Catalyst combinations and methods and systems for oxidizing nitric oxide in a gas stream
One embodiment of the invention may include a product comprising a catalyst combination comprising a perovskite catalyst and a second catalyst that is not a perovskite catalyst.
1. A product comprising:
a catalyst combination comprising a perovskite catalyst and a second non-perovskite catalyst, the perovskite catalyst having the general formula ABO 3 , AA′BO 3 , ABB′O 3 , or AA′BB′O 3 , wherein A comprises a rare earth metal from the Lanthanide Series and/or an alkaline-earth metal and wherein B comprises a transition metal, and a particulate filter.
2. A product as set forth in claim 1 , wherein said perovskite catalyst has the general formula AA′BO 3 ;
wherein A comprises a rare earth metal from the Lanthanide Series and/or 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.
3. A product as set forth in of claim 2 , wherein A′ comprises Strontium.
4. A product as set forth in claim 1 , wherein said perovskite catalyst has the general formula ABB′O 3 ,
wherein A comprises a rare earth metal from the Lanthanide Series and/or 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.
5. A product as set forth in claim 1 , wherein said perovskite catalyst has the general formula AA′BB′O 3 ,
wherein A comprises a rare earth metal from the Lanthanide Series and/or 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.
6. A product as set forth in claim 1 , wherein A is Lanthanum.
7. A product as set forth in claim 6 , wherein B is Cobalt or Manganese or Iron.
8. A product as set forth in claim 1 further comprising a catalytic oxidation reactor and wherein the catalyst combination is received in the reactor, wherein the catalyst combination is coupled to a substrate comprising at least one of reactor packing structures and materials, beads, pellets, fluidized bed powders or other solid particulate material suspendable in a flow of gas, a flow-through monolith, a wall-flow monolith, a metal monolith, a ceramic monolith, metal or ceramic fabricated supports.
9. A product as set forth in claim 8 wherein the catalyst combination has a loading of about 1-100 g/ft 3 .
10. A product as set forth in claim 8 wherein the second non-perovskite catalyst comprises palladium having a loading of 5-100 g/ft 3 .
11. A product as set forth in claim 8 wherein the second non-perovskite catalyst comprises platinum having a loading of 1-60 g/ft 3 .
12. A product as set forth in claim 1 further comprising a catalytic oxidation reactor and wherein the catalyst combination is received in the reactor, wherein the catalyst combination is not coupled to a substrate.
13. A product as set forth in claim 12 wherein the catalyst combination has a loading of about 1-100 g/ft 3 .
14. A product as set forth in claim 1 further comprising a catalytic oxidation reactor and wherein the catalyst combination is received in the reactor, wherein the catalyst combination has a form or shape comprising at least one of flat panels, beads, pellets, flow-through or wall-flow monoliths, or reactor packing material shapes.
15. A product as set forth in claim 1 further comprising a catalytic oxidation reactor and wherein the catalyst combination is received in the reactor, wherein the catalyst combination has a form or shape comprising at least one of, rings, saddles, hollow cylinders or Raschig rings.
16. A product as set forth in claim 1 wherein the second non-perovskite catalyst comprises at least one metal from the precious metal or nobel metal group of the periodic table.
17. A product as set forth in claim 1 wherein the second non-perovskite catalyt comprises at least one of palladium, platinum, rhodium or ruthenium, or catalyst systems including the same.
18. A product as set forth in claim 1 wherein the second non-perovskite catalyst comprises at least one of palladium or platinum, or catalyst systems including the same.
19. A system for reducing NO x and particulate matter emissions in an exhaust stream comprising:
a catalytic oxidation reactor comprising a perovskite catalyst and a non-perovskite catalyst, the perovskite catalyst having the general formula ABO 3 , AA′BO 3 , ABB′O 3 , or AA′BB′O 3 , wherein A comprises a rare earth metal from the Lanthanide Series and/or an alkaline-earth metal and wherein B comprises a transition metal;
a particulate filter; and
a catalytic reduction reactor having a selective catalytic reduction catalyst.
20. The system of claim 19 , wherein said perovskite catalyst said perovskite catalyst is of the general formula AA′BO 3 ;
wherein A comprises a rare earth metal from the Lanthanide Series and/or 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.
21. A system as set forth in claim 19 , wherein said perovskite catalyst said perovskite catalyst is of the general formula ABB′O 3 ;
wherein A comprises a rare earth metal from the Lanthanide Series and/or 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.
22. A system as set forth in claim 19 , wherein said perovskite catalyst said perovskite catalyst is of the general formula AA′BB′O 3 ;
wherein A comprises a rare earth metal from the Lanthanide Series and/or 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.
23. A system as set forth in claim 19 , wherein said catalytic oxidation reactor further comprises:
a platinum based catalyst or a palladium based catalyst or a platinum and palladium based catalyst coupled to another portion of said substrate material.
24. A system as set forth in claim 19 , wherein said catalytic oxidation reactor further comprises:
a platinum based catalyst or a palladium based catalyst or a platinum and palladium based catalyst coupled to said portion of said substrate material.
25. A system as set forth in claim 19 further comprising:
an injector device for injecting ammonia or urea to the exhaust stream before said catalytic reduction reactor.
26. A system as set forth in claim 25 further comprising:
a NO x sensor contained within the exhaust stream and coupled to said injector device, said NO x sensor located upstream of said catalytic reduction reactor.
27. A system as set forth in claim 25 further comprising:
a temperature sensor coupled to said catalytic reduction reactor and said injector device, said temperature sensor measuring a temperature of a selective catalytic reduction catalyst contained in said catalytic reduction reactor.
28. A product as set forth in claim 19 wherein the second non-perovskite catalyst comprises palladium having a loading of 5-100 g/ft 3 .
29. A product as set forth in claim 19 wherein the second non-perovskite catalyst comprises platinum having a loading of 1-60 g/ft 3 .
30. A method for oxidizing nitric oxide in a gas stream from a hydrocarbon fueled power source operated with a fuel lean combustion mixture, the method comprising:
passing the gas stream through a catalytic oxidation reactor, the catalytic oxidation reactor comprising a perovskite catalyst and a non-perovskite catalyst, the perovskite catalyst having the general formula ABO 3 , AA′BO 3 AA′BB′O 3 , or AA′BB′O 3 , wherein A comprises a rare earth metal from the Lanthanide Series and/or an alkaline-earth metal and wherein B comprises a transition metal, and a particulate filter.
31. A method as set forth in claim 30 further comprising:
forming a catalytic oxidation reactor comprising a perovskite catalyst has the general formula AA′BO 3 coupled to a substrate material, wherein A comprises a rare earth metal from the Lanthanide Series and/or 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.
32. A method as set forth in 30 further comprising:
forming a catalytic oxidation reactor comprising a perovskite catalyst has the general formula ABB′O 3 coupled to a substrate material, wherein A comprises a rare earth metal from the Lanthanide Series and/or 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.
33. A method as set forth in claim 30 further comprising:
forming a catalytic oxidation reactor comprising a perovskite catalyst has the general formula AA′BB′O 3 coupled to a substrate material, wherein A comprises a rare earth metal from the Lanthanide Series and/or 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.
34. A method as set forth in claim 30 wherein the perovskite catalyst is coupled to a substrate comprising at least one of reactor packing structures and materials, beads, pellets, fluidized bed powders or other solid particulate material suspendable in a flow of gas, a flow-through monolith, a wall-flow monolith, a metal monolith, a ceramic monolith, metal or ceramic fabricated supports.
35. A method as set forth in claim 30 wherein the perovskite catalyst is not coupled to a substrate.
36. A method as set forth in claim 30 wherein the perovskite catalyst includes a form or shape comprising at least one of flat panels, beads, pellets, flow-through or wall-flow monoliths, or reactor packing material shapes.
37. A method as set forth in claim 30 wherein the perovskite catalyst includes a form or shape comprising at least one of, rings, saddles, hollow cylinders or Raschig rings.
38. A product comprising:
a catalyst combination comprising a perovskite catalyst and a second non-perovskite catalyst, the perovskite catalyst having the general formula ABO 3 , AA′BO 3 ABB′O 3 , or AA′BB′O 3 , wherein A comprises a rare earth metal from the Lanthanide Series and/or an alkaline-earth metal and wherein B comprises a transition metal, and further comprising a catalytic oxidation reactor and wherein the catalyst combination is received in the reactor, wherein the catalyst combination has a form or shape comprising at least one of, rings, saddles, hollow cylinders or Raschig rings.
39. A product comprising:
a catalyst combination comprising a perovskite catalyst and a second non-perovskite catalyst, wherein said perovskite catalyst has the general formula AA′BO 3 ;
wherein A comprises a rare earth metal from the Lanthanide Series and/or 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.
40. A method as set forth in 39 , further comprising:
forming a catalytic oxidation reactor comprising a perovskite catalyst has the general formula ABB′O 3 coupled to a substrate material, wherein A comprises a rare earth metal from the Lanthanide Series and/or 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.
41. A method for oxidizing nitric oxide in a gas stream from a hydrocarbon fueled power source operated with a fuel lean combustion mixture, the method comprising:
passing the gas stream through a catalytic oxidation reactor, the catalytic oxidation reactor comprising a perovskite catalyst and a non-perovskite catalyst, the perovskite catalyst having the general formula AA′BO 3 wherein A comprises a rare earth metal from the Lanthanide Series and/or an alkaline-earth metal and wherein B comprises a transition metal, and wherein A′ comprises a substitution of a promoter material for a portion of A.
42. A product comprising:
a substrate having a first catalyst washcoat thereon and a second catalyst washcoat thereon, the first catalyst washcoat comprising a perovskite catalyst, the second catalyst comprising a second non-perovskite catalyst, the perovskite catalyst having the general formula ABO 3 , AA′BO 3 , or AA′BB′O 3 , wherein A comprises a rare earth metal from the Lanthanide Series and/or an alkaline-earth metal and wherein B comprises a transition metal.