of gases, and washcoats for use in preparing such a substrate. Also provided are methods of preparation of the nanoparticle catalysts and NO x storage materials, as well as methods of preparation of the substrate comprising the nanoparticle catalysts and NO x storage materials. More specifically, the present disclosure relates to a coated substrate comprising nanoparticle catalysts and NO x storage materials for lean NO x trap (LNT) systems, useful in the treatment of exhaust gases.
1. A coated substrate comprising:
a substrate;
a washcoat layer comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising oxidative composite nanoparticles bonded to a first micron-sized carrier particle, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle;
a washcoat layer comprising reductive catalytically active micron-particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles bonded to a second micron-sized carrier particle, the reductive composite nanoparticles comprising a second support nanoparticle and a reductive catalytic nanoparticle; and
a washcoat layer comprising NO x trapping particles, the NO x trapping particles comprising a micron-sized cerium oxide-containing material.
2. The coated substrate of claim 1 , wherein the micron-sized cerium oxide-containing material comprises cerium oxide, cerium-zirconium oxide, cerium-lanthanum oxide, cerium-yttrium oxide, cerium-zirconium-lanthanum oxide, cerium-zirconium-yttrium oxide, cerium-lanthanum-yttrium oxide, or cerium-zirconium-lanthanum-yttrium oxide.
3. The coated substrate of claim 2 , wherein the micron-sized cerium oxide-containing material comprises cerium-zirconium-lanthanum oxide or cerium-zirconium-lanthanum-yttrium oxide.
4. The coated substrate of claim 1 , wherein the washcoat layer comprising reductive catalytically active micron-particles is located closer to the substrate than the washcoat layer comprising oxidative catalytically active micron-particles.
5. The coated substrate of claim 4 , wherein the washcoat layer comprising oxidative catalytically active micron-particles is located closer to the substrate than the washcoat layer comprising NO x trapping particles.
6. The coated substrate of claim 1 , wherein the NO x trapping particles further comprise barium oxide impregnated in the micron-sized cerium oxide-containing material.
7. The coated substrate of claim 6 , wherein the barium oxide is impregnated in the micron-sized cerium oxide or the micron-sized cerium oxide-containing material by wet chemistry.
8. The coated substrate of claim 1 , wherein the NO x trapping particles further comprise platinum or palladium impregnated in the micron-sized cerium oxide-containing material.
9. The coated substrate of claim 8 , wherein the platinum or palladium is plasma-generated.
10. The coated substrate of claim 8 , wherein the platinum or palladium is impregnated in the micron-sized cerium oxide-containing material by wet chemistry.
11. The coated substrate of claim 1 , wherein the NO x trapping particles further comprise the perovskite FeBaO 3 impregnated in the micron-sized cerium oxide-containing material.
12. The coated substrate of claim 1 , wherein the NO x trapping particles further comprise metal oxides selected from the group consisting of samarium, zinc, copper, iron, and silver oxides impregnated in the micron-sized cerium oxide-containing material.
13. The coated substrate of claim 1 , wherein the washcoat layer comprising NO x trapping particles further comprises micron-sized aluminum oxide particles.
14. The coated substrate claim 1 , wherein the oxidative catalytically active micron-particles comprise a material selected from the group comprising platinum, palladium, or a platinum-palladium alloy.
15. The coated substrate of claim 1 , wherein the NO x trapping particles further comprise zirconium oxide.
16. The coated substrate of claim 1 , wherein the first micron-sized carrier particle, first micron-sized porous carrier, or first support particle comprises aluminum oxide.
17. The coated substrate of claim 1 , wherein the second micron-sized carrier particle, second micron-sized porous carrier, or second support particle comprises cerium oxide.
18. The coated substrate of claim 1 , wherein the washcoat layer comprising oxidative catalytically active micron-particles or the washcoat layer comprising reductive catalytically active micron-particles further comprises filler particles or boehmite particles; wherein the filler particles are metal oxide particles.
19. The coated substrate according to claim 1 , wherein the micron-sized cerium oxide-containing material comprises cerium oxide.
20. A catalytic converter comprising a coated substrate of claim 1 .
21. An exhaust treatment system comprising a conduit for exhaust gas and a catalytic converter according to claim 20 .
22. A vehicle comprising an exhaust treatment system according to claim 21 .
23. A vehicle comprising a catalytic converter according to claim 20 .
24. A method of treating an exhaust gas, comprising contacting the coated substrate of claim 1 with the exhaust gas.
25. A method of treating an exhaust gas, comprising contacting the coated substrate of claim 1 with the exhaust gas, wherein the substrate is housed within a catalytic converter configured to receive the exhaust gas.
26. A coated substrate comprising:
a substrate;
a washcoat layer comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising oxidative composite nanoparticles embedded in a first micron-sized porous carrier, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle;
a washcoat layer comprising reductive catalytically active micron-particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles embedded in a second micron-sized porous carrier, the reductive composite nanoparticles comprising a second support nanoparticle and a reductive catalytic nanoparticle; and
a washcoat layer comprising NO x trapping particles, and the NO x trapping particles comprising a micron-sized cerium oxide-containing material.
27. The coated substrate of claim 26 , wherein the micron-sized cerium oxide-containing material comprises cerium oxide, cerium-zirconium oxide, cerium-lanthanum oxide, cerium-yttrium oxide, cerium-zirconium-lanthanum oxide, cerium-zirconium-yttrium oxide, cerium-lanthanum-yttrium oxide, or cerium-zirconium-lanthanum-yttrium oxide.
28. The coated substrate of claim 27 , wherein the micron-sized cerium oxide-containing material comprises cerium-zirconium-lanthanum oxide or cerium-zirconium-lanthanum-yttrium oxide.
29. The coated substrate of claim 26 , wherein the washcoat layer comprising reductive catalytically active micron-particles is located closer to the substrate than the washcoat layer comprising oxidative catalytically active micron-particles.
30. The coated substrate of claim 29 , wherein the washcoat layer comprising oxidative catalytically active micron-particles is located closer to the substrate than the washcoat layer comprising NO x trapping particles.
31. The coated substrate of claim 26 , wherein the NO x trapping particles further comprise barium oxide impregnated in the micron-sized cerium oxide-containing material.
32. The coated substrate of claim 31 , wherein the barium oxide is impregnated in the micron-sized cerium oxide or the micron-sized cerium oxide-containing material by wet chemistry.
33. The coated substrate of claim 26 , wherein the NO x trapping particles further comprise platinum or palladium impregnated in the micron-sized cerium oxide-containing material.
34. The coated substrate of claim 33 , wherein the platinum or palladium is plasma-generated.
35. The coated substrate of claim 33 , wherein the platinum or palladium is impregnated in the micron-sized cerium oxide-containing material by wet chemistry.
36. The coated substrate of claim 26 , wherein the NO x trapping particles further comprise the perovskite FeBaO 3 impregnated in the micron-sized cerium oxide-containing material.
37. The coated substrate of claim 26 , wherein the NO x trapping particles further comprise metal oxides selected from the group consisting of samarium, zinc, copper, iron, and silver oxides impregnated in the micron-sized cerium oxide-containing material.
38. The coated substrate of claim 26 , wherein the washcoat layer comprising NO x trapping particles further comprises micron-sized aluminum oxide particles.
39. The coated substrate claim 26 , wherein the oxidative catalytically active micron-particles comprise a material selected from the group comprising platinum, palladium, or a platinum-palladium alloy.
40. The coated substrate of claim 26 , wherein the NO x trapping particles further comprise zirconium oxide.
41. The coated substrate of claim 26 , wherein the first micron-sized carrier particle, first micron-sized porous carrier, or first support particle comprises aluminum oxide.
42. The coated substrate of claim 26 , wherein the second micron-sized carrier particle, second micron-sized porous carrier, or second support particle comprises cerium oxide.
43. The coated substrate of claim 26 , wherein the washcoat layer comprising oxidative catalytically active micron-particles or the washcoat layer comprising reductive catalytically active micron- particles further comprises filler particles or boehmite particles; wherein the filler particles are metal oxide particles.
44. The coated substrate according to claim 26 , wherein the micron-sized cerium oxide-containing material comprises cerium oxide.
45. A catalytic converter comprising a coated substrate of claim 26 .
46. An exhaust treatment system comprising a conduit for exhaust gas and a catalytic converter according to claim 45 .
47. A vehicle comprising a catalytic converter according to claim 46 .
48. A vehicle comprising an exhaust treatment system according to claim 47 .
49. A method of treating an exhaust gas, comprising contacting the coated substrate of claim 26 with the exhaust gas.
50. A method of treating an exhaust gas, comprising contacting the coated substrate of claim 26 with the exhaust gas, wherein the substrate is housed within a catalytic converter configured to receive the exhaust gas.
51. A coated substrate comprising:
a substrate;
a washcoat layer comprising oxidative catalytically active composite nanoparticles attached to a first micron-sized support particle, the oxidative catalytically active composite nanoparticles being plasma-generated and comprising a first support nanoparticle and an oxidative catalytic nanoparticle;
a washcoat layer comprising reductive catalytically active composite nanoparticles attached to a second micron-sized support particle, the reductive catalytically active composite nanoparticles being plasma-generated and comprising a second support nanoparticle and a reductive catalytic nanoparticle; and
a washcoat layer comprising NO x trapping particles, and the NO x trapping particles comprising a micron-sized cerium oxide-containing material.
52. The coated substrate according to claim 51 , wherein the micron-sized cerium oxide-containing material comprises cerium oxide.
53. A method of forming a coated substrate, the method comprising:
a) coating a substrate with a washcoat composition comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising composite oxidative nanoparticles bonded to a first micron-sized carrier particle, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle;
b) coating the substrate with a washcoat composition comprising reductive catalytically active micron-particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles bonded to a second micron-sized carrier particle, the reductive composite nanoparticles comprising a second support nanoparticle and a reductive catalytic nanoparticle; and
c) coating the substrate with a washcoat composition comprising NO x trapping particles, the NO x trapping particles comprising a micron-sized cerium oxide-containing material.
54. A method of forming a coated substrate, the method comprising:
a) coating a substrate with a washcoat composition comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising oxidative composite nanoparticles embedded in a first micron-sized porous carrier, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle;
b) coating the substrate with a washcoat composition comprising reductive catalytically active micron-particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles embedded in a second micron-sized porous carrier, the reductive composite nanoparticles comprising a second support nanoparticle and reductive catalytic nanoparticle; and
c) coating the substrate with a washcoat composition comprising NO x trapping particles, the NO x trapping particles comprising a micron-sized cerium oxide-containing material.
55. A method of forming a coated substrate, the method comprising:
a) coating a substrate with a washcoat composition comprising oxidative catalytically active composite nanoparticles attached to a first micron-sized support particle, the oxidative catalytically active composite nanoparticles being plasma-generated and comprising a first support nanoparticle and an oxidative catalytic nanoparticle;
b) coating the substrate with a washcoat composition comprising reductive catalytically active composite nanoparticles attached to a second micron-sized support particle, the reductive catalytically active composite nanoparticles being plasma-generated and comprising a second support nanoparticle and a reductive catalytic nanoparticle; and
c) coating the substrate with a washcoat composition comprising NO x trapping particles, the NO x trapping particles comprising a micron-sized cerium oxide-containing material.
56. A coated substrate comprising:
a substrate;
a first washcoat layer comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising oxidative composite nanoparticles bonded to a first micron-sized carrier particle, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle; and
a second washcoat layer comprising reductive catalytically active micron-particles and NO x trapping particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles bonded to a second micron-sized carrier particle, the reductive composite nanoparticles comprising a second support nanoparticle and a reductive catalytic nanoparticle, and the NO x trapping particles comprising a micron-sized cerium oxide-containing material.
57. A coated substrate comprising:
a substrate;
a washcoat layer comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising oxidative composite nanoparticles embedded in a first micron-sized porous carrier, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle; and
a washcoat layer comprising reductive catalytically active micron- particles and NO x trapping particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles embedded in a second micron-sized porous carrier, the reductive composite nanoparticles comprising a second support nanoparticle and a reductive catalytic nanoparticle, and the NO x trapping particles comprising a micron-sized cerium oxide-containing material.
58. A coated substrate comprising:
a substrate;
a washcoat layer comprising oxidative catalytically active composite nanoparticles attached to a first micron-sized support particle, the oxidative catalytically active composite nanoparticles being plasma-generated and comprising a first support nanoparticle and an oxidative catalytic nanoparticle;
and a washcoat layer comprising NO x trapping particles and reductive catalytically active composite nanoparticles attached to a second micron-sized support particle, the reductive catalytically active composite nanoparticles being plasma-generated and comprising a second support nanoparticle and a reductive catalytic nanoparticle, and the NO x trapping particles comprising a micron-sized cerium oxide-containing material.
59. A method of forming a coated substrate, the method comprising:
a) coating a substrate with a washcoat composition comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising oxidative composite nanoparticles bonded to a first micron-sized carrier particle, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle; and
b) coating the substrate with a washcoat composition comprising reductive catalytically active micron-particles and NO x trapping particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles bonded to second micron-sized carrier particle, the reductive composite nanoparticles comprising a second support nanoparticle and a reductive catalytic nanoparticle, and the NO x trapping particles comprising a micron-sized cerium oxide-containing material.
60. A method of forming a coated substrate, the method comprising:
a) coating a substrate with a washcoat composition comprising oxidative catalytically active micron-particles, the oxidative catalytically active micron-particles comprising oxidative composite nanoparticles embedded in a first micron-sized porous carrier, the oxidative composite nanoparticles comprising a first support nanoparticle and an oxidative catalytic nanoparticle; and
b) coating the substrate with a washcoat composition comprising reductive catalytically active micron-particles and NO x trapping particles, the reductive catalytically active micron-particles comprising reductive composite nanoparticles embedded in a second micron-sized porous carrier, the reductive composite nanoparticles comprising a second support nanoparticle and a reductive catalytic nanoparticle, and the NO x trapping particles comprising a micron-sized cerium oxide-containing material.
61. A method of forming a coated substrate, the method comprising:
a) coating a substrate with a washcoat composition comprising oxidative catalytically active composite nanoparticles attached to a first micron-sized support particle, the oxidative catalytically active composite nanoparticles being plasma-generated and comprising a first support nanoparticle and an oxidative catalytic nanoparticle; and
b) coating the substrate with a washcoat composition comprising NO x trapping particles and reductive catalytically active composite nanoparticles attached to a second micron-sized support particle, the reductive catalytically active composite nanoparticles being plasma-generated and comprising a second support nanoparticle and a reductive catalytic nanoparticle, and the NO x trapping particles comprising a micron-sized cerium oxide-containing material.